Catastrophic explosion could have happened at Kruger's Corner Brook mill, expert says

The Corner Brook Pulp and Paper mill's failure to maintain its boiler's pressure safety system could have resulted in a disaster, says a boiler expert. 

In April, operations ceased at the mill for a couple of weeks after the provincial government found that Corner Brook Pulp and Paper had failed to comply with safety regulations. 

In May, documents obtained by CBC News through an access-to-information request revealed that the company, a division of Montreal-based Kruger, Inc., had neglected to inspect the facility's boiler system's pressure relief devices.

Seventy-eight devices had not been serviced in over 30 years. 

"It can be catastrophic and that's why it's very important to make sure the safety valves are in functioning order," said Desmond Saldanha of the Canadian Boiler Society, a group of energy and environmentally concerned companies in the boiler industry. 

Saldanha said safety valves, mounted on pressurized equipment or piping systems, open when the system's pressure exceeds a certain threshold. They're essential for avoiding boiler problems and dangerous situations, he said — preventing pressure increases that could cause malfunctions, fire hazards, product damage or even explosions. 

"If the valve fails to open, the pressure within the system can build up beyond its design capacity. This can result in equipment damage and associated components leading to ruptures or explosions," he said. 

On the other hand, if the valve doesn't seal properly, there's a risk substances within the system will not be contained, he said, which poses a significant safety risk to personnel working around the system, because of potential leaks or spills of hazardous gases and fluids. 

"This can lead to explosions, fires or chemical exposures," he said.

Pressure relief failures that lead to safety incidents can also have legal consequences, including fines and sanctions, he said.

The documents obtained by CBC News found that the Corner Brook paper mill had significant code violations.

A year before the mill's shutdown, the company had been directed to develop a program to maintain all safety relief devices and registered pressure systems. 

When provincial officials inspected the 78 overdue pressure equipment items, they found the program, which required the company to service the pressure systems every year or two, was not being implemented.