UK – Esso Fined £1 Million After Major LPG Leak at Fawley Refinery
Esso Petroleum has been fined £1 million following a significant liquefied petroleum gas (LPG) leak at its Fawley refinery in Hampshire, after an investigation by the Health and Safety Executive (HSE) found that a structural failure linked to long-term corrosion led to the release.
The incident occurred on 8 November 2022 when part of a large steel tower at the refinery partially collapsed, causing connected pipework to rupture and release LPG. According to the HSE, approximately 2,400 kg of gas escaped over a period of around 33 hours, with an estimated 400 kg released within the first 30 minutes of the incident.
Emergency response measures were implemented to manage the situation and minimise the risk of ignition. Refinery personnel deployed water curtains to help disperse the flammable vapour cloud while efforts were made to isolate the affected equipment and safely divert remaining product to the site’s flare system. The release was eventually brought under control after approximately 33 hours.
The HSE investigation found that workers were present in the vicinity of the incident and were exposed to hazards associated with both the release of flammable gas and falling debris resulting from the structural failure. Although no injuries were reported, the regulator stated that the consequences could have been far more serious had the gas ignited.
Investigators concluded that the collapse was caused by extensive corrosion affecting the steel tower. The regulator said deterioration of the structure had been identified more than a decade earlier, but sufficient action was not taken to adequately manage the risk and maintain the integrity of the equipment.
Following prosecution by the HSE, Esso Petroleum Company Limited pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc. Act 1974. The company was fined £1 million at Southampton Magistrates’ Court and was also ordered to pay £12,277 in costs.
The case highlights the importance of effective asset integrity management within high-hazard industrial facilities, particularly the need for robust inspection and maintenance programmes to identify and address corrosion-related risks before they lead to major incidents.
Source: HSE. All rights reserved.