HSE PUBLISH MAJOR INVESTIGATION REPORT INTO INCIDENTS AT BP GRANGEMOUTH COMPLEX

HSE press release: E160:03 -18 August 2003

The Health and Safety Executive (HSE) today published its Major Incident Investigation report into three events at BP's Grangemouth complex in 2000. The full report is available on the HSE website at: http://www.hse.gov.uk/comah/bpgrange/index.htm

The report describes the causes of three incidents in May and June 2000 - a power distribution failure causing refinery shut down, failure of a steam main resulting in minor injury to a member of the public and a serious fire at a process unit.

The report is the result of a joint investigation (led by HSE) with the Scottish Environment Protection Agency (SEPA). It highlights clear messages about the business case for health and safety as a key component of corporate governance for the chemical and refinery industries. The key lessons from the report for the chemical and refinery industries are:

• the ability to properly measure major hazard performance is crucial in allowing companies to detect deteriorating standards and enable managerial intervention before a major incident occurs;
  
• making sure process safety is properly managed by specific focus on major hazard control as distinct from "conventional" health and safety management; and
  
• don't underestimate the dangers from the more mundane systems on a chemical site such as disruption to utility supply systems (steam, electricity etc). These can cause significant problems and have the potential to result in a major incident.

Alistair McNab, HM Principal Inspector of Health and Safety who led the investigations said:

"This was a thorough and wide-ranging investigation which extended beyond the plant and installation to examine human factors, management of health and safety and the safety culture. The investigation started immediately after the first incident in May 2000 and at its peak involved up to 20 Inspectors.

"BP have cooperated fully throughout the investigation and have given their commitment to the lessons and messages in the report. Since these incidents there has been a sustained improvement of safety performance across the Grangemouth complex.

"I am also pleased to say that the UK Petroleum Industry Association the Chemical Industries Association and the Chemical and Downstream Oil Industry Forum (a tripartite HSE/industry/trades union advisory body) will be encouraging use of the lessons learned from the report as an agent for change in the industry."

Notes to editors

1. HSE gave a commitment to publish a report following the conclusion of legal proceedings in January 2002. (See Note 6).

2. This is a particularly thorough report of over 130 pages. This reflects the complexity of the investigations, and the action BP has taken to date to learn lessons and improve performance. It is unique in that it is the first internet-only public investigation report published by HSE. Electronic links have been provided throughout to enable readers to cross-reference the report's various sections, and to select the depth of detail required.

3. HSE considers that Major Hazard process industries need to learn lessons from the report and incorporate these lessons into managerial procedures to ensure that process safety is properly managed. Process safety requires specific managerial focus on major hazard control as distinct from "conventional" health and safety management (to prevent falls from height etc).

The ability to properly measure major hazard performance is crucial to allow companies to detect deteriorating performance and enable managerial intervention before a major accident occurs.

4. BP Grangemouth is part of Grangemouth petrochemical complex.

5. There are approximately 1,093 sites in the UK that are regulated under the Control of Major Accident Hazard (COMAH) Regulations 1999.

6. Following the investigation BP were prosecuted by the procurator fiscal service (Scotland's independent public prosecution service).

Details of the charges are:

• BP Grangemouth Oil Refinery Ltd was charged with an offence under the Health and Safety At Work etc Act 1974, Section 2, for failing to ensure the safety of employees so far as was reasonably practicable, following a fire in a catalytic cracker on 10 June 2000 and were fined £750,000.
  
• BP Chemicals Ltd was charged with an offence under the Health and Safety at Work etc Act 1974, Section 3, for failing to ensure the safety of non-employees (members of the public), so far as was reasonably practicable, following a steam main rupture on 7 June 2000 and were fined £250,000.

7. HSE and SEPA jointly investigated as the Competent Authority for the enforcement of the COMAH Regulations 1999. HSE led the investigation as safety issues predominated.

8. HSE and SEPA have continued the follow-up of the agreed actions to ensure that the performance of the complex improves in line with the commitments given by BP.

9. An Executive Summary of the report is attached. The full report can be obtained on the HSE website http://www.hse.gov.uk/comah/bpgrange/index.htm

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