News

18th June 2026

Fawley Refinery Incident: The Importance of Managing Corrosion Risks

A partial collapse of a steel tower highlighted key failings within the organisation whereby the company failed to take appropriate action for corrosion which had developed over many years initially being identified as early as 2010.

The incident occurred at the Fawley Refinery on the western shore of Southampton Water in Hampshire on the 08^th of November 2022. A large steel tower containing liquefied petroleum gas (LPG) partially collapsed causing the structure to slew and rupture some of the pipework leading to an uncontrolled discharge. Over a 33-hour period approximately 2400kg of LPG was released, with 400kg being in the first 30 minutes after the initial collapse. Fortunately, there were no injuries, but workers in the immediate vicinity were at risk from falling debris and serious burns had the LPG ignited.

LPG is a versatile, clean burning fuel which primarily consists of propane and butane. It can be transported and stored in various quantities and has use in various settings including domestic, commercial, industrial, hospitality, manufacturing, and agricultural.

Following the incident emergency procedures were implemented to reduce the highly flammable vapour from spreading, ultimately allowing the workforce to isolate the affected process and vent the remaining stored LPG to the flare system. The flare system is a safety mechanism and pressure-relief valve for the plant, during the emergency is allowed for a controlled combustion instead of releasing combustible gases directly into the air. Reports from the night of the incident confirmed the ‘big orange glow’ from the flare systems were visible from at least 25 miles away.

Why this could matter to local residents and businesses

Fawley refinery is an upper tier establishment under the COMAH (Control of Major Accident Hazards) Regulations. As a result of this position, they are required to provide safety information to the public if you fall within the surrounding public information zone (PIZ). Infomration will include an explanation of the risks from the refinery and what to do in the event of an emergency including what to do when the COMAH alarm sounds which may require you to shelter in place.

 

The refinery does however have a dedicated team of responders who undergo vigorous training to ensure emergency preparedness. Part of this training is working closely with local emergency services to ensure a swift and effective response that will safeguard the workforce, public, and local environment.

HSE Prosecution

Esso Petroleum plead guilty to breaching section 3(1) of the Health and Safety at Work Act 1974 and were fined £1,000,000 and ordered to pay costs of £12,277 at Southampton Magistrates court on the 12^th of June 2026.

 

Key Health and Safety Lessons

• The integrity of plant and pipework must be maintained.
• Equipment must be kept in a safe condition.
• Where there is a risk of corrosion it should be identified and managed to prevent the loss of containment of a hazardous substance.
• Chemical storage systems must be regularly inspected and maintained to prevent catastrophic failure.
• Routine inspections and preventative maintenance are carried out.
• Where corrosion is identified, appropriate action is taken to resolve the issue.

 

Legal Responsibilities for UK Employers

UK businesses handling hazardous substances must comply with legislation including:

• The Health and Safety at Work etc. Act 1974
• COSHH Regulations
• COMAH Regulations
• PUWER
• PSSR

Failure to properly manage these risks can lead to serious injury, prosecution, substantial fines, and reputational damage.

Summary

This incident demonstrates how seemingly minor defects can develop into major safety risks when they are not effectively managed. Although no one was injured, the consequences could have been far more serious given the quantity of LPG released and the potential for ignition.

The case serves as a reminder that asset integrity, routine inspection, preventative maintenance, and timely corrective action are fundamental elements of process safety. Where issues such as corrosion are identified, organisations must ensure that appropriate action is taken and that risks are continually reviewed and monitored.

By learning from incidents such as this, businesses can strengthen their safety management systems, reduce the likelihood of a loss of containment event, and better protect their employees, contractors, local communities, and the environment.

For ongoing health and safety advice and support, including assistance with risk management, compliance, inspections, and training, please contact the HCS Safety team to discuss how we can support your organisation.