FOUR MAJOR ACCIDENTS AT MAJOR HAZARD SITES IN 2000/01

3 Feb 2003 01:15 PM

There were four major accidents in 2000/01 at industrial premises subject to the Control of Major Accident Hazards (COMAH) Regulations 1999, according to a new report published today. None of the four accidents resulted in serious or fatal injuries.

'COMAH major accidents notified to the European Commission, England, Wales & Scotland 2000-2001', is published by the Health & Safety Executive (HSE), the Environment Agency in England and Wales (EA), and the Scottish Environment Protection Agency (SEPA) who together form the Competent Authority, (CA), which enforces the COMAH regulations,.

The report describes the four EC Reportable Accidents (ECRAs) that occurred during the period April 2000 and March 2001, and provides a summary of each incident, including their consequences and enforcement action taken by the CA. The report has been published on the Internet, and is in line with the COMAH Regulations for giving greater public access to information relating to major accident hazards. It can also be used to learn lessons from the past and help to prevent accidents in the future. It is the second report to be published following the launch of the series with the report covering 1999/00.

The number of reportable accidents in 2000/01 is similar to the average number for recent years. Whilst recognising that it is difficult to draw conclusions from such a small sample, these can be used as a crude measure of safety performance. There is concern at the magnitude and frequency of these accidents and at the repeated underlying causes of major accidents. HSE, EA and SEPA. will continue to use the regulations to improve corporate governance of major hazard sites.

The COMAH regulations require the CA to notify the European Commission (EC) of certain major accidents. The criteria include: the release of a specified quantity of a dangerous substance; specified harm to persons (such as a death); specified harm to the environment (such as significant damage to more than 10km (6 miles) of river) or in some circumstances a 'near miss' of particular technical interest. The EC then uses the data to inform its decisions on future changes to legislation regarding major accident hazards.

The COMAH Regulations 1999 apply to approximately 1,100
establishments that have the potential to cause major accidents because they use, or store, significant quantities of dangerous substances, such as oil products, natural gas, chemicals and explosives. The general duty of the regulations is that: 'Every operator shall take all measures necessary to prevent major accidents and limit their consequences to persons and the environment'.

Notes to Editors

1. In April 1999 the COMAH regulations came into force in England, Wales and Scotland, replacing the Control of Industrial Major Accident Hazards (CIMAH) regulations that had been in place since 1984. A Competent Authority (CA), comprising HSE working jointly with the EA and SEPA implements the COMAH regulations. This arrangement reflects the requirements to ensure the protection of both persons and the environment.

2. The COMAH Regulations 1999 (S.I. 1999 No.743) impose requirements for the control of major accident hazards involving dangerous substances. The Regulations implement Council Directive 96/82/EC (known as the Seveso II Directive) which was implemented in the UK in April 1999. They apply to establishments where dangerous substances are present in quantities equal to or exceeding scheduled quantities.

3. A major accident is defined as an occurrence (including in particular, a major emission, fire or explosion) resulting from uncontrolled developments in the course of the operation of any establishment and leading to serious danger to human health or the environment, immediate or delayed, inside or outside an
establishment, and involving at least one dangerous substance. Where a major accident meets the criteria in Schedule 7 of COMAH then it is reportable to the European Commission.

4. A two-page fact sheet is being published in conjunction with the report and copies will be available from HSE, EA and SEPA regional offices.

PUBLIC ENQUIRIES: Call HSE's InfoLine, tel: 08701 545500, or write to: HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG.

HSE information and press releases can be accessed on the Internet: http://www.hse.gov.uk

COMAH major accidents notified to the European Commission, England, Wales & Scotland 2000-2001 - 'Factsheet -

This factsheet provides summary details of the four COMAH major accidents in England, Wales and Scotland, notified to the European Commission in the period April 2000 to March 2001.

The Control of Major Accident Hazards (COMAH) Regulations 1999 apply to approximately 1100 establishments that have the potential to cause major accidents because they use, or store, significant quantities of dangerous substances, such as oil products, natural gas, chemicals or explosives. The general duty of the regulations is that "Every Operator shall take all measures necessary to prevent major accidents and limit their consequences to persons and the environment". The regulations are unusual in that they are implemented by a Competent Authority (CA), which is not a single body, but comprises the Health and Safety Executive (HSE) working jointly with the Environment Agency (EA) and the Scottish Environment Protection Agency (SEPA). This arrangement reflects the requirements to ensure the protection of both persons and the environment.

The CA is required to notify certain major accidents to the European Commission (EC). The criteria for a COMAH EC Reportable Accident (ECRA) include: the release of a specified quantity of a dangerous substance; specified harm to persons (e.g. 1 death); specified harm to the environment (e.g. significant damage to more than 10 km of river) or in some circumstances a "near miss". This factsheet and the main report cover the second year that the regulations have been in force, from April 2000 to March 2001.

Summary details of the four ECRAs are provided in the table overleaf. The key points to note are that of the four accidents:
- two of the accidents occurred at top tier sites and two at lower tier sites.
- No fatal/ serious injuries occurred.
- One accident required 60 residents to be evacuated for 12 hours, with further evacuations taking place due to possible off-site effects.
- One accident resulted in on-site property damage in excess of 2 million ECU.
- Two other accidents cost a total of £65,000 in on-site damage and losses.
- The CA investigated all four accidents. One investigation is still ongoing.
- One accident resulted in a prosecution with a fine of £750,000 imposed.
- Prohibition and/or improvement notices were served in relation to three of the accidents. In one other case improvement was recommended without the need for formal enforcement.
- One accident has led to the preparation of a public report to be published on the HSE Internet website early in 2003.

Conclusions
- There were four ECRAs in 2000/01. This is similar to the average number of major accidents that were reported annually under the previous CIMAH regulations.
- Whilst recognising that it is difficult to draw conclusions from such a small sample, ECRAs can be used as a crude measure of safety performance. The Accident Frequency Rate (AFR) for the period April 2000 to March 2001 is 3.6 ECRAs per thousand COMAH establishments per annum. Alternatively this can be expressed as one ECRA per 277 COMAH establishments per annum.
- There is concern at the magnitude and frequency of these accidents and at the repeated underlying causes of major accidents. The CA will continue to use the COMAH Regulations as the vehicle for improving corporate governance of major hazard sites.

The main report, "COMAH Major Accidents Notified to the European Commission England, Wales and Scotland 2000-2001" is available on the HSE website: www.hse.gov.uk/hid Anyone who does not have access to the Internet may obtain a copy from the public register at the Anglian Region office of the Environment Agency in Peterborough. Tel No: 01733 371811.

This is the second such report that the COMAH Competent Authority has produced and it would welcome feedback. If you have any comments or would like any further information please contact: -

Anton Wilson, Hazardous Installations Directorate, Chemical Strategy and Support Unit, Health and Safety Executive, St Anne's House, Stanley Precinct, Bootle, Merseyside L20 3RA (email:
anton.wilson@hse.gsi.gov.uk)

Andrew Hitchings, COMAH Policy Advisor, Environment Agency, Block 1, Government Buildings, Burghill Road, Westbury on Trym, Bristol BS10 6EZ (email: andrew.hitchings@environment- agency.gov.uk) or;

John Burns, Policy Advisor, SEPA Edinburgh Office, Clearwater House, Heriot-Watt Research Park, Avenue North, Riccarton, Edinburgh EH14 4AP (email: john.w.burns@sepa.org.uk).

Table - COMAH EC Reportable Accidents 2000-2001

Operator, Location & Date
Accident Description & Dangerous Substances
Accident Consequences & ECRA Notification Criteria
Causes and Actions Taken

BP Amoco, Part of BP Grangemouth Petrochemicals Complex, Falkirk 10 June 2000.
Release and ignition of 13 tonnes of extremely flammable hydrocarbons (Naptha) from Fluidised Catalyst Cracking Unit.
No serious injuries to site personnel or injuries to the public. No harm to the environment. Significant fire damage to plant. Loss of more than 5% of top tier threshold inventory. Property damage in excess of 2 million ECU.
Failure of a redundant 3" branch in main transfer line due to lack of support resulting in vibration fatigue. Prosecution taken and company fined £750,000. A public report of this accident is to be published on the HSE website early in 2003.

Uniqema (ICI Chemicals and Polymers Ltd t/a), Wilton, Middlesbrough 6 October 2000.
4 tonnes of flammable and toxic liquid Ethylene Oxide at approximately -5°C released to a bund during filling of a road tanker.
No injuries, plant damage or harm to the environment. Approximately £25,000 lost in material costs. Loss of more than 5% of top tier threshold inventory.
Overflow of vent knock out (KO) pot due to spring operated hand valve not closing. The CA recommended that a trip be fitted to transfer pump on high level in vent KO pot to reduce reliance on manual intervention.

Cleansing Services Group Ltd, Upper Partington Works, Sandhurst, Nr Gloucester 30 October 2000.
Fire in the storage area of a chemical waste transfer station. Approximately 180 tonnes of flammable and toxic material consumed in the fire.
Minor injuries to 9 people (4 fire brigade personnel, 1 police officer and 4 local residents). Evacuation of 60 people for more than 12 hours. Loss of more than 5% of top tier threshold inventory and evacuation of persons for more than 500 person hours.
Accident is still under investigation by the Competent Authority. Precise cause not yet established. COMAH Prohibition Notice issued in relation to the safe storage of packaged dangerous goods- since withdrawn (COMAH no longer applies to the site). Replaced by 2 Improvement Notices concerning safe storage of dangerous substances and revision of emergency planning arrangements.

Nipa Laboratories, Ruabon Works, Wrexham 13 January 2001. 14 tonnes of toxic Phenol released from storage tank into a bunded area.
No injuries, plant damage or harm to the environment. Losses and cleanup amounted to £39,800. Loss of more than 5% of top tier threshold inventory.
Incorrect manual setting of phenol transfer system caused a stock tank to overflow. Improvement Notice served resulting in re- design of safety control system.

(C) CROWN COPYRIGHT. This publication may be freely reproduced, except for advertising, endorsement or commercial purposes. Please acknowledge the source as HSE.
Published February 2003