UK chemical plants warned against ‘complacent’ safety standards as cold weather approaches

PLANTS handling hazardous chemicals should not be “complacent” to the risks associated with extreme cold weather, a safety expert has warned.

Sean O’Sullivan, chair of IChemE’s safety and loss prevention special interest group, told TCE: “No one can say that cold temperatures and other extreme weather events can’t happen in the UK, and no one can guarantee that they won’t happen this winter.”

He added: “In the UK, we are fortunate not to have regularly extreme weather similar to that seen in some continental or high latitude locations. This is a blessing but can also foster complacency.”

O’Sullivan’s warning comes after the US Chemical Safety and Hazards Investigation Board (CSB) issued advice to plants to prepare for winter, citing data that shows a notable increase of incidents during the colder months.

Cold weather hazards at chemical facilities were brought into focus by the 2007 Valero McKee refinery fire in Texas. The plant contained a dead-leg – redundant piping with no flow through it – holding stale propane. A leak in the pipe allowed water inside which formed ice, creating cracks in the piping as it thawed.

Propane then escaped the pipe and formed a cloud above the refinery, which ignited as it drifted over the boilers. The incident resulted in four injuries and more than US$50m in damage.

As a result of the Valero fire the CSB put particular emphasis on the importance of removing or isolating dead-legs ahead of winter in its guide to preparing for cold temperatures.  

CSB chair Steve Owens said: “Chemical facilities are especially susceptible to incidents during the winter months when they can be affected by extreme cold weather.

“Every chemical facility must take steps now to winterise its processes in order [to] prevent a major chemical incident from occurring and putting communities, workers and the environment in serious risk.”