Esso Petroleum Company Limited has been fined £1 million following a significant gas leak at its Fawley Oil Refinery in Hampshire on 8 November 2022. The incident, which saw the uncontrolled release of approximately 2,400kg of highly flammable liquefied petroleum gas (LPG) over 33 hours, exposed workers to severe risks of injury and burns. The Health and Safety Executive (HSE) prosecuted the company after its investigation revealed long-standing corrosion of a steel tower was the root cause.
Corrosion led to 2,400kg LPG release at Fawley refinery
The incident unfolded when a large steel tower at the Fawley Refinery suffered a partial collapse. This structural failure caused the tower to slew, rupturing critical pipework and initiating the substantial escape of LPG. Within the first 30 minutes alone, an estimated 400kg of the dangerous gas was released. Workers present in the vicinity at the time faced immediate hazards from falling debris and the potentially catastrophic risk of the gas igniting. Fortunately, no injuries were reported, a testament to the emergency measures deployed, including water curtains, which helped mitigate the spread of the extremely flammable vapour. It took a considerable 33 hours to fully isolate the affected process and safely vent the remaining substances into the flare system.
The subsequent investigation by the Health and Safety Executive uncovered that the structural collapse was directly attributable to corrosion of the steel tower, a problem that had developed over many years. Crucially, this corrosion had been identified as early as 2010, yet the company failed to implement appropriate and effective actions to control the escalating risk. This oversight represents a serious breach of safety protocols designed to prevent major industrial accidents.
The HSE, as Britain’s national regulator for workplace health and safety, oversees major hazard industries such as oil refineries under a framework of specialist regulations. These regulations are specifically designed to prevent major accidents involving dangerous substances, placing a strong emphasis on asset integrity, robust inspection regimes, and the proactive management of risks like corrosion. Such risks, if left unchecked, can lead to devastating losses of containment, as demonstrated by the Fawley incident. HSE guidance explicitly mandates that dutyholders must ensure the integrity of all plant and pipework is meticulously maintained and that equipment remains in a safe operational condition. This includes the vital process of identifying and managing corrosion to prevent the escape of hazardous substances.
At Southampton Magistrates’ Court on 12 June 2026, ESSO Petroleum Company Limited, based in Leatherhead, Surrey, pleaded guilty to breaching Section 3(1) of the Health and Safety at Work etc. Act 1974. In addition to the £1 million fine, the company was ordered to pay costs amounting to £12,277. Amanda Huff, an Inspector within HSE’s specialist Chemicals, Explosives & Major Hazards Division, highlighted the gravity of the situation, stating that the uncontrolled release of a large quantity of flammable gas exposed workers to very real and potentially life-threatening risks. She further emphasised that the underlying cause was a failure to properly manage the integrity of plant and equipment, despite the corrosion being identified many years prior. This prosecution underscores the HSE’s commitment to ensuring companies operating with highly flammable chemicals maintain robust systems to manage critical infrastructure safely, protecting both their workforce and the wider public.
This story was originally published by HSE Media Centre
