Corrosion‐related accidents in petroleum refineries : lessons learned from accidents in EU and OECD countries

Petroleum refineries are generally acknowledged to be high hazard sites due to the nature of petroleum products and the processing technologies that produce them in the current era. For the most part, however, the risks are well-known and refinery operators have applied considerable knowledge and resources over the past decades to control and minimize risk potential. Nonetheless, major accidents in refineries tend to regularly occur with impacts not only on human health and the environment, but also in many cases on social and economic well-being. A recurring cause of accidents in petroleum refineries is well-known to be corrosion. This report studies corrosion-related accidents in refineries within the European Union (EU) and the Organization for Economic Co-operation and Development (OECD), comparing accident occurring before and after 2000 and with the view to providing insights into recent causal trends and identifying lessons learned that could influence prevention strategies in future. The report highlights process and equipment conditions and potential risk management failures that were cited in 99 different corrosion-related accidents occurring between 1965 and 2008. In particular, the study provides some evidence to confirm concerns among experts in both government and industry that the risk of corrosion failures causing major accidents in EU and OECD countries remains a strong area of concern. The aim of this analysis is to aid particular inspectors by providing a concise summary of refinery corrosion hazards and examples of how they have been manifested in past accidents. The findings may be also useful to operators in renewing aspects of their risk management strategy or training personnel on how to recognize and evaluate potential corrosion risks.