HSE warns aerosol companies to adopt good industry working practices after explosion at Merseyside factory killed one worker and seriously injured three others

Date:

5 June 2008

Release No:

HSE/NW/PROS/016/08

The Health and Safety Executive (HSE) has warned aerosol companies of the need to adopt good industry working practices when the change over of propellant is required.

The warning follows the prosecution of North West Aerosols Ltd of Brookfield Drive, Aintree, Liverpool, following a major fire on their premises in December 2005 where one man was killed and three others received serious burns.

The company was not represented in court as they have since gone into voluntary liquidation, but the case was proven in their absence against two charges under Section 2 (1) of the Health and Safety at Work etc Act 1974.

They were charged under Section 2 (1) that they failed to ensure the health and safety of employees by providing necessary information, instruction, training and supervision and that they failed to provide and maintain safe working systems for filling aerosols.

Liverpool Crown Court Judge Graham Morrow described it as a very serious incident and said had the company not been in liquidation he would have been considering a fine in the region of £250,000, but had to take into account the company’s financial position. The company were fined a total of £2 with £1 costs,

The court heard that at 7.45am there was a release of flammable Liquid Petroleum Gas (LPG), as production started in the morning, the gas ignited creating a fireball in the factory that initially extended half way across the adjacent Hanson Road. Many cans of aerosol exploded in the fire and were jettisoned around the factory and over Hanson Road.

Christopher Knoop died from his injuries and three other people – Gary Brine, Kevin Armstrong and Graham Ryder – all received serious burns.

HSE Inspector Keith Morris said:

"HSE investigations concluded the company had not adopted good industry practice for the change-over of propellants, and had not provided self-sealing quick-release coupling or flame-retardant clothing for all the maintenance staff.

"There was no specific procedure for the changeover of propellants in the gashouses, and there were significant errors in the procedures for start-up and shutdown. On the day of the incident, a trainee engineer had been delegated to start up the production line.

"The sad circumstances of this incident should remind the whole chemical industry to ensure they have clear and accurate procedures that cover all aspects of plant operation. All employees must be properly trained and supervised for their work. Had the company done this then Chris Knoop would not have died and Gary Brine, Kevin Armstrong and Graham Ryder, would not have been seriously injured."

The practice North West Aerosols Ltd followed for changeover of fill gas propellants resulted in open ends left in LPG pipework for extended periods. Opening of a single manual valve would lead to a release of LPG into the gashouse. It was reasonably foreseeable that, sooner or later, someone would inadvertently open the wrong valve causing a release of LPG.

The HSE is calling for the aerosol industry to ensure that LPG piping systems are securely sealed. For change over of propellants this can be achieved by use of self-sealing quick-release couplings, as recommended in guidance by the British Aerosol Manufacturers Association (BAMA) and HSE guidance.

Notes to editors

1. The Health and Safety at Work etc Act 1974 Section 2 (1) says:
   
   "It shall be the duty of every employer to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all his employees."
   
   Section (2) (a) say:
   
   "The provision and maintenance of plant and systems of work that are, so far as is reasonably practicable, safe without risks to health"
   
   Section 2 (2) (c) says:
   
   "The provision of such information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety at work of his employees."
2. Northwest Aerosols went into voluntary liquidation in November 2006. It was considered the circumstances of the incident were so serious that it was important to proceed with the prosecution to place on record and give a broader warning to the chemical industry.

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Issued on behalf of HSE by COI News and PR North West