Ineos fined £400,000 after worker suffers serious burns at Grangemouth site

HSE found the metal grating in the sump had given way, plunging the workers leg into the caustic solution. (Pic: HSE)

The petrochemical company was fined after a worker’s leg plunged into a sump containing a caustic solution on November 25, 2019.

The 47-year-old, who was attempting to clear the sump at the time, sustained permanent scarring to his leg.

Ineos pleaded guilty to an offence under Section 2(1) and Section 33(1)(a) of the Health and Safety at Work etc. Act 1974. The company was fined £400,000 at Falkirk Sheriff Court on Friday, the Health and Safety Executive (HSE) said.

The worker had been carrying out a routine task at the Grangemouth plant when the accident happened. (Pic: HSE)

HSE said the worker fell into the sump due to inadequate grating and sustained severe burn injuries.

The sump had needed emptying as its contents had reached the high-level design threshold the day before on November 24.

After laying out various hoses in preparation of emptying the sump, the worker then entered the sump area. While in the sump area, the worker stepped onto the corner of the grating with his right leg.

The grating however gave way, with the worker’s right leg falling into the sump and becoming saturated with the caustic solution. He was submerged in the solution for three seconds before pulling himself out of the sump and was later treated at the burns unit at St John’s Hospital in Livingston.

The man sustained permanent scarring to his right leg and was in pain for four weeks following the incident before returning to work in the December.

An HSE investigation into the incident found Ineos had failed to undertake a risk assessment of the work involved. There was also no safe system of work in place. The grating was not secured and there were no barriers in place to prevent a fall into the sump.

HSE inspector Lindsey Stein said: “The duties on employers to undertake a suitable and sufficient assessment of risks and to provide a safe system of work are absolute within health and safety legislation and well understood. The dangerous properties of caustic are widely known and this incident could so easily have been avoided with the implementation of straightforward control measures identified through assessment.”

Debbie Carroll, who leads on health and safety investigations for the Crown Office and Procurator Fiscal Service (COPFS), said: "This accident could have been avoided had the risks been recognised and appropriate systems of work put in place in ensuring workers were protected from harm when working in this area.

“Ineos Chemicals Grangemouth Limited’s failure to assess the risks posed resulted in the severe injury and permanent disfigurement of one of their workers.

“This prosecution should remind duty holders that a failure to manage and implement effective measures can have serious consequences and they will be held accountable for this failure.”