Maintenance-related major accidents: Classification of causes and case study

The potential for major accidents is inherent in most industries that handle or store hazardous substances, for e.g. the hydrocarbon and chemical process industries. Several major accidents have been experienced over the past three decades. Flixborough Disaster (1974), Seveso Disaster (1976), Alexander Kielland Disaster (1980), Bhopal Gas Tragedy (1984), Sandoz Chemical Spill (1986), Piper Alpha Disaster (1988), Philips 66 Disaster (1989), Esso Longford Gas Explosion (1998), Texas City Refinery Explosion (2005), and most recently the Macondo Blowout (2010) are a few examples of accidents with devastating consequences. Causes are being exposed over time, but in recent years maintenance influence tends to be given less attention. However, given that some major accidents are maintenance-related, we intend to concentrate on classifying them to give a better insight into the underlying and contributing causes. High degree of technological and organizational complexity are attributes of these industries, and in order to control the risk, it is common to deploy multiple and independent safety barriers whose integrity cannot be maintained without adequate level of maintenance. However, maintenance may have a negative effect on barrier performance if the execution is incorrect, insufficient, delayed, or excessive. Maintenance can also be the triggering event. The objectives of this article are: (1) To investigate how maintenance impacts the occurrence of major accidents, and (2) To develop classification schemes for causes of maintenance-related major accidents. The paper builds primarily on model-based and empirical approaches, the latter being applied to reports on accident investigation and analysis. Based on this, the Work and Accident Process (WAP) classification scheme was proposed in the paper.