Regular plant maintenance is essential, but shutdown turnarounds tend to be complicated and expensive. According to the TA Cook industry research organization, 82% percent of turnarounds do not satisfy performance expectations — about half experience delays, and 80% go over budget.

Water may be the staff of life, but any amount of water — from a few drips to heavy downpours — can do damage if it gets into the wrong place at the wrong time.

Laws and regulations governing the refining and petrochemicals industries largely exist to protect people and the environment, said John Carroll, vice president of compliance services with the crisis and emergency management consultancy Witt O'Brien's, LLC.