Multi-Agency Firefighting Exercise at Fawley
A major multi-agency training exercise took place in September at the Esso Refinery in Fawley, Southampton, simulating one of the most challenging scenarios in the petrochemical sector—a crude oil storage tank overfill that ignites within the bund, escalating into a multi-tank fire. The drill brought together firefighting personnel, high-volume pumping units, law enforcement, and the refinery’s own Fire & Response Group (FRG), testing real-time coordination at the UK’s largest refinery.
As a top-tier COMAH (Control of Major Accident Hazards) site, Esso Fawley handles up to 22 million tonnes of crude and refined products each year and processes 270,000 barrels of oil daily. Its scale, complexity, and proximity to residential areas make high-level emergency preparedness essential.
Coordinated Response to a Simulated Multi-Tank Fire
When the simulated alarm was raised, firefighting crews and high-volume pumps (HVPs) from four neighbouring counties were mobilised. They worked alongside Esso’s FRG to supply water to the Williams Six-Gun Monitor, a high-capacity industrial firefighting system crucial for controlling tank fires.
The exercise ran from 09:00 to 13:00, concluding with a hot debrief involving Hampshire Fire & Rescue Service (HFRS), Hampshire Constabulary, and ExxonMobil’s emergency management team.
Testing Real Operational Procedures
The refinery’s FRG first responded to a simulated bund fire in Tank 312 and then requested support from HFRS. Fire control deployed appliances from local stations—crews knew they were participating in an exercise but were unaware of the scenario details.
Upon arrival, teams established Process Forward Control, liaising closely with site emergency managers. Objectives included:
- Validating joint operational plans between HFRS and ExxonMobil
- Testing site evacuation, communication, and command procedures
- Assessing the capability of high-volume pumps to meet large-scale industrial firefighting demands
- Evaluating interoperability using the Airwave TETRA network, used nationwide for mission-critical communications
Interoperability and Communication Under Pressure
One of the key focus areas was communication across agencies. Although police regularly use Airwave talk groups, fire services typically use them less frequently. The exercise provided an ideal opportunity for firefighters—especially those from out-of-county brigades—to practise changing channels and communicating through shared talk groups.
An Airwave Tactical Advisor was present to coach incoming units, demonstrating the need for dedicated radio specialists during real incidents.
The exercise also tested the METHANE major incident model, used to communicate structured information:
- Major incident declared
- Exact location
- Type of incident
- Hazards
- Access
- Number of casualties
- Emergency services present/required
High-Volume Pump Deployment and Water Strategy
Four HVPs were deployed from East Sussex, West Sussex, Dorset, and Kent. In a real event, these appliances would travel long distances in convoy under police escort, so the exercise replicated this movement.
Instead of pulling from a distant lake—standard practice in real tank fires—the team used three saltwater holding tanks connected to the refinery’s marine terminal. Even with reduced flow pressure (4 bar), the available water supply met the minimum requirements for the Williams Six-Gun Monitor, which operates between 7,571 and 22,700 LPM.
Strengths and Learning Outcomes
The exercise highlighted several positive results:
- Rapid site access facilitated by security personnel
- Precise navigation to Forward Control despite unfamiliar terrain
- Effective establishment of Silver Command in the management coordination centre
- Smooth communication on Airwave and TETRA networks
- Strong interagency cooperation, particularly between police and fire hazmat advisors
However, some learning points emerged. As senior fire officers arrived, responsibility for command shifted repeatedly—causing delays as site managers had to re-explain the scenario multiple times. Enhanced briefing protocols could streamline this in real incidents.
Some participants felt that implementing foam application would have improved realism, although the refinery did stage foam stock mobilisation.
Commitment to Continual Improvement
Despite minor challenges, the exercise was widely deemed a success. Hardley Station Watch Commander Chas McGill, who helped coordinate planning over nine months, noted the value of more frequent exercises at petrochemical sites—ideally on an annual basis—given the evolving nature of plant operations, personnel changes, and new firefighting methods.
With Fawley’s industrial landscape surrounded by schools, nurseries, and residential areas, ongoing training is critical for protecting both employees and the local community.
To learn more about COMAH regulations in the UK . Please visit website hse.gov.uk.
