In a case that has resonated across the UK’s industrial workforce, an engineering services firm has been handed a substantial penalty after a worker sustained devastating injuries during refurbishment work at the Mossmorran petrochemical complex in Fife. This incident, again highlights the profound importance of rigorous safety oversight in high-risk environments.
Kirkcaldy Sheriff Court imposed a £900,000 fine, accompanied by a £67,500 victim surcharge, on contractors Altrad Babcock for breaching essential health and safety duties. The firm—known at the time as Doosan Babcock Ltd—had been contracted to dismantle and replace key components within the KF05 furnace at ExxonMobil’s Fife Ethylene Plant near Cowdenbeath. What should have been a carefully controlled operation turned into a serious and avoidable accident that left experienced rigger Darren Spagnoletta, then aged 47, with extensive and lasting injuries.
During the refurbishment process, workers were required to remove long, heavy metal coils—commonly referred to as “pencils”—that lined the firebox. These coils often extended up to seven metres in length and weighed significant amounts, requiring the use of specialised lifting equipment. Under normal circumstances the team would rely on a Niko rail system to stabilise and lower the coil sections, ensuring full control during the descent.
However, on the night of 20 July 2021, the nightshift team discovered that the Niko rail was unavailable. Concerned about meeting operational targets, the team introduced an alternative method involving slings and chain blocks. Crucially, this change in process was made without the necessary reassessment of risk—despite the inherent danger of handling such large suspended components within a confined furnace environment.
Shortly after midnight, a coil measuring 7.63 metres and weighing around 130kg was mistakenly cut despite not being properly secured. The metal section dropped violently to the base of the firebox, where Mr Spagnoletta was positioned. The impact resulted in a serious injury at work with three skull fractures, deep lacerations requiring extensive medical treatment, a broken shoulder and a prolonged period of recovery lasting 15 months. After 24 years of service with the company, he ultimately left his role as a result of the incident.
Investigators from the Health and Safety Executive later confirmed that although an initial risk assessment existed, it failed to address the hazards introduced when the working method was altered. The absence of a structured, reviewed, and approved approach left workers in a position where they had to improvise with heavy machinery—an error of judgement that carried severe consequences.
Debbie Carroll of the Crown Office and Procurator Fiscal Service underscored the gravity of the failings, noting that the organisation’s failure to adjust its safety planning after the late change in equipment availability created conditions ripe for disaster. She emphasised that this case should stand as a reminder to all employers: when alternative methods are used, risk assessments must be updated immediately. Any delay can expose workers to unacceptable danger.
For UK workers, particularly those employed in engineering, maintenance, and other industrial sectors, the case reinforces a fundamental truth: robust safety culture is not optional. Every worker deserves a secure environment, and every employer has a non-negotiable obligation to ensure that secure systems of work are consistently maintained, reviewed, and reinforced—especially in hazardous settings like petrochemical plants.
Jonathan Morgan, spokesperson for The Workers Union stated, “this incident underscores why vigilance, oversight, and worker-focused safety measures must remain a daily priority. While justice has been served in the form of financial penalties, the physical and emotional toll on the injured worker cannot be undone. What can be done is ensuring that lessons are not only learned but embedded into future operations across the sector. Our commitment remains clear: we stand with UK workers, ensuring that their rights, their safety, and their welfare remain central to the national conversation on workplace standards.”
