The city I live in has two major refineries inside the city limits. The refineries both claim to have safe reliable equipment and modern procedures but much of the equipment is over 50 years old and cobbled together over years of repairs and upgrades. On April 2, 2010 5 local men and 2 local women lost their lives when the refining process went wrong. The explosion was so loud I thought my windows had blown out. I grabbed my camera and went outside. This is what it looked like (yes, the explosion woke me up and I took the photo around 1AM):
Unfortunately, I knew one of the victims and many local family members of other victims.
These refineries sell most of their product in Washington and Oregon. What's unusual about this refinery (compared with most refineries in Texas) is that the raw crude oil it processes comes from many different sources including the North Slope of Alaska and Alberta Tar sands. North slope crude varies widely in quality, some of it is very difficult to refine and the crude mined from the Alberta tar sands is even worse. Most Texas refineries refine sweet, light crude, a very different product.
So, how do these fatal accidents happen in a modern refinery? The answer is, it's not very modern and owners don't like to shut them down or spend a lot of money on upgrades. The equipment is not modern at all, it's very old and crude (excuse the pun).
Tesoro’s long list of willful violations included: "Failing to inspect equipment consistent with recognized engineering practices and industry standards; failing to test for cracks and other defects in equipment prone to damage from thermal fatigue, chemical exposure; failing to implement its own corrosion awareness and management program". The company also failed to repair equipment, had no start-up protocols for the heat exchangers, describing the potential hazards, and neglected to ensure workers were properly trained for the task.
These were not accidents, they were WILLFULL violations. And the fact is, most of the quality testing is not done by government regulators - the regulators primary source of information about the quality of the fuels leaving the refinery is straight from the labs of the refineries themselves. Yes, the very people who have to answer to the shareholders when profits are not as good as expected. Nope, they NEVER fudge the numbers - I know because I go to church with them on Sunday, LOL! You would have to be quite gullible to believe the industry speak about how safe and modern the equipment and processes are and how good their quality control is. That's just BS put out by greedy people who don't want to spend $750 million to bring the plant up to modern safety and quality standards. Not only does quality suffer - people lose their lives, children lose parents because of it.
And, yes, different batches of fuels ARE blended together when one or more batches are substandard in one way or another. But this doesn't make the final product consistent because there is only so much blending they can do and the crude oil arrives on huge tankers and there is only so much storage available at the refinery (for both crude oil and refined product).
I believe in Texas you may have a more consistent final product because, as far as I know, most of the low grade, heavy crude oil is processed and sold up north. The refining process is much simpler and it is easier to get a more consistent product when you are not dealing with huge variation in the raw product and the associated problems with meeting air quality emissions standards while refining this heavy crude. Of course, they really don't meet the air quality standards all the time but the EPA gets it's compliance data from the refineries themselves! The regulators trust the refineries so much that they announce IN ADVANCE when they will be showing up to check for compliance.
So don't for a minute try to snow us with feel good oil industry speak about how consistent the final product is across the country. Not only does it vary within the allowed specification but some of it doesn't even meet the minimum specifications even after it's blended. But the labs have complicated formulas they can use to "show" that it does. And even fuel that meets the minimum octane requirement can vary in how likely it is to cause detonation under different conditions. All fuel that meets the legal specification of 87 octane does not behave the same way in your engine because there are different methods a refinery can use to meet the minimum octane spec. and not all the methods create fuels that behave the same in your engine.
And to top that off, the alcohol content of fuel labeled "regular unleaded" in the U.S. can vary from 0% to 10% and the retailer's are not required to tell you what it is because they often don't know themselves once fuels of varying alcohol content are dumped into their underground service station tanks. That alone shows that fuels can vary from fill-up to fill-up, even at the same station from week to week.
About the only thing we agree upon is that by sticking with one brand or another you are not guaranteed to be getting better fuel than with any other brand. Personally, I fill up at the cheapest station in my area because they do a lot of volume and have newer tanks and pumps.
BTW, the refinery in the photo above is owned by Tesoro, a Texas company.