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Valero Oil Refinery came close to ‘catastrophic incident’

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EXCLUSIVE REPORT

 

A POTENTIALLY ‘catastrophic incident’ took place at Valero’s Pembroke Oil Refinery last year involving leaking gas and an ignition source, the Pembrokeshire Herald can reveal.

​​This newspaper has been contacted by a number of workers at the site who have told us that it is only ​’pure luck’ which prevented leaking gases from​ being blown into an ignition source, believed to be a furnace, which could have led to another lethal incident at the plant.
Valero have confirmed that they are working with statutory authorities who are investigating the event, which occurred ​on November 3​0​ last year. It involved the Alkylate Iso-Stripper, which creates Alkylate – a premium component of petrol that has exceptional anti-knock properties and is clean burning. The Iso-Stripper is a high risk area of refining, and uses either sulphuric acid or hydrofluoric acid as a catalyst for its chemical reactions.
The oil refinery’s management told The Herald that it is working with ‘continued co-operation’ with regulators, and highlighted in a statement that ‘no personnel were injured’ and that ‘there was no impact on the community’​.​
Valero, which says it is one of the leading employers in south Wales, added that they are unable to comment further during the period of investigation.
HSE INVESTIGATES
A Health & Safety Executive spokesperson told The Herald in a prepared statement: “We are aware of an incident at the Valero Energy Limited Pembroke Refinery in November 2017 which was reported to the Health and Safety Executive under RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013).
“We can confirm that the incident took place on the Alkylate Iso-Stripper, and is being investigated.
“No enforcement action has been taken, though the investigation remains ongoing.”
PUSHING THE PLANT HARDER
Our source​s​ working at the refinery told The Pembrokeshire Herald, on condition of anonymity, that the incident last year was due to the refinery being pushed harder than before. This, combined with the ageing infrastructure at the site, lead to the close call.
He told us: “They have increased output which puts more strain on the equipment.​”
Another employee at the site, who also did not wish to be named, confirmed this. He said that since the refinery was bought from Chevron, it is being stretched and running ​20-30% harder than before.
This, combined with a lack of maintenance, is making it an ‘accident waiting to happen’, he added.
RECENT LEAK OF GAS
Valero confirmed that last month’s activation of emergency sirens was in response to another leak of gas at the plant. But it is not currently known from which part of the refinery.
Readers contacted The Pembrokeshire Herald by telephone​ and social media on the morning of March 29 concerned after hearing a warning sound, which started at exactly 8.01am.
On contacting the refinery the Herald was initially told by a security worker: “We have no information at the moment, we are not sure if it’s a test or not.”
Looking to clarify his answer, our reporter asked: “So you are not sure if it’s a test or a real emergency?”
The Herald was told: “That’s right”
It is understood that there was confusion due to previous false alarms.
Later this newspaper received a statement from Valero spokesperson and Refinery Public Affairs Manager, Stephen Thornton, who said: “At 8:00 am on 29th March 2018, the alarm sounded on site due to identification of a minor gas leak.
“Operations responded promptly to isolate and de-pressure the line to stop the leak.”
SAFETY A ‘GUIDING PRINCIPLE’
In a statement prepared by Valero for The Pembrokeshire Herald, the company said: “Safety is the guiding principle for all that we do at Pembroke Refinery, and Valero takes strong exception to any suggestions otherwise. As one of Europe’s largest and most complex refineries, our highly skilled workforce at Pembroke Refinery operates according to comprehensive and rigorous management systems and standards of safety.
Valero does not comment on operational activities at Pembroke Refinery, however all our activities are conducted within approved regulatory permit limits. All refinery work is undertaken according to stringent regulatory, industry and company standards that ensure the continued effective integrity of the plant, regardless of working capacity. Our advanced and sophisticated operational, inspection and maintenance procedures at the refinery are underpinned by a safety culture fostered across all our personnel, focused on recognising and eliminating hazards before they occur.
“In addition to our own focus on safety, Valero also actively works alongside public bodies such as the Health and Safety Executive, emergency services, the local authority and other agencies to manage risk. This includes Valero’s continued cooperation with regulators regarding an ongoing investigation into an event that occurred in November 2017. No personnel were injured during this incident and there were no impacts on the community, however we are unable to comment further during this investigation.
“Anyone making enquiries regarding Valero’s operations, including our site alarm system, should ask to speak to a member of Valero’s Policy, Government & Public Affairs Department.
“All calls received at the refinery are dealt with by our dedicated security team who follow protocol of not confirming refinery operational details, but will pass your details on if requested.​”​

Akylation unit: The location in the refinery where ‘dangerous incident’ occurred

OIL REFINING – A HAZARDOUS ENTERPRISE

Refinery fire: 2011 accident tragically claimed four lives

It is not the first time that Valero have had the safety of their workplace questioned, nor the first time an incident has affected the Pembroke refinery.
Valero were fined £400,000 at Swansea Crown Court after an incident involving a walkway collapsing and an employee left hanging from ropes at their refinery in Pembroke. It was found that Valero, the American oil company which purchased the Pembroke site in a £447m deal in March 2011, failed to follow procedure and carry out a comprehensive risk assessment on the access tower of which the gangway collapsed seriously injuring a worker.
It was said in court that the maintenance contractor of Valero had their suggestions ignored over the potential risks of the access tower, as they raised the point that there was a ‘potential fatal accident waiting to happen.’ Valero were also seen to give inadequate training and instructions to employees, regarding the safe operation of the tower and gangway.
The incident took place on March 5 2012, as David Thomas, an operator at the refinery, was making his way towards an unloading oil tanker via the gangway of the access tower. The walkway suddenly collapsed and he was dropped 3.5 metres. Mr Thomas, 55, was left swinging from wire rope that had wrapped round his legs, but, as a keen rock climber, was able to distribute the weight from his legs by gripping a cross beam. Despite this, he suffered a dislocated knee as well as lacerations and fractures. Mr Thomas was released from hospital after 17 days, but soon developed arthritis, and ultimately didn’t return to work.
It was deemed that three other related incidents at the refinery previous to the gangway accident, in August 2010, February 2011 and September 2011, were poorly investigated and that a proper checklist assessment was not carried out.
At the time of the infamous explosion in June 2011, which resulted in four fatalities, the refinery was still operated by Chevron, yet the deal to sell the refinery to Valero had already been organised. In November 2015, the Crown Prosecution Service ultimately decided against pressing charges of corporate manslaughter.

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Closure of Tata Steel’s coke ovens sparks political and union backlash

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THE recent announcement by Tata Steel to close the coke ovens at its Port Talbot plant in South Wales has ignited a firestorm of political and industrial action, highlighting the deepening crisis within the British steel industry and the challenges facing the transition to green steel.

Jo Stevens MP, the Shadow Welsh Secretary, expressed her concerns over the impact of the closure on the Welsh steel industry and the workers affected. Stevens emphasized the need for assurances about the workers’ immediate future and pledged that a UK Labour government would invest in the steel industry to support the transition to green steel, harnessing the skills, talent, and ambition of Welsh steelworkers.

The closure, slated for Wednesday due to concerns over the ovens’ “operational stability,” has been criticized by regional Senedd Members for South Wales West, Tom Giffard MS, and Dr. Altaf Hussain MS. They accused the Labour Welsh Government of neglecting its support for the Tata Steelworks in Port Talbot, highlighting a lack of financial assistance since 2019 and calling for a change in response to the current developments.

Unite, the UK’s leading union, has been vocal in its opposition to Tata’s decision, describing it as a shock and a “result of years of betrayal.” The union criticized Tata for not disclosing the imminent risk of closure during recent consultations and announced a ballot for industrial action among 1,500 Tata workers. Unite insists there should be no job losses at Port Talbot or Llanwern and that a blast furnace should remain operational.

Peter Hughes, Unite’s regional secretary for Wales, called for Tata to halt its closure plans in anticipation of Labour’s promised £3 billion investment to rejuvenate the UK steel industry. He accused Tata of managing the decline of UK steel while accepting government subsidies, describing the company’s actions as “deliberate industrial vandalism.”

The closure has not only raised concerns about the future of steel production in the UK but also spotlighted the political and economic strategies required to ensure the industry’s survival and transition towards more sustainable practices. The unfolding situation underscores the need for a collaborative approach between the government, industry stakeholders, and the workforce to navigate the complex challenges ahead.

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Firefighters tackle blaze at block of garages in Monkton

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ONE person was injured as a result of a sunday afternoon garage fire in a block of garages in Monkton.

A spokesperson for Mid and West Wales Fire and Rescue Service told The Pembrokeshire Herald said: “At 1.31pm on March 17, Pembroke Dock and Milford Haven crews were called to extinguish a fire in an alight central garage and were forced to use two breathing apparatus and two hose reels.

“The firefighters reportedly left the scene at 3.02pm after continuing to dampen the fire and check for fire spread.

“The casualty was treated by ambulance service personnel also in attendance.”

The police confirmed that a garage fire had been dealt with by Mid and West Wales Fire and Rescue Service and Welsh Ambulance Service attended.

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Air ambulance called following incident at Aldi Pembroke Dock

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THE WALES AIR AMBULANCE, along with the Welsh Ambulance Service and police were called on Monday morning to an incident at the Aldi supermarket car park in Pembroke Dock.

The Herald understands that the alarm was raised after a car hit a person in the car park after 9am.

We have been told that the incident involved a local taxi.

The emergency services have been asked for a comment.

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