News

Valero Oil Refinery came close to ‘catastrophic incident’

Published

8 years ago

April 14, 2018

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 30 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 sources 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.

Community

Six untaxed vehicles seized in Milford Haven police operation

Published

12 minutes ago

December 17, 2025

Tom Sinclair

SIX untaxed and abandoned vehicles were seized during a joint roads policing operation in Milford Haven on Tuesday morning.

Officers from the Milford Haven Neighbourhood Policing and Prevention Team (NPPT) worked alongside the Pembrokeshire Roads Policing Team as part of targeted enforcement across the town.

In addition to the vehicle seizures, a number of traffic offence reports were issued to drivers during the operation.

Police said the action formed part of ongoing efforts to improve road safety and tackle vehicle-related offences in the Milford Haven area.

Community

Candlelit carol service brings community together in Milford Haven

Published

25 minutes ago

December 17, 2025

Tom Sinclair

ST KATHARINE and St Peter’s Church in Milford Haven hosted its annual Candlelit Festival of Nine Lessons and Carols, bringing together members of the community for a traditional celebration of Christmas.

The service featured readings from the Mayor of Milford Haven, representatives of the Soroptimists, Milford Haven Amateur Operatic Society, the Headteacher and Head Prefects of Milford Haven School, Milford Haven Town Band, and NCI Wooltack Point.

Music for the evening was provided by organist Seimon Morris, Milford Haven Town Band and the Milford Haven Cluster Band, whose performances added to the atmosphere of the candlelit service.

The Friends of St Katharine and St Peter’s Church thanked all those involved and wished the community a happy Christmas.

Crime

Man jailed after strangling partner and attacking police officer

Published

51 minutes ago

December 17, 2025

Court Reporter

A MILFORD HAVEN man who strangled his partner during a violent domestic assault before attacking a police officer has been jailed for two years.

Timothy John, aged 38, of Howarth Close, Milford Haven, appeared at Swansea Crown Court after admitting a series of offences arising from an incident in October.

The court heard that John had been arguing with his partner about his drug use when the situation escalated into violence. Prosecutor Craig Jones said the defendant grabbed the woman by the throat and held her in a chokehold for around ten seconds, leaving her struggling to breathe and fearing she would lose consciousness.

During the attack, John also punched and kicked the victim before smashing a glass bong over her head. At the time, the woman was still in her underwear and managed to flee the property and run into the street to seek help.

John also damaged the victim’s mobile phone by biting the screen, rendering it unusable.

Police attended the address the following day to take a statement from the victim and discovered John hiding in a bedroom. When officers attempted to detain him, he assaulted a female police officer, knocking her glasses to the floor, before escaping from the property.

The defendant handed himself in around 24 hours later.

John pleaded guilty to intentional strangulation, assault occasioning actual bodily harm, assaulting an emergency worker, criminal damage, and escaping from lawful custody. The court was told he has five previous convictions for six offences, although none for violence.

Defending, Dan Griffiths said John accepted the relationship was over and had been using cocaine at the time of the incident, which had made him paranoid, volatile and unpredictable.

He told the court that John had previously worked as a fisherman, roofer and welder, but had struggled with alcohol and substance misuse. Mr Griffiths added that a pre-sentence report highlighted a difficult upbringing and noted a lack of insight into his offending, with concerns that he attempted to minimise his behaviour.

The defence urged the court to consider a suspended sentence to allow John to work with probation services.

Sentencing, Judge Catherine Richards said the offence involved serious strangulation and a sustained assault on an intimate partner, leaving the victim frightened in her own home.