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.

Crime

Man charged with strangulation and assault offences after October incident

Published

3 hours ago

December 14, 2025

Court Reporter

A MAN recorded in court as having no fixed abode has appeared before magistrates charged with intentional strangulation and two further assault offences.

Michael Sudbury, 50, whose address was not read out in court, but in Herald records is Glan Hafan, Llangwm, appeared before the bench facing multiple charges.

The charges relate to an incident on 22 October 2025 and include:

Intentional strangulation, contrary to section 75A of the Serious Crime Act 2015
Common assault
Assault by beating

No further details of the alleged incident were opened in court, and no plea was entered at this stage.

Sudbury was remanded on conditional bail, with the case listed to return to magistrates later this month.

Crime

Haverfordwest man sent to Crown Court on multiple serious charges

Published

4 hours ago

December 14, 2025

Court Reporter

Defendant remanded in custody

A HAVERFORDWEST man has been sent to Swansea Crown Court to stand trial on a series of A 49-year-old Haverfordwest resident has been committed to Swansea Crown Court to face trial on multiple serious charges deemed too grave for magistrates to handle.

David Guy, of Market Street, Haverfordwest, appeared before Haverfordwest magistrates facing a series of allegations stemming from a single case. The charges, which were not detailed in open court, include:

Assault occasioning actual bodily harm (ABH)
A second count of assault
Criminal damage
An additional allegation of interpersonal violence
A public order offence

Magistrates declined jurisdiction, determining that the matters exceeded their sentencing powers, and sent the case in its entirety to Swansea Crown Court.

Guy was remanded in custody pending his next appearance. The court register notes: “Sent to Crown Court for trial in custody – next hearing at Swansea Crown Court.”

A date for the initial Crown Court hearing will be set administratively. Guy will remain in custody until then.

The Pembrokeshire Herald will provide further updates as the case progresses in the Crown Court.

Crime

Castlemartin man back before magistrates over multiple alleged assaults

Published

4 hours ago

December 14, 2025

Court Reporter

Defendant remanded on conditional bail ahead of further hearing

A CASTLEMARTIN man has appeared repeatedly before magistrates this month over a string A 40-year-old man from Castlemartin has made repeated appearances before magistrates this month in connection with a series of serious alleged offences, including assault occasioning actual bodily harm (ABH), intentional non-fatal strangulation, common assault, and criminal damage.

Anthony Alcock, of Pwll Street, Castlemartin, is facing six linked charges stemming from incidents said to have occurred earlier this year. These appear to relate to the same complainant in what is understood to be a single ongoing domestic abuse prosecution.

During recent administrative hearings at Haverfordwest Magistrates’ Court, Alcock did not enter pleas while matters of bail and case management were addressed.

Charges Include:

Assault occasioning actual bodily harm (ABH)
Intentional non-fatal strangulation
Common assault on a woman
Criminal damage in a domestic context
Additional assault allegations involving the same complainant
Breach of bail conditions

Alcock was initially granted conditional bail but was subsequently brought before the court on two occasions for alleged breaches. On those instances, magistrates remanded him in custody ahead of further hearings. He was later re-granted conditional bail, subject to strict conditions such as no contact with the complainant and exclusion from specified locations.

Magistrates have now declined jurisdiction, ruling that the case—particularly the more serious charges involving non-fatal strangulation—is too grave for summary trial. It has been committed to Swansea Crown Court for plea, trial, or sentencing.

No detailed evidence has been presented in open court at this preliminary stage. Alcock remains on conditional bail pending his next appearance at the Crown Court.