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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.

News

Community projects celebrate their UK Government funding successes

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A CELEBRATION event brought together 25 community projects that have benefited from more than £1.3million in UK Shared Prosperity Funding in Pembrokeshire.

Pembrokeshire County Council facilitated the development programme for third sector organisations and social enterprises which covered three intervention areas across the County – capital projects, green infrastructure and social action.

The diverse range of projects including community facilities, youth projects, growing sites, environmental awareness action, pet therapy, museums and more.

Project leads came together at HaverHub, Haverfordwest on January 22nd to celebrate and discuss the outcomes of their work, with the majority having exceeded targets with some breath-taking achievements highlighted.

Some key successes already evidenced include the improvement or creation of around 25,764m² of publicly accessible spaces, 934 community events or activities supported and 2228 volunteering opportunities created/ supported, with final reports still to be submitted.

SPF Communities Coordinator Heidi Holland said: “This network of organisations has strengthened and benefited from opportunities to come together, visit other projects, share good practice and willingness to develop collaborative approaches as a legacy moving forward to impact on future generations.”

Among those at the event were Cilrath Acre, Sandy Bear, Cleddau Project, Milford Haven Maritime and Heritage Museum, West Wales Rivers Trust, Point – Fishguard and Goodwick Youth Project and Menter Iaith Sir Benfro.

Cllr Paul Miller, Cabinet Member (SPF Lead), said: “It was great to see such a wide range of projects, from right across Pembrokeshire, who have benefited from the SPF Communities Funding. SPF funding will re-launch in April 2025 and we look forward to being able to support more organisations across the county delivering meaningful improvements in their communities.”

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News

Grandmother jailed for killing baby girl in Withybush Hospital crash

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A GRANDMOTHER has been sentenced to four years in prison for causing the death of eight-month-old Mabli Cariad Hall in a tragic crash outside Withybush Hospital, Haverfordwest.

Bridget Carole Curtis, 71, of Begelly, appeared at Swansea Crown Court, where she admitted to causing death by dangerous driving. She was also banned from driving for eight years and must pass an extended test to regain her licence.

Tragic: Baby Mabli Cariad Hall died in 2023 after being hit by a car driven by Bridget Curtis (Image: DPP/WNS)

The devastating incident occurred on June 21, 2023, when Curtis’s white BMW struck Mabli’s pram at the hospital entrance. The baby, described as “bright” and “beautiful,” suffered severe traumatic brain injuries. Despite being airlifted to the University Hospital of Wales in Cardiff and later transferred to Bristol Royal Hospital for Children, Mabli passed away four days later, on June 25.

The court heard that Curtis had been searching for her handbag on the rear seat while the engine was running. Dash cam footage showed her car mounting a kerb and traveling 28 metres at a top speed of 29mph, hitting a tree after striking the pram. Data revealed the throttle was fully open for four-and-a-half seconds, with no brakes applied.

A family shattered

Flowers at the scene of the accident (Image: BBC)

Mabli’s father, Rob Hall, sustained injuries in the crash, which occurred as the family visited the hospital to say their goodbyes to Mr Hall’s mother, who was receiving palliative care. The court heard a heart-wrenching victim impact statement from Mabli’s mother, Gwen Hall, who said: “I don’t know who I am anymore… my heart breaks constantly.” She described watching helplessly as her baby died in her arms.

Mr Hall said Curtis’s actions had “ripped my baby out of my hands,” adding he has replayed the horrific moment “over and over again.”

‘Grossly reckless’ actions

Swansea Crown court where the case was heard (Image: BBC)

Judge Geraint Walters described Curtis’s driving as “grossly reckless,” emphasizing the devastating and irreversible consequences. “Mabli died senselessly and needlessly, and her death has changed lives forever,” he said.

Prosecutor Craig Jones told the court there was no evidence Curtis had suffered a medical episode, but rather what was described as a panic attack. The court heard she was previously of good character, with a clean driving record.

Curtis, who voluntarily surrendered her licence after the crash, expressed deep remorse in a letter read to the court. “I am so deeply sorry,” she wrote. “The sadness and grief will be with me ’til my dying day.”

Her defence barrister, John Dye, said Curtis now suffers from PTSD and depression, with frequent flashbacks of the incident.

In sentencing, Judge Walters acknowledged that Curtis had not intended harm but underscored the gravity of her actions. “You are responsible for the life-changing devastation,” he concluded.

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Crime

Farmer cleared of restraining order breach at Haverfordwest court

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A PEMBROKESHIRE man has been found not guilty of breaching a restraining order after being accused of referencing a protected individual in a Facebook post.

Philip Stoddart, 58, of Monkhill Farm, St Ishmaels, appeared at Haverfordwest Magistrates’ Court on Monday (Jan 20) to face the charge. The prosecution, led by Ann Griffiths on behalf of the crown, alleged that between December 4 and December 13, 2023, Stoddart made a Facebook post that, by inference, referred to a person he was prohibited from contacting under a restraining order imposed by Swansea Crown Court on April 16, 2021.

The restraining order, issued under Section 360 of the Sentencing Act 2020, barred Stoddart from making any form of contact with her.

Prosecutors argued that the Facebook post constituted a breach of the order, contrary to Section 363 of the same act.

Stoddart denied the allegations and entered a not guilty plea during a prior hearing on October 1, 2024.

Magistrates Professor N. Negus, Mr. J. Steadman, and Mrs. J. Morris presided over the trial, which concluded on Monday.

After reviewing the evidence, the bench found Stoddart not guilty, dismissing the case.

The dismissal brings to a close legal proceedings that had been ongoing for over a year.

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