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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.

Business

Trains resume between Carmarthen and Pembroke Dock as works end

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TRAIN services resumed this morning (Thursday 28 March) after ten days of essential round-the-clock work to upgrade track and drainage between Carmarthen and Pembroke Dock.

The railway was closed from Monday 18 March to Wednesday 27 March to allow Network Rail teams to replace more than 200 metres of track and 300 tonnes of ballast (track stones) between Pembroke station and Pembroke Dock.

Work to improve the drainage between Narbeth and Kilgetty stations was also completed at the same time.

Nick Millington, Network Rail Wales and Borders route director, said: “This essential work in Pembrokeshire demonstrates our commitment to improving the reliability of the service we provide to passengers along our route.

“We know that replacing the track can be disruptive and very noisy, so I would like to thank the residents of Pembroke for their patience while our team carried out this crucial work.”

Colin Lea, Planning and Performance Director at Transport for Wales said: “We’re pleased that our colleagues in Network Rail have completed this essential work and that Transport for Wales rail services resumed today.

“We’d like to thank passengers for their patience while this work has progressed and look forward to welcoming passengers back in time for the Easter weekend.”

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Welsh Water has increased sewage discharges into waterways ‘by 40%’

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NEW figures released by the Environment Agency have shown that Dwr Cymru discharged sewage into waterways for a staggering 23,354 hours last year, a 40% increase on 2022. 

The Welsh Liberal Democrats are now calling for tougher action against sewage dumping in Welsh waterways.

The party has also called for a halt on bonuses for water company bosses whose firms have dumped sewage into waterways.

Conservative MPs have consistently voted against measures which would have helped to tackle the crisis.

The Leader of the Welsh Liberal Democrats Jane Dodds MS said: “It is a complete scandal that filthy sewage is being pumped into our nation’s rivers and waterways without consequence.

“It’s beggars’ belief that both the UK Conservative Government and the Welsh Labour government are allowing water firms to get away with this environmental vandalism.

“We as a party are calling for tougher action to stop sewage being dumped in local waterways. We have also called for a halt on bonuses for water company fat cats whose firms have pumped filth into our waterways.”

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New bus services announced by Pembrokeshire County Council

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A NUMBER of changes to local bus services will be introduced in the coming weeks as a result of a shake up to bus funding. 

From April 2024, the funding which has been provided directly to bus operators by the Welsh Government to keep services going in the wake of the Covid pandemic will cease. 

Additional funding will instead be provided to Local Authorities to support their local bus network.

In total, Pembrokeshire County Council and the Welsh Government will provide over £3million in support for bus services in Pembrokeshire during the coming year.

As part of this process, all Pembrokeshire’s local bus services have been re-tendered. 

A public consultation, receiving over 300 responses, helped to inform decisions about which services should be prioritised. 

Councillor Rhys Sinnett, Pembrokeshire County Council Cabinet Member for Residents’ Services said: “I am delighted to be able to report that we are able to maintain the whole of Pembrokeshire’s current local bus network in the coming year.

“We have also secured key improvements such as reinstating an hourly service on the 349 route between Haverfordwest and Tenby via Pembroke Dock, and the popular Strumble Shuttle and Puffin Shuttle coastal bus services during the summer.”

The changes will also see two key services, the 302 Haverfordwest to Milford Haven and 349 Haverfordwest to Tenby via Pembroke Dock, brought under Council oversight for the first time. 

This will give the Council greater oversight of service operations and fares.  Pembrokeshire residents will also benefit from a new fare structure on all First Cymru services, due to be introduced from 1 April 2024. 

This will use Tap On Tap Off to allow passengers to pay the cheapest fare depending on the number of journeys they make or distance travelled, and will cap the maximum adult fare at £3 single and £5.40 return. 

More information about these fares can be found on the First Cymru website

A number of additional service changes and improvements are being considered for introduction during the course of the coming year in response to feedback received from the public consultation.  

The following bus service changes have been confirmed:

From 23 March 2024:

  • The Celtic Coaster (403) on the St Davids peninsular will restart for the 2024 season on Saturday 23 March and will run until Sunday 29 September. This is an hourly service, increasing to half-hourly during the whitsun half term and school summer holidays. There will be no service departing Caerfai Road at 13.00 and 13.30.
  • The 351 (Tenby to Pendine via Amroth) will return to its summer timetable.

From 1 April 2024

  • An hourly service will return on the 349 (Haverfordwest to Tenby via Pembroke Dock) service (April to September only).
  • The 356 (Milford Haven to Monkton) service will no longer call at Waterston and Hazelbeach due to operational issues caused by the narrow lanes in this area. The Fflecsi service will still be available.
  • A Saturday service, between 07:30 and 18:30, will be reintroduced in the Fflecsi Mid Pembrokeshire zone (formerly known as Bwcabus). This zone covers the area between Letterston, Crymych, Clunderwen and Wiston.  Passengers can also travel from this zone to Fishguard and Haverfordwest. 
  • The 302 (Haverfordwest to Milford Haven) and 349 (Haverfordwest to Tenby via Pembroke Dock) services operated by First Cymru will come under Pembrokeshire County Council control, giving the Council greater oversight of service operations and fares.
  • The 322 (Haverfordwest to Carmarthen) and 381 (Haverfordwest to Tenby via Narberth) services will be run by First Cymru. The 322 timetable will remain the same. The 381 timetable will remain the same from Haverfordwest to Tenby but journeys from Tenby to Haverfordwest will depart slightly earlier (37 past the hour instead of 45).
  • The X22 and X61 services which provided journeys at the start and end of the day between Pembroke Dock and Kilgetty, and Pembroke Dock and Haverfordwest will be withdrawn.
  • The 410 (Fishguard Town) and T11 (Haverfordwest to Fishguard via St Davids) services will be operated on a commercial (T11 part commercial) basis by Richards Bros. An improved connection with the ferry at Fishguard Harbour will be provided at 12.30.

From 19 May 2024

  • The Tenby Coaster service between Tenby and Saundersfoot will return for the summer season.

From 25 May 2024

  • The 400 Puffin Shuttle and 404 Strumble Shuttle services will return to the coast between Marloes and St Davids, and St Davids and Fishguard. These services will operate 7 days a week until 29 September 2024.  The Fflecsi service is also available in this area throughout the year.
  • The 387/388 Coastal Cruiser service around the Angle Peninsula will also return to its summer timetable, operating 7 days a week until 29th September 2024.

Further information about all Pembrokeshire bus services can be found on the Council’s website.

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