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.

Local Government

Armed Forces flag flies over County Hall

Published

1 hour ago

June 23, 2026

Tom Sinclair

THE ARMED FORCES flag is flying proudly at County Hall this week ahead of Armed Forces Day on Saturday, June 27.

Leader of Pembrokeshire County Council, Cllr Tessa Hodgson, and the Council’s Armed Forces Champion, Cllr Simon Hancock were among those who marked the flag raising on Monday morning (June 22).

Also present were the Chairman of Council, Cllr Delme Harries, the Chief Executive, Will Bramble and the Regional Armed Forces Covenant Liaison Officer, Hayley Edwards.

Cllr Hancock said: “It is always a very proud moment to see the Armed Forces Flag flying over County Hall.

“Armed Forces Day is a chance to show our deep appreciation for the men and women who serve, as well as the families and communities who support them.

“Our county has a rich history of connection with the Armed Forces, and we are proud to uphold and strengthen that bond.

“As a Council we are committed to ensuring that members of the Armed Forces community in Pembrokeshire receive the recognition and support they truly deserve and we are proud to be a Defence Employer Recognition Scheme Gold Award holder.”

Crime

Accused Milford Haven rapist to stand trial at Crown Court

Published

2 hours ago

June 23, 2026

Sarah Jane Absalom

A MILFORD HAVEN man has appeared before magistrates accused of rape and sexual assault.

James Kershaw, 46, is charged with raping a woman in Milford Haven between February 1, 2013, and March 31, 2014.

He also faces a charge of sexually assaulting a female over the age of 13 by penetration with his finger between December 1 and December 30, 2012.

Kershaw appeared before Haverfordwest Magistrates’ Court on Tuesday (Jun 23) by video link and denied both charges.

Due to the seriousness of the allegations, magistrates declined jurisdiction and sent the case to Swansea Crown Court, where Kershaw is due to appear for a pre-trial hearing on July 24.

He was released on conditional bail, with the sole condition that he must not contact the complainant.

News

Bus overturns in major incident near Kidwelly

Published

3 hours ago

June 23, 2026

Tom Sinclair

All passengers rescued as emergency services remain at scene

A BUS overturned on the A484 between Kidwelly and Ferryside on Tuesday (Jun 23), prompting a major emergency response and lengthy road closures.

The incident happened shortly after 12:20pm near the Kidwelly roundabout at Parc y Bocs.

Emergency services, including firefighters from Kidwelly, Carmarthen and Tumble, were sent to the scene following reports of a serious collision involving the bus.

Mid and West Wales Fire and Rescue Service confirmed that all passengers were safely removed from the vehicle.

A spokesperson said: “All passengers have been safely removed from the bus and are receiving appropriate care.”

A rest centre has been established at the John Burns Centre in Kidwelly, where welfare arrangements are being made for those involved.

The scale of the incident led Dyfed-Powys Police to declare a major incident earlier in the day, with officers urging members of the public to avoid the area.

The A484 remains closed between the Kidwelly roundabout at Parc y Bocs and Llandyfaelog while emergency services continue their response and carry out investigations into the cause of the crash.

Police, ambulance and fire crews remain at the scene.

Motorists are being advised to find alternative routes and are warned that the road is expected to remain closed for a considerable time.

Emergency services have also issued advice for drivers caught in congestion during the hot weather, urging people to stay hydrated, keep vehicles ventilated and never leave children, vulnerable adults or pets inside parked vehicles.

The cause of the incident has not yet been confirmed.