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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.

Crime

Swansea man dies weeks after release from troubled HMP Parc: Investigation launched

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A SWANSEA man has died just weeks after being released from HMP Parc, the Bridgend prison now at the centre of a national crisis over inmate deaths and post-release failures.

Darren Thomas, aged 52, died on 13 November 2025 — less than a month after leaving custody. The Prisons and Probation Ombudsman (PPO) has confirmed an independent investigation into his death, which is currently listed as “in progress”.

Born on 9 April 1973, Mr Thomas had been under post-release supervision following a period at HMP/YOI Parc, the G4S-run prison that recorded seventeen deaths in custody in 2024 — the highest in the UK.

His last known legal appearance was at Swansea Crown Court in October 2024, where he stood trial accused of making a threatening phone call and two counts of criminal damage. During the hearing, reported by The Pembrokeshire Herald at the time, the court heard he made threats during a heated call on 5 October 2023.

Mr Thomas denied the allegations but was found guilty on all counts. He was sentenced to a custodial term, which led to his imprisonment at HMP Parc.

Parc: A prison in breakdown

HMP Parc has faced sustained criticism throughout 2024 and 2025. A damning unannounced inspection in January found:

  • Severe self-harm incidents up 190%
  • Violence against staff up 109%
  • Synthetic drugs “easily accessible” across wings
  • Overcrowding at 108% capacity

In the first three months of 2024 alone, ten men died at Parc — part of a wider cluster of twenty PPO-investigated deaths since 2022. Six occurred within three weeks, all linked to synthetic drug use.

Leaked staff messages in 2025 exposed a culture of indifference, including one officer writing: “Let’s push him to go tomorrow so we can drop him.”

Six G4S employees have been arrested since 2023 in connection with alleged assaults and misconduct.

The danger after release

Deaths shortly after release from custody are a growing national concern. Ministry of Justice data shows 620 people died while under community supervision in 2024–2025, with 62 deaths occurring within 14 days of release.

Short sentences — common at Parc — leave little time for effective rehabilitation or release planning. Homelessness, loss of drug tolerance and untreated mental-health conditions create a high-risk environment for those newly released.

The PPO investigates all such deaths to determine whether prisons or probation failed in their duties. Reports often take 6–12 months and can lead to recommendations.

A system at breaking point

The crisis at Parc reflects wider failures across UK prisons and probation. A July 2025 House of Lords report described the service as “not fit for purpose”. More than 500 people die in custody annually, with campaigners warning that private prisons such as Parc prioritise cost-cutting over care.

The PPO investigation into the death of Darren Thomas continues.

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Crime

Woman stabbed partner in Haverfordwest before handing herself in

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A WOMAN who stabbed her partner during a drug-fuelled episode walked straight into Haverfordwest Police Station and told officers what she had done, Swansea Crown Court has heard.

Amy Woolston, 22, of Dartmouth Street in Milford Haven, arrived at the station at around 8:00pm on June 13 and said: “I stabbed my ex-partner earlier… he’s alright and he let me walk off,” prosecutor Tom Scapens told the court.

The pair had taken acid together earlier in the day, and Woolston claimed she believed she could feel “stab marks in her back” before the incident.

Police find victim with four wounds

Officers went to the victim’s home to check on him. He was not there at first, but returned shortly afterwards. He appeared sober and told police: “Just a couple of things,” before pointing to injuries on his back.

He had three stab or puncture wounds to his back and another to his bicep.

The victim said that when he arrived home from the shop, Woolston was acting “a bit shifty”. After asking if she was alright, she grabbed something from the windowsill — described as either a knife or a shard of glass — and stabbed him.

He told officers he had “had worse from her before”, did not support a prosecution, and refused to go to hospital.

Defendant has long history of violence

Woolston pleaded guilty to unlawful wounding. The court heard she had amassed 20 previous convictions from 10 court appearances, including assaults, battery, and offences against emergency workers.

Defending, Dyfed Thomas said Woolston had longstanding mental health problems and had been off medication prescribed for paranoid schizophrenia at the time.
“She’s had a difficult upbringing,” he added, saying she was remorseful and now compliant with treatment.

Woolston was jailed for 12 months, but the court heard she has already served the equivalent time on remand and will be released imminently on a 12-month licence.

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News

BBC apologises to Herald’s editor for inaccurate story

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THE BBC has issued a formal apology and amended a six-year-old article written by BBC Wales Business Correspondent Huw Thomas after its Executive Complaints Unit ruled that the original headline and wording gave an “incorrect impression” that Herald editor Tom Sinclair was personally liable for tens of thousands of pounds in debt.

The 2019 report, originally headlined “Herald newspaper editor Tom Sinclair has £70,000 debts”, has now been changed.

The ECU found: “The wording of the article and its headline could have led readers to form the incorrect impression that the debt was Mr Sinclair’s personal responsibility… In that respect the article failed to meet the BBC’s standards of due accuracy.”

Mr Sinclair said: “I’m grateful to the ECU for the apology and for correcting the personal-liability impression that caused real harm for six years. However, the article still links the debts to ‘the group which publishes The Herald’ when in fact they related to printing companies that were dissolved two years before the Herald was founded in 2013. I have asked the BBC to add that final clarification so the record is completely accurate.”

A formal apology and correction of this kind from the BBC is extremely rare, especially for a story more than six years old. 

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