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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.

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‘Honest’ caravan site owner ran site ‘under the radar’ for 20 years

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A PEMBROKESHIRE caravan site owner who “honestly” admitted “dodging under the radar” by running his site without permission for some 20 years will not be allowed to continue doing do.

In an application before Pembrokeshire County Council’s April planning committee, Nicholas Kinahan sought retrospective permission to continue operating his caravan site with 19 touring pitches, along with caravan storage and the erection of a storage shed at Penrath Farm, Ryelands Lane, Kilgetty.

The long-running site operation, a kilometre from nearby Kilgetty, off the narrow Ryelands Lane, was discovered as part of an ongoing enforcement action.

The application was recommended for refusal on a long list of grounds including the site was in the open countryside, did not propose any community facility, was not supported by a Green Infrastructure Statement, no biodiversity enhancement features, the nearby road being a narrow single-track lane with no visibility splays for access, and concerns over foul waste disposal.

Kilgetty/Begelly Community Council has objected to the scheme on the basis of a lack of information provided within the application and access safety.

One third party representation was also received, raising concerns including a lack of information in respect of type of caravans and their use, no surface water or foul waste drainage details, a lack of an ecology survey, and no highway impact assessment.

Speaking at the meeting, farmer and caravan site owner Mr Kinahan said there were three caravans on-site after he moved to Kilgetty in 2004, housing tenants “on benefits,” with nine caravans on-site by 2010 and ‘vans from other sites stored on site later.

“We’ve done wrong and we know we’ve done wrong,” he told councillors, adding: “I can’t afford to live there without this little bit of extra income.”

Speaking on behalf of neighbour Micheal Ormond of Ryelands Caravan Park and his concerns, Andrew Vaughan-Harries – a planning agent who normally represents applicants – said to the applicant: “When I look at this application, personally, I think you’ve tried to do the application yourself.

“We see many, many problems with this application, a septic tank is not acceptable in 2024, there are lots of issues; it’s unsustainable and has to fail.”

Councillor Mark Carter said: “What can I say really? I think we’re looking at a very honest man, unfortunately in this case he’s got it wrong; he’s had a 20-year run of dodging under the radar.

“We have to respect the law and the policy and be fair to every caravan site.”

Moving the application be turned down, he said: “Much as I admire the gentleman for his initiative, I have to go with the officer recommendation for refusal.”

Councillor Rhys Jordan thanked the applicant for his honesty, adding: “I don’t think he’s tried to ride roughshod over planning, I think he’s been naïve, but I can’t support this application.”

The application was unanimously refused by planners.

Members heard the saga of Kinahan’s caravans may not be ended with a planning refusal, the option of a potential certificate of lawfulness – if he could prove the development had been in place enforcement-free for a decade-plus – being mooted at the meeting.

Committee chairman Cllr Jacob Williams said: “If you can prove it’s immune from enforcement it could be a ‘trump card’.”

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Housing secretary plays down talk of Wales following Scotland on rent controls

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THE HOUSING secretary poured cold water on suggestions Wales could follow Scotland’s lead by introducing similar rent controls, saying early indications show it has not worked.

Julie James was pressed for her views on rent controls in Scotland while giving evidence to a Senedd inquiry on the private-rented sector.

Altaf Hussain quizzed the housing secretary about affordability, raising concerns about rent rises since the pandemic, with landlords asking for big deposits and months’ rent upfront.

The Conservative warned this is leading some into unmanageable debt as he questioned whether there is a need to regulate a maximum deposit and rent.

Asked about the Welsh Government’s current thinking on rent regulation, Ms James told the local government and housing committee: “It hasn’t really worked in Scotland, I’m afraid.

“We’ve got some evidence, although it’s early days, to be fair, so we’ll want to monitor that for a longer time period. But, so far, the evidence is it’s not having the desired effect.”

Ms James pointed to a Welsh Government green paper calling for evidence on the right to adequate housing and rent control policies, with a second consultation to follow in summer.

She said: “We’re very keen to look at international examples from all over the place in terms of what works to get affordable rents into the sector.”

Ms James said she was very nervous the renters bill and leasehold reforms will not make it through the UK Parliament before a general election is called.

She warned: “We’ve got two years left of the legislative programme and the possibility of bringing a large bill through to replicate this is slim to none.”

Lee Waters, who was Ms James’ deputy until last month, said many tenants have damp or disrepair issues, but are unaware of their rights or too frightened for fear of eviction.

Suggesting the Welsh housing quality standard should be extended to the private sector, the Llanelli MS warned of a fundamental power imbalance between landlords and tenants.

Ms James criticised the UK Government for reneging on a commitment to uplift quality standards for the private rented sector at the last minute.

The housing secretary said protections under Wales’ Renting Homes Act have led to a substantial drop in evictions since coming into force in December 2022.

Mr Waters said tenants who are forced to move because their landlord has decided to sell face an average cost of about £1,700, suggesting two months’ rent should be waived.

Jack Sargeant, also a Labour backbencher, asked about pet-friendly policies, warning some homeless people face the dilemma of having a place to stay or giving up a companion.

Ms James said she was not able to pick which parts of the UK’s renters bill would apply, but she accepted an offer to be involved in “no benefits claimants” and “no children” exclusions.

She pointed to guidance that landlords cannot unreasonably refuse the right to have a pet but Ms James stressed there must be sensible limits

Recalling how she was once called to a high-rise building while working for Swansea council, she said: “We took an engineer with us and the lift kept breaking because people on the seventh floor were keeping a horse in their kitchen.

“This horse was relieving itself in the lift on the way down and it was breaking the mechanism. It was quite something to see this horse in this kitchen, I have to say.”

John Griffiths, who chairs the committee, raised concerns about a mismatch between the number of students and the amount of purpose-built accommodation in university cities.

Ms James said she has tried to persuade council planning departments they have the power to enforce better standards for student accommodation, so it can be more easily repurposed.

She admitted: “I have not been terribly successful at this but I plan to have another go.”

The former lawyer told committee members other levers will be looked at, including any unintended consequences of the council tax exemption for students.

Mr Griffiths also asked about scope for institutional investment in build-to-rent schemes, which often include shared facilities such as gyms.

Ms James said: “It’s not huge in Wales. It’s a lot less huge than it has become in England,” as she argued build-to-rent is not the solution to the housing crisis.

Mr Waters asked about low take-up of Leasing Scheme Wales, which offers incentives for owners to lease homes to councils, amid concerns the application process is “a bit of a faff”.

Ms James said the housing maintenance allowance, which has been frozen for years until the turn of the financial year in April, has been the main barrier.

She vowed to continue pushing the UK Government to say as soon as possible whether it is a one-off or if it will be uplifted next year in line with inflation.

“I think it’s pretty awful that they haven’t said so,” she told the meeting on April 24.

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Welsh National Scooter Rally gears up for a revival in Tenby

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SCOOTER enthusiasts from across the country are set to descend on Tenby for the eagerly anticipated return of the Welsh National Scooter Rally this May Bank Holiday weekend. This marks the event’s grand return to the popular seaside destination for the first time since 2022, promising a vibrant celebration of scooter culture.

Organised by the Scooter Collective South Wales, the rally is expected to draw hundreds to Pembrokeshire’s “jewel in the crown.” Attendees can look forward to a colourful array of scooters lining the historic Tenby High Street, adding a splash of retro charm to the town’s picturesque scenery.

The weekend’s schedule is packed with activities, starting with a scenic ‘ride-out’ from Tenby United RFC on Heywood Lane on Saturday afternoon. This event promises to be a visual spectacle, with a parade of beautifully maintained and creatively decorated scooters cruising through the local area.

Music lovers have plenty to get excited about as well. The Specials Limited, a renowned two-tone tribute band, will be performing at the De Valence Pavilion on Friday night, supported by DJ Steve Foster. Concurrently, the Ex-Servicemen’s Club and Tenby Rugby Club will host rooms dedicated to Northern Soul and Reggae soul, respectively, ensuring that there’s something to suit all musical tastes.

Saturday’s festivities will also feature a customs show and traders fair at the Rugby Ground. This event provides a perfect opportunity for enthusiasts to showcase their scooters and exchange tips and accessories with fellow aficionados.

As the rally winds down, the weekend will conclude with a grand end-of-rally party at the Rugby Club, where participants can celebrate their shared passion for scooters and music, reflecting on a weekend full of fun and camaraderie.

For those planning to attend, the Welsh National Scooter Rally not only offers a chance to revel in scooter culture but also to explore the enchanting town of Tenby.

With its rich history and stunning coastal views, Tenby provides the perfect backdrop for an event that celebrates classic style and community spirit.

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