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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.

 

Community

New parking rules spark concern at Dew Street site

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Residents question phone-only payments, rising permit costs and future of former library building

RESIDENTS in Haverfordwest’s upper town say new parking rules behind the former County Library on Dew Street risk excluding older and less tech-savvy drivers, as concerns grow over both rising permit prices and the uncertain future of the prominent community building.

The car park is owned by Ateb Group, which allowed free public use over Christmas. However, signs installed this week state that drivers must pay either by phone or online.

Campaigners say both options effectively require a smartphone or internet access, leaving some motorists without a practical way to pay.

Mike Daffern, acting secretary of the Dew Street Campaign, told The Herald: “Realistically these are the same method. Both depend on a phone. For many older people, or anyone without mobile data, that simply isn’t accessible.

“Government guidance says there should be more than one way to pay. Most car parks still offer cash or card. We feel this discriminates against some of the very people who rely most on town centre parking.”

Permit prices questioned

Residents also say they were previously informed that Ateb intended to mirror the charging structure used by Pembrokeshire County Council.

They expected this would reduce the cost of residential permits. Instead, several have reported being quoted figures more than four times higher than equivalent council permits, alongside what they describe as a 30 per cent rise on last year.

One nearby resident, who did not wish to be named, said: “We were told it would be in line with the council. When the price came through it was nowhere near. For some households it just isn’t affordable.”

The Herald has approached Ateb for clarification on its pricing structure and the choice of payment systems.

Building left in limbo

Beyond parking, frustration is mounting about the long-term future of the former library itself.

Planning permission to refurbish the site was granted in 2023, but residents say little visible progress has been made. There is speculation the housing association may instead base operations in Milford Haven following the closure of Meyler House.

Campaigners argue that if the building is no longer required for offices, alternative community uses should be explored rather than allowing further deterioration.

A petition signed by ninety-five locals has been submitted to Cadw requesting the structure be considered for listing.

The request is backed by Royal Commission on the Ancient and Historical Monuments of Wales and The Twentieth Century Society, both of which recognise its architectural significance as an example of late 20th-century civic design. The building also features in Simon Phipps’ book Brutal Wales / Cymru Friwtalaidd, which celebrates modernist architecture across Wales.

Mr Daffern said: “It’s part of Haverfordwest’s story. Even people who don’t love the look of it accept it’s an important public building. Leaving it empty helps no one.”

Temporary arrangement

Public use of the car park may only ever be short-term. The 3.5-acre site, including the former library, was sold by the council for £250,000 in 2022.

A consultation held in early 2024 on potential redevelopment proposals drew criticism, with some residents describing suggested housing plans as “cut-price” and out of keeping with the conservation area surrounding the historic upper town.

No formal planning application has yet been submitted.

Residents say clearer communication is needed on both the future of the land and day-to-day parking arrangements.

Mr Daffern added: “People understand the site will change one day. But while it’s open, it should be fair and accessible. All we’re asking for is common sense and proper engagement with the community.”

 

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international news

Mandelson quits Labour over Epstein controversy

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Former cabinet minister says stepping down is ‘in best interests of the party’ as questions raised over historic payments

LORD MANDLESON has resigned his membership of the Labour Party, saying he does not want to cause “further embarrassment” following renewed controversy over his past links to convicted sex offender Jeffrey Epstein.

The former cabinet minister and one-time UK ambassador to the United States confirmed his decision in a letter to Labour’s general secretary after fresh documents released by the US Department of Justice appeared to reference him in connection with Epstein’s finances.

The files suggest that three payments of $25,000 — totalling $75,000, about £55,000 at today’s exchange rates — were allegedly made to Peter Mandelson in 2003 and 2004.

Lord Mandelson said he had “no record or recollection” of the transactions and believes the allegations may be false, but intends to investigate the matter himself.

In his resignation letter, he wrote that he felt “regretful and sorry” to be linked again to what he described as the “understandable furore” surrounding Epstein.

He added that stepping down from party membership was the responsible course of action while he reviewed the claims.

“I do not wish to cause further embarrassment to the Labour Party,” he said. “I have dedicated my life to the values and success of the party and believe I am acting in its best interests.”

Ambassador role ended

Lord Mandelson had been appointed the UK’s ambassador to Washington by Prime Minister Keir Starmer in December 2024.

However, he was removed from the post last year after earlier revelations about his past friendship and contact with Epstein, including emails showing communication after the financier’s 2008 conviction.

The latest release of files has also included photographs said to show Lord Mandelson alongside an unidentified woman. He said he could not place the location or circumstances of the images.

There is no suggestion that appearing in the documents or photographs indicates criminal wrongdoing.

‘Deep regret’

Earlier this weekend, Lord Mandelson reiterated his regret for ever having known Epstein and apologised “unequivocally” to the women and girls who suffered abuse.

“I want to repeat my apology to the women and girls whose voices should have been heard long before now,” he said.

Epstein died in prison in 2019 while awaiting trial on sex trafficking charges, but investigations into his network of associates continue to generate political fallout on both sides of the Atlantic.

Labour has not yet issued a detailed statement beyond confirming it had received Lord Mandelson’s resignation.

 

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Health

Doctor struck off after sexual misconduct findings at Withybush Hospital

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Hospital medic erased from register for second time after tribunal finds abuse of trust and repeated inappropriate behaviour

A DOCTOR who worked at Withybush Hospital has been struck off the medical register after a tribunal found he sexually harassed junior colleagues and abused his position of trust.

Dr Velmurugan Kuppuswamy was erased from the register by a panel convened by the General Medical Council following findings that he made inappropriate sexual comments, engaged in unwanted physical contact, and displayed what was described as a pattern of sexually motivated behaviour towards more junior members of staff.

The Medical Practitioners Tribunal Service heard the misconduct occurred over several weeks between August and September 2021 while he was working at the Haverfordwest hospital.

The panel concluded he made inappropriate remarks to female colleagues at a social event and touched staff without their consent. His conduct was described as repeated, targeted, and exploitative of the power imbalance between senior and junior medics.

Catherine Moxon, chairing the tribunal, said the behaviour represented a clear abuse of his professional position and a serious failure to maintain appropriate boundaries.

The tribunal found his actions undermined colleagues’ dignity and confidence and risked damaging public trust in the medical profession.

Although Dr Kuppuswamy denied the allegations and pointed to his clinical competence, the panel ruled the misconduct was serious, persistent, and not easily remediable. Erasure, it said, was necessary to protect the public and maintain confidence in doctors.

His name has now been removed from the medical register with immediate effect.

Troubled history

This is not the first time Dr Kuppuswamy’s fitness to practise has been called into question.

Tribunal records show he was previously struck off in 2012 after being found dishonest during an application and interview for a postgraduate cardiology training post at an NHS deanery in England.

The earlier hearing found he falsely claimed to have submitted a Doctor of Medicine thesis, said he was a member of the Royal College of Physicians, and stated he had passed a practical clinical skills assessment.

He initially admitted the deception before retracting parts of his account. The tribunal concluded he had maintained dishonest accounts and wrongly accused another witness of misleading evidence.

He was erased from the register and returned to India, where he later worked at a cardiac hospital.

Return and fresh concerns

In 2020, he successfully applied to be restored to the UK register despite opposition from the GMC, which raised concerns about the timing of his remorse and the lack of independent evidence about his overseas work. The regulator also noted he had not undertaken ethics training.

At the time, a tribunal accepted his assurances that he had changed, describing his evidence as “compelling, heartfelt and genuine,” and concluded that a well-informed member of the public would not be concerned about his return.

Shortly after being reinstated, he began working shifts at Withybush Hospital, part of Hywel Dda University Health Board.

Within months, the fresh allegations that have now led to his second erasure emerged.

The health board has not publicly commented on the outcome of the hearing.

 

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