PK Refinery
PK Refinery
PK Refinery
111
Executive Summary
Sustainability Report 2007 outlines Pakistan Refinery Limiteds (PRL) performance when viewed
through the lens of HSEQ, Economic & Social Policies. PRL is a hydro-skimming refinery with a
refining capacity of 50,000 barrels per day. Refining process details (specified in the report) form
the basis of our Management System and other monitoring and reporting requirements. As part of
this management system various Key Performance Indicators (KPIs) are set and monitored on an
annual basis. These KPIs range from refinery emissions to effluents to economic and social
performance. The projects that enable us to meet these metrics are also tracked as part of this
effort.
An Environmental Process Review was performed during the year. This review evaluates
numerous aspects of our refining process with regard to their environmental impact. The resulting
recommendations, along with our Internal Compliance Audit, enabled us to make our operations
even more environmental friendly during the current year and have also set the basis for items to
focus on in 2008.
The Companys corporate governance model continues to guide all facets of our business.
Commitment to our mission of remaining a leader in the oil refining business of Pakistan was
demonstrated by our robust financial performance during the first quarter ended September 30,
2007.
PRL is actively engaged with the local community, playing its role as a responsible corporate
citizen. In 2007, the Company invested Rs.11.8 million in numerous meaningful community
projects. With PRLs assistance a non-invasive cardiology lab is being established at Indus
Hospital, Korangi. This hospital is one of the largest charitable entities in the area serving the
medical needs of the local community. PRL also took the lead in helping families affected by
torrential rains during the month of July 2007. Medical and food supplies were generously provided
to communities living in slum area of Ibrahim Hyderi, worst hit by the rain.
For year 2007, by and large the company has either met or exceeded targets set by the
Management System. A comparison with performance in 2006 is also presented; which
demonstrates a trend of gradual improvement. Most noticeable is the decrease in emission of
VOCs, resulting from design upgrades in various tanks. Many of objectives have been completed
and the remaining ones are making satisfactory progress. The PRL Upgrade Project, mandated by
environmental regulations is also on track. The Company will make a significant capital investment
over the life of this project.
An important component of Management System is Contractor Management. This ensures that,
not only PRL employees and assets are protected, but the people working for us in various
capacities also remain safe. Significant emphasis was placed in educating and training contractors
on HSE policies, so that they could perform their jobs in a safe and environment friendly manner.
PRL is also well aware of its legal obligations and has a sound Crisis Management Plan to cater to
all possible emergencies related to its activities in the area.
222
333
Sincerely,
Z. Haleem
444
555
Board of Directors
PRL Management Team
Company Profile
Overall Operational Network
Process Summary
Occupational Health & Safety Management
666
Mr. Rahmatullah is a law graduate from University of Peshawar. He joined Burmah Shell Oil and
Distribution Company in 1968 and worked in different capacities i.e. Chemicals, Human
Resources, Marketing, Supply, Distribution, Retail, etc.
Transferred to Shell International London in 1994, Mr. Rahmatullah was appointed as a Manager
in the Business Strategy Division and was involved in various portfolios covering over 140
countries. On his return in 1998, Mr. Rahmatullah was appointed as Head of Operations of Shell
Pakistan and was looking after Middle East and South Asia (MESA).
In 2001, Mr. Rahmatullah was appointed as Chairman of Shell Companies in Pakistan and
Managing Director of Shell Pakistan Limited. He has been a founding member of PAPCO (Pak
Arab Pipeline Company). He retired from Shell on 30th June, 2006. Mr. Rahmatullah has been
Chairman of Pakistan Refinery Limited (PRL) since June, 2005. In addition to this, he is currently
the Director General of Civil Aviation Authority of Pakistan. He is also the Chairman of LEADS
Pakistan, founding member of Pakistan Human Development Fund, Director on the Board of
Society for Sustainable Development, member of Resource Development Committee of Aga Khan
University Hospital, member of National Commission of Government Reforms, member of
Pakistan Stone Development Company, and member of Board of Trustees of Legends Trust
formed by the Government of Sindh.
777
Board of Directors
888
Board of Directors
999
Board of Directors
101010
Zafar Haleem
Mr. Nauman joined PRL in 1971 & over the years progressed in
career and currently holding the position of General Manager
Administration & Special Assignments. He is also heading office
HSEQ committee .He is a law graduate.
Khawaja M. Nauman
Aftab Husain
M. Akram Peracha
10
111111
Hafsa Shamsie
Mr. Shah is a Chemical Engineer & has done his MBA. He has
worked in various disciplines including Plant Operations, Technical
Services, Human Resource & Administration. Currently he is holding
the position of General Manager Technical & Projects and is leading
the Refinery Upgrade Project. He is also Management
Representative for the HSEQ Management System.
M. Naman Shah
Khalid Junejo
11
121212
Company Profile
Pakistan
Refinery Limited
(PRL)
was
built
and
MS
Unleaded
90
RON,
Naphtha,
since
inception
has
been
the
principal
excellence
and
high
degree
of
citizen
by
serving
community
and
12
131313
13
141414
Process Summary
Units Installed
Desalter Unit
Crude Unit
Platformer Unit
14
151515
Process Units
Desalter
Crude oil often contains impurities such as
free water, inorganic salts, suspended
solids and water-soluble trace metals. As a
first step in the refining process, to reduce
corrosion, plugging, fouling of equipment
and to prevent poisoning of catalyst in
processing units, these contaminants are
removed by desalting. In desalting process,
brine particles are coalesced with added
wash water and consequently separated by
gravity.
Crude Unit
The objective of the oil refining
process is to separate the crude oil
into number of fractions, each of
which then contains a narrower
range of hydrocarbons, which are
more suitable for conversion into
saleable products.
15
or
processing,
as
are
feed
stock
adversely
for
further
affected
by
16
suspended
solids,
phenols,
compounds.
treatment are:
Physical
Chemical
Biological
17
Methods
of
Filtration
Disinfection
Chemical treatment
Reverse osmosis
in
more
fuel
consumption
to
18
19
PRL records all incidents, accidents & near misses to investigate their causes and takes
necessary corrective action to minimize their recurrence. PRL believes that taking into
consideration a near miss seriously, can result in reducing incidents in the future.
Man-hours achieved without lost time injury (LTI) up to December 20, 2007 were 1.2 Million
from last LTI. The milestone is1.5 Million Man-hours.
Parameters
Lost Time Injury
Million Man-hours (Cumulative)without
LTI
Actual Value
01
Fatal Incidents
01
TRC
02
00
36
00
Environmental incidents
01
1.2
20
21
22
23
Scope of Report
Environmental
Aspects
Impacts
Analysis
24
25
Keamari Terminal
-Contamination of land
-Contamination of sea water
- Loss of property/ life
- Air Pollution
-Waste generation
Observations
- Spill Cleanup and fire fighting is the res ponsibility of
KPT .
- Decanting activity at Jetty is performed by Oil Tanker.
- Marine oil spill response center is being formed to
combat Tier I and Tier 2 oil spills. T he refineries , Oil
marketing companies, KPT and Pakistan Navy will
share the resources.
-Refinery has prepared their own Spill Response Plan.
Observations
- Any incidents (Fire/ Spillage) at the jetty is the
responsibility of KPT.
- PRL has its own fire tender, which if required can
assist KPT in fire fighting.
- Clean up activities are carried out by the KPT.
- Possible spillage
- Release of VOCs
- Possibility of fire
- Maintenance activities
Crude Oil Pumping
through pipeline
from jetty to
Keamari Terminal
Decanting of Crude
Oil from tanker at
Jetty
Impact
Effluent
Water with traces of crude oil
Odo r
Use of rad ioactive material
(Radiography)
- Soil contamination
Observations
-Sludge from crude tanks is dumped in the yards
concrete pits for natural biodegradation at remote
location through land farming
- Water drained from the tank is sent to the API
Separator for further treatment.
-Routine maintenance of tanks and bund walls is being
carried out.
- Periodic inspections are carried out.
- Maintenance of Sluice gates is done.
- Tank cooling system is regularly checked
- Fire fighting drills are conducted regularly.
Recommendations
- Maintenance of existing alarm sys tem at the tanks to
be carried out as per plan.
Crude Oil
Effluents
- Water + Oil + other contaminants
- Flushing water as a result of
cleaning
API Separator
Skimmed Oil
Solid Waste
- Hay Bas kets
- Oil sludge as a result of cleaning
- API Separator tank bottom s ludge
- Maintenance activities
Effluents
Water+ Oil+ other impu rities
-Waste generation
- Generation of waste
Observations
-Crude tank is not drained for water at Keamari
Terminal.
- Environmental friendly disposal of Hay Bask ets and
sludge is in place.
-Land Contamination
- Loss of property and life
- Waste generation
- Depletion of resource
26
Observations
- Fire fighting facilities are available.
- Routine maintenance of pumps is carried out.
Recommendations
- Proper drainage is required for crude spillage from the
flanges.
Im pact
Crude Pumping
Efflu ent
- Caustic +Amines Solution
- Water Discharge
- Crude Test Sample
Use of Chemicals
Sulphuric Acid
De- emulsifier (D S-950)
Caustic + mine Solution
De-salting
Solid Waste
Sediments during cleaning
- Contamination of Water
- Degradation of air quality
- Waste generation
- Waste Generatio n
Observations
- Effluents are drain ed to API Separator.
- Steam Leakages from turbin es.
Observations
- Effluent water drained to API Separator
- Cleaning frequenc y of des alter is 1-11/2
month.
- Ac id handling and s torage instructions
are available.
- Environmental friendly disposal of
waste.
Fractionation Process
Crude Heatin g
Air Emissions
Furnace flue gases
Heat generation
Energy Use
Furnace Oil/ Refinery gases/
Natural gas
- Air Pollution
- Depletion of Natural R esource
Heat Generation
Noise
Efflu ent
- Steam condensate from the traps.
Odor
Maintenance
Observations
- 3 F urnaces gas/ oil fired.
- Possibility of explosion due to backfire.
- Steam is used for atomizing the fuel in
the furnace.
Recommendations
- Steam condensate recov ery options
should be determined.
- F urnaces s afeguardin g option to be
explored.
- Wastage of resource
- Waste generation
Furnace Oil
(Stored)
Distillation
Air Emissions
VOCs form pressure relie f valves
Noise
Relief Valve Operation
HSD
(Stored)
HSD Stripper
- Waste generation
- Waste generation
27
Observations
- Outlet of pressure relief valves of
distillation towers is opened to the
atmosphere.
Recommendations
- Options to be explored to put the outlet
of the relief valv es in a closed system.
- Monitoring of relief valve pressures to
be incorporated in the operating
procedures.
Effluent
i. Water
ii. Water from the Coalescer
iii. Absorbed H2s in water.
Separation Vessel
& Coalescer
Fuel gas to
flare system
Fuel
gases
Used in
furnaces
- Contamination of Water
- Degradation of air quality/ air pollution.
Maintenance activities
- Waste generation
Liquid Feed
Hydro Reactor
Separation Vessel
Air Emissions
Furnace Flue Gases
- Air Pollution
Noise
- Noise Pollution
Maintenance activities
- Waste generation
Heat Generation
Energy Use
- Natural Gas, R/G and oil
Solid waste
- Spent Catalyst, which has
completed its useful life.
- Ash and particulate matters due
burning of catalyst during
regeneration/ off-loading of
catalyst.
Maintenance activities
Air Emissions
- Release of CO2 during
regeneration
Emissions
Fuel Gases
Maintenance activities
Liquid HC
- Waste Generation
- Health hazard
- Waste generation
Observations
- The burners are of new model with 20%
excess air and the noise level is also low.
- Gases are released through stack at
sufficient height
Observations
- Catalyst used- Cobalt Molybdenum
- Total quantity disposed is approx = 46
tons.
- Catalyst dumped as per CFR 29.
- Safety measure are incorporated for
off-loading.
Observations
- Use for burning in furnaces
- Excess gas is flared out at sufficient
height.
- Waste generation
Air Emissions
VOCs form pressure relief valves
Maintenance activities
- Waste generation
Air Emissions
Fuel gases
Maintenance activities
- Waste generation
Splitter Tower
Observations
- Outlet of pressure relief valves of
distillation towers is opened to the
atmosphere.
- Monitoring of relief valve pressures
incorporated in the operating procedures.
Recommendations
- Options to be explored to put the outlet
of the relief valves in a closed system.
Naphtha
(Top fraction)
Separator
F/G
Observations
- Absorbed H2s in water.
- H2s not stripped off from the water.
- H2S monitoring devices with operators
Recommendations
- Testing of H2s above the drains to be
carried out.
Kerosene
(Stored)
Naphtha
(Mid
fraction) to
Observation/ Recommendations
Gases from
splitter
compressor
Hydro- Furnace
H2 gas
Impact
28
Impact
- Fuel gases
Stabilizer
Light Naphtha
(Stored)
Air Emissions
VOCs form pressure relief valves
Maintenance activities
- Waste generation
Effluent
Waste Water
- Contamination of water
Effluent
Steam Condensate
Release of LPG
Maintenance activities
- Wastage of resource
- Air degradation
- Waste generation
L
P
G
103 F Vessel
Steam
Buffer Drum
Observation/ Recommendations
Observations
- Outlet of pressure relief valves of
distillation towers is opened to the
atmosphere.
Recommendations
- Options should be explored to put the
outlet of the relief valves in a closed
system.
- Monitoring of relief valve pressures
should be incorporated in the operating
procedures.
.
Observations
- Wastewater is drained to API
Separator.
Recommendations
- Explore possibility of installation of auto
drainers.
Recommendations
- Steam condensate recovery options to
be determined.
Steam Condensate
LPG
29
Caustic Injection
Effluent
- Weak caustic
- Na2S
Maintenance activities
Caustic Treated
Column
Water Washing
Column
Effluent
Water+ Caustic+ other impurities
with Na2S
Maintenance activities
Use of Natural Resource
Water
Water
Surge Drum
- Contamination of water
- Waste generation
- Contamination of water
- Waste generation
- Depletion of natural resource
Effluent
Water+ Caustic+ other impurities
with Na2S
- Contamination of water
Maintenance activities
- Waste generation
Effluent
Water+ Caustic+ other impurities
with Na2S
- Contamination of water
Maintenance activities
- Waste generation
Observations
- Continuous discharge of weak caustic
to API Separator.
Recommendations
- Explore possibility of caustic
neutralization at source of discharge.
Observations
- Waste- water is discharged to the API
Separator.
- Treatment is done to meet NEQS.
Observations
- Waste- water is discharged to the API
Separator.
- Treatment is done to meet NEQS.
Observations
- Waste- water is discharged to the API
Separator.
- Treatment is done to meet NEQS.
ASPECTS / IMPACTS
Aspects
Naphtha feed
from Splitter
Tower
Leakages
Maintenance activities
Impact
- Air pollution / water contamination
- Waste generation
Observation/ Recommendations
- Routine maintenance
104 E
Heavy Naphtha
storage
(Tank Farm)
30
Petroleum Product
Storage
(Korangi & Keamari)
Petroleum Products
pumping through
Pipeline to
Keamari Terminal
Airport
PARCO
KESC
Activities performed both
at Korangi & Keamari
Impact
- Soil and ground water contamination
- Air pollution
- Soil and ground water contamination
- Possibility of fire
- Odor
Maintenance Activities
- Waste generation
- Resource Depletion
Air Emissions
- VOCs during ball launching
- VOCs due to Spillage
Observation/ Recommendations
Observations
- Possible land and ground water
contamination
-Routine maintenance of tanks and bund
walls being done.
- Soil and ground water testing being
done on annual basis.
- Tank cleaning procedures established,
including management of oil sludge.
- Crisis Management plan in place.
Recommendations
- Testing of VOCs to determine the level
of emissions.
Observations
- Existing pipelines right of way passes
through residential area.
- Emergency procedures include actions
for prompt communication with the out
side agencies, in case of spills from
pipelines.
Noise
Odor
Liquid Releases
- Possible oil spillage
- Water due to area cleaning
- Minor drippings of FO from
loading arm
-Oily Water (Rain)
Emissions to Air
- Emissions of VOCs.
- Tank Lorry Exhaust
- VOC emissions due to spillage
LPG pumping to
Marketing Co.
(Korangi Refinery)
Noise
Electricity
Odor
Maintenance Activities
- Waste generation
- Air pollution
-Maintenance Activities
-Possibility of Fire
- Waste generation
Electricity Usage
Observations
- Any spilled oil goes to API Separator
through the drains present at the filling
site.
- Spilled oil enhances load on the API
Separator.
- Procedure established for working at
the gantry.
- CMP in place.
- CMP in place
31
Boiler
Air Emissions
- Flue gases
- Soot (Soot Blowing)
Effluents
- Boiler Blow down
Energy use
- Natural Gas/ Furnace Oil as fuel
Cooling Tower
Water Softening
- Air Pollution
- Water Pollution
- Causes increase in TDS level of
discharging water.
Maintenance Activities
- Waste generation
Air Emissions
Airborne water traces
Effluents
- Blow down water
- Filter Washing
- Water pollution
Effluents
Back Wash Water
(High TDS Content)
Solid Waste
- Cartridge Filters
- Carbon Powder
- Maintenance
- Water pollution
- Possibility of spillage causing land
contamination,
- Degradation of Land/ Health Effect
Observations
- Cooling Towers qty=2
- Filter washing is done 3 times a day
and water is drained in API separator.
- Blow down water goes to the API
Separator.
- Cooling towers blow down water is
collected in a tank, which can be used for
fire fighting purposes.
Observations
- Water is drained to API Separator and
ETP is in operation to cater pH
variations.
- Proper containment is built at chemical
storage site.
- Waste generation
- Water Contamination
- Waste Generation
Use of Chemicals
Observations
- Total 3 oil/ gas fired boilers
- Periodic and continuous blow down
water goes to API Separator.
- Emergency shut down system present.
- Emissions testing is carried out.
Use of Chemicals
- Bio Depressant
- Corrosion Inhibitor
Effluents
- Filter Washing
- Water Discharge
Use of Chemicals
- Sulphuric Acid
- Anti Scalars
- Anti Oxidants
Observation/ Recommendations
Noise
Vibration
Heat Generation
Fire
Explosion
R-O Plant
Impact
32
Observations
- Back wash water is discharged in the
open land near RO Plant.
- Cartridge filters are disposed at waste
yard.
- Carbon is removed during annual
maintenance.
Air Emissions
- Generator exhaust emissions
- VOCs from the diesel storage
tank for the generator.
Noise
Generator
Effluents
- Oil drained from the air cleaner.
- Possibility of spillage of diesel
from the diesel storage tank
- Possible spillage of lube oil
- Possibility of fire
Observations
- Total 3 standby generators
- Fuel used - -- Diesel
-Testing of exhaust emissions is carried
out.
- Soil contamination
- Waste generation due to maintenance
activities
Fuel Used
Diesel
Solid Waste
- Glass Breakage
- Waste Paper
- Plastic Materials
- Empty Chemical Bottles
Effluents
- Residue and other products after
testing, which contains oil and
different chemical etc.
- Residue after testing of the leaded
product.
Laboratory
Air Emissions
- Emissions from octane testing
engine. (Daily usage- 2- 2 hrs)
- VOCs
Hazardous Substances
- Release of Gases (Acetylene,
Nitrogen, Hydrogen)
- Waste Generation
- Water Pollution
Observations
- Glass breakage is disposed off through
waste yard.
- Drain outlet from the lab goes to the
API Separator.
Recommendations
- Solid waste to be segregated and
options for possible recycling of materials
to be explored
- Explosive Chemicals
- Possibility of spillage of chemicals
Noise
Odor
- Depletion of resource.
33
Shutdown
Activities
Air Emissions
- VOCs from opened vessel
- Purged Nitrogen
- Fugitive Emissions
Liquid Releases
- Effluent due to flushing
- Oily Water
- Flushing steam water
- Water Pollution
Solid waste
- Metal scrapings from the
equipment
Chemical Handling
MMT Blending
Observations
- Adequate HSE staff is available in
the area and also the area is properly
gas freed before any hot job
- Degradation of Land
- Health Impact
Aspects
Impact
Spills
Emissions
- Land contamination
- Air pollution
Observation/ Recommendations
- Handling procedure is available
Amine/ Caustic
Process
Spills
Emissions
- Land contamination
- Air pollution
34
Observations
- Procedures in place for safe unloading.
- Controls exercised on the supplier
providing transportation services.
ASPECTS / IMPACTS
Aspects
Solid Waste
- Waste metal chips
- Cotton waste rags
- Unserviceable M/c parts
- Packing Material
- Empty drums.
Effluents
- Used oils/ lubricants
- Emissions of the welding gases.
Impact
- Waste Generation
Observation/ Recommendations
Observations
- Waste metal, rags are segregated in
the designated drums and then
transferred to the waste yard.
- Waste oil is collected in the
designated drum for disposal at API
Separator.
Possibility of Fire
Stationary Work
Shop
Solid Waste
- Waste metal chips
- Cotton waste rags
- Unserviceable M/c parts
- Packing Material
- Empty drums.
Liquid Releases
- Used oils/ lubricants
Air Emissions
Welding Fumes
- Waste Generation
- Water Pollution
Observations
- Waste metal, rags are segregated in
the designated drums and then
transferred to the waste yard.
- Waste oil is collected in the
designated drum for disposal at API
Separator.
Possibility of Fire
Electrical Work
Shop
Solid Waste
- Cotton waste rags
- Unserviceable M/c parts
- Packing Material
- Waste Generation
Effluents
- Used oils/ lubricants
- Water Pollution
Energy Usage
Electricity
- Consumption of Resource
Observations
- Solid waste is disposed off through
waste yard.
- Waste oil is collected in the
designated drum for disposal at API
Separator.
Possibility of Fire
Instrumentation
Work Shop
Solid Waste
- Cotton waste rags
- Unserviceable instruments
- Packing Material
Liquid Releases
- Used oils/ lubricants
- Mercury collected from the
instruments
- Waste Generation
- Water Pollution
- Health Hazard
Solid Waste
- Wood Waste/ Saw Dust.
- Empty paint containers
- Packing Material
- Waste Generation
Sand Blasting
Observations
- Mercury is collected from the
instruments and is stored for disposal.
35
Observations
- Waste dumped at waste yard for
ultimate disposal.
- Safety procedures are in place for
sand blasting.
Recommendations
- Waste segregation must be done at
civil workshop.
Projects and
Construction
Workshop
Solid Waste
- Steel waste, pipe pieces.
- Empty paint containers
- Packing Material
- Storage of Acetylene, Oxygen
cylinders
- Gas & Arc Welding
- Emissions of gases during welding
Impact
Waste Generation
Observation/ Recommendations
Observations
- Waste dumped at waste yard.
Ware House
Lubricants/ Gases/
Chemical storage
Nitrogen Storage
H2 Storage
Solid Waste
- Packaging Material
- Empty cans, drums.
- Waste Generation
Electricity Usage
- Resource Consumption
Fire
Solid Waste
- Packaging Material
- Empty cans, drums.
- Waste Generation
- Land contamination
- Possibility of fire.
- Explosion
- Loss of property.
Observations
- Solid waste is collected at the waste
yard.
- Empty drums are either collected by
the supplier or reused.
- Waste handling and disposal
procedures are in place
Observations
- Solid waste is collected at the waste
yard.
- Empty drums are either collected by
the supplier or reused.
- Containments are available to
prevent impacts as a result of spillage.
Air Emissions
- Release of gases
- VOCs due to spillage
- Air Pollution
- Health Hazard
- Air pollution
Observation
- Handling and storage procedures
are in place
- Possible leaks of H2
- Safety Hazard
- Air pollution
Observation
- Handling and storage procedures
are in place
-Crisis Management Plan in place
- Possibility of fire
36
Impact
Air Emissions
- Exhaust Emissions
Motor Vehicles
Observation/ Recommendations
- Air Pollution
- Engines are
recommendations
tuned
as
per
- Waste generation
Energy Use
- Electricity
- Natural gas
- Depletion of resource
Effluent
- Waste water.
- Water pollution
Solid Waste
- Waste Paper
- Printer, fax toners and cartridges
Offices
Office Building
Control Room
Decanting Office
- Consumption of resource
- Depletion of resource
Effluent
- Waste Water
- Water pollution
Ozone Depletion
- Presence of ozone depleting
refrigerant in the air-conditioning
system.
Toilets,
Canteen, Lab
(PRL Korangi)
- Global Warming
- Waste Generation
Energy Use
- Electricity
Observations
- Disposal of waste by placing it in
waste bags.
Recommendations
- Waste segregation in the office to be
promoted.
- Cartridges/ toners to be disposed off
in environmental friendly manner
(either reuse or send for recycling).
- Options for waste paper recycling to
be considered by giving it to recycler.
- Objective of reduction of electricity
consumption to be considered.
- Global Warming
Liquid Waste
- Sewage water
Observations
- Water is treated in effluent treatment
plant.
Toilets
(Keamari Terminal)
- Underground water contamination
- Sewage water
37
- Effluent Treatment
operation.
Plant is in
Aspect
Impact
Scale
Life Cycle
Impact Data
Common Effect
Required
Actions
INPUTS
Crude Oil
Depletion of
natural
resources
Global
Nitrogen
Dioxide (NO2)
Oxides of
Sulphur (SOx)
Methane (CH4)
Volatile Organic
Compounds
(VOC)
Sludges
Raw Water
Depletion of
natural
resources
Global
Increased
moisture rate
Electrical
Consumption
Depletion of
natural
resources
Global
Increase in
ambient air
temperature
38
Ozone depleting
potential
Land and Air
pollution
Global warming
Acid rain
potential
Respiratory
diseases
Efficient
operation of
plant
Proper disposal
procedures
Global warming
Scarcity of water
Efficient
utilization
Re-use of water
Global warming
Efficient
utilization of
energy
Energy
conservation
Aspect
Impact
Life Cycle
Impact Data
Scale
Common Effect
Required
Actions
Usage of
chemicals in
products to boost
performance like
TEL
Poisonous gases
generation as a
result of
combustion
Leakages from
Tanks and
Fugitive emission
Accidental release
of products from
tanks
Hazardous waste
Global warming
Stratospheric
ozone depletion
Health hazards
Acidification
Photochemical
smog
Aquatic toxicity
Soil and ground
contaminants
Human health
Aquatic toxicity
Soil and ground
contaminants
Human health
Carbon
Dioxide(CO2)
Nitrogen
Dioxide (NO2)
Methane (CH4)
Chloro flouro
carbon (CFCs)
Global
Global
Ethylene
dichloride (EDC)
Lead oxides
Regional
/Local
Sulphur Dioxide
(SOx)
Nitrogen Oxides
(NOx)
Hydrochloric
Acid (HCl)
Ammonia (NH4)
Non-Methane
Hydrocarbon
(NMHC)
Local
Global/
Regional
/Local
Global/
Regional
/Local
39
Toxic chemicals
with a reported
lethal
concentration to
fish
Total releases to
water and soil
Quantity disposed
off in a landfill
Global Warming
Potential
Note: Global
Warming
potential can be
50, 100 or 500
year potentials
Ozone Depleting
potential
Cancer and
respiratory track
diseases
Furnace burners
to be changed
with low excess
air burners
The vehicles to
be well tuned
No more use of
TEL in Pakistan
Environmental
friendly
chemicals to be
used
Acidification
potential
Photochemical
oxidant creation
potential
Health Hazards
Regular
monitoring
Containments to
be provided
Methods being
explored to get rid
of hazardous
waste in
Environmental
friendly manner
40
41
Corporate Governance
42
Approve and sign statements of Ethics and Business practices and ensure its
communication to all employees.
Approve major decisions and exercise powers specified (law and code).
Establish sound internal control systems and issue statement on internal control.
Define the role and responsibilities of the Chairman of the Board and Chief Executive
Officer.
Books of account.
43
Operations
&
Supply
Commercial
&
Corporate
Affairs
Internal Audit
Technical
&
Projects
Engineering
Managing
Director
44
&
Special
Assignments
Administratio n
Finance
Medical
Human
Resources
PRL Organogram
Project Organogram
45
46
Responsible for ensuring the project is executed in line with business needs.
Project Manager:
The PRL upgrade project will be managed and guided by the Asset development Management
Team (ADMT)/ Project Steering Committee (PSC).
47
Audit Committee
The Audit Committee comprises three members, including the Chairman, from the non-executive
Directors of the Board all of whom have sufficient financial management expertise. The Chief
Internal Auditor is the Secretary of the Committee.
The Committee held four meetings during the year and held separate meetings with the Chief
Financial Officer, Chief Internal Auditor and External Auditors as required under the Code of
Corporate Governance. The Committee assists the Board of Directors in ensuring adequate
safeguard of Company assets, effectiveness and adequacy of the Company's system of internal
control and compliance with operational, financial and risk management policies of the Company.
The Committee supervises the Company's financial reporting process including review of interim
and annual accounts prior to Board of Directors' approval and subsequent publication with focus
on areas of material impact and compliance with applicable accounting standards, listing
regulations and best practices as per the Code of Corporate Governance. The Committee is
responsible for review of External Auditors' communications including management letters and
discussion on major findings from interim and final audits and any matter that the External Auditors
may wish to highlight. Additionally, the Committee has the permit to review and investigate any
matter or issue as may be assigned by the Board of Directors.
48
Other Committees
Purchase Committee
Chief Financial Officer, GM (Administration & Special Assignments), Sr. Manager
Commercial & Planning.
Executive Committee
Chief Financial Officer, GM (Administration & Special Assignments), GM (Engineering),
GM (Operations & Supply).
49
50
51
Basis of Preparation
These financial statements are prepared in accordance with approved accounting standards as
applicable in Pakistan and the requirements of the Companies ordinance, 1984. Approved
accounting standards comprise of such International Accounting Standards as have been notified
under the provisions of the Companies Ordinance, 1984. Wherever, the requirements of the
Companies Ordinance, 1984 or directives issued by the Securities and Exchange Commission of
Pakistan differ with the requirements of these standards, the requirements of the Companies
Ordinance, 1984 or the requirements of the said directives have been followed.
Fixed Assets
Fixed assets are stated at cost less accumulated depreciation/ amortization except capital workin- progress, which is stated at cost.
These are valued at cost, determined using weighted average method, less provision for
obsolescence. Items in transit are valued at cost comprising invoice value plus other charges
incurred thereon.
52
Provisions
Provisions are recognized when the Company has a present legal or constructive obligation as a
result of past events; it is probable that an outflow of resources will be requires to settle the
obligation; and a reliable estimate of the amount can be made.
Revenue Recognition
(a) Local sales are recorded on the basis of products pumped in oil marketing companys tanks.
(b) Export sales are recorded on the basis of products shipped to customers.
(c) The prices of refinery products are notified by the Oil & Gas Regulatory Authority (OGRA)
which is primarily based on import parity pricing formula.
(d) Dividends are recognized when the right of receipt is established.
Income on bank deposits is recognized on accrual basis.
53
HSEQ Policy
54
PRL has introduced a HIV /AIDS policy in its organization to protect staff and business interest and
contribute to prevent spread of HIV/AIDS.
Security Policy
55
Ethics Policies
Conflict of Interest
It is PRL policy that employees and others acting on PRLs behalf must be free from conflicts of
interest that could adversely influence their judgment, objectivity or loyalty to the company in
conducting companys business activities and assignments. The company recognizes that
employees may take part in legitimate financial, business and other activities outside their PRL
jobs, but any potential conflict of interest raised by those activities must be disclosed promptly to
management.
Gifts
The term business gifts in this policy includes business entertainment, as well
as gift items. The giving of business gifts is a customary way to strengthen
business relationships and, with some restrictions, is a lawful business practice.
It is PRL policy that company employees may give and receive appropriate,
lawful business gifts in connection with their PRL work, provided that all such
gifts are nominal in value and not given or received with the intent or prospect of
influencing the recipients business decision-making.
Harassment
PRL is committed towards maintaining a working environment free from harassment of all kinds,
which includes sexual, racial, age, religious, ethnic, disability, national origin, color and any other
form of forbidden harassment of any Company employee or applicant for employment. As per
policy of the company no individual be subjected to any unwelcome conduct that is or should be
known to be offensive because of his or her gender, appearance, religious beliefs, color, place of
origin, mental or physical disabilities, family status, or other protected category. Such harassment
in any form or manner is strictly prohibited.
Political affiliation:
No employee may make any political contribution of any kind in the name of, or by utilizing
Company funds, assets, services or facilities. All employees are free to make personal political
contributions or engage in personal political activities so long as such contributions or activities do
not infringe upon the employees duties for the Company, are not inconsistent with this Policy, and
the employee does not trade upon the name of the Company.
56
PRL recognizes alcohol or drug dependency as a treatable condition. Employees who suspect
they have an alcohol or drug dependency are encouraged to seek professional advice and
treatment. Affected employees should advise the Company of the existence of an alcohol or drug
dependency before it results in job performance problems. No employee will be dismissed due to
advising the Company of such a dependency and of involvement in a rehabilitation effort while
they are fulfilling their normal job requirements.
SRA Policy
PRL has developed and implemented special recognition programs to acknowledge employees'
contributions to the overall objectives of the refinery.
Recognition Program covered by this Policy are not intended to replace the provisions of the
Service Recognition Policy or the Compensation Policy, but may be used to supplement them.
57
58
59
60
61
8.4
2007
2007
53.8
2006
2005
2004
36.7
2004
2003
41.2
2003
20
40
5.0
2006
69.0
2005
3.3
60
80
100
5.0
5.0
5.0
Net Turnover
(in Million PKR)
2007
2006
57404
2006
1334.9
1724.9
2005
60963
2004
2005
733.5
44442
2003
2004
824.3
28286
2002
2003
60.6
28072
0
500
26.5
2007
3.0
2004
2626.0
2004
4.4
2084.8
2005
4.1
2003
1149.2
1278.6
2003
12
15
18
21
2000
579.0
2006
4.0
2005
1500
Operating Profit
(in Milliom PKR)
2007
2006
1000
24
27
30
62
600
1200
1800
2400
3000
Gross Profit
(in Million PKR)
2007
2007
1.4
776.0
2006
2006
2401.4
2005
2005
2936.8
2004
700
4.8
2003
1397.9
6.6
2004
1370.0
2003
3.9
1400
2100
2800
5.0
3500
2007
2007
160.2
2006
222.0
2006
182.1
213.9
207.9
2005
2005
163.2
2004
2004
150.0
80.5
2003
2003
181.7
46.3
0
50
100
150
200
50
Reserves
(in Million PKR)
2006
4505.1
2006
4301.5
700
1400
45.6
2003
89.0
2002
726.5
0
2100
2800
250
52.8
2004
1410.1
2003
200
29.5
2005
3063.8
2004
150
2007
2005
100
3500
4200
4900
30.0
63
20
40
60
80
100
64
Risk Management
o Risk Management Framework
o Business Understanding
o Business Objectives
o Risk Response
o SWOT Analysis
o Implementation
HSEQ Management System
Main HSEQ Committee
o Operations HSEQ Committee
o Office HSEQ Committee
o Engineering HSEQ Committee
o Emergency / Crisis Management
o Assurance / Authenticity
o Demonstration of Commitment
o Awards
65
FINANCIAL RISKS
STRATEGIC RISKS
COMPETITION
INTEREST RATES
CUSTOMER CHANGES
FOREIGN EXCHANGE
INDUSTRY CHANGES
CREDIT
CUSTOMER DEMAND
LIQUIDITY &
CASH FLOW
ACCOUNTING CONTROLS
INFORMATION SYSTEMS
PUBLIC ACCESS
RECRUITMENT
EMPLOYEES
SUPPLY CHAIN
PROPERTIES
PRODUCTS &
SERVICES
CONTRACTS
REGULATIONS
NATURAL
EVENTS
CULTURE
SUPPLIERS
BOARD
COMPOSITION
ENVIRONMENT
OPERATIONAL RISKS
HAZARD RISKS
66
Business Understanding
Objectives Formulation
Mission Statement
Attractiveness of Industry
67
Business Objectives
The objectives will be better understood if they are SMART
Specific
Measurable
Aligned
Realistic/Resourced
Timely
Risk Definitions
Risks Identification
68
Risk Response
Minimize likelihood
Mitigate the impact of the risk.
Maximize the likelihood or the impact.
The level of response decisions are dependent on the following factors:
The level and relevant importance of the objective.
The nature of the risk upside or downside.
The risk appetite i.e. level of acceptable risk.
The cost of applying risk response.
Take
Fully accept
Tolerance levels
Establish and monitor key risk indicators
Build in contingencies
Develop recovery plan
Investigate and take follow up action
Transfer
Insure
Contract out
Terminate
Cease activity
Redesign business processes, systems, and tools.
Treat
Operational
Monitoring
Challenge sessions
Performance measurement / milestone reviews
Observations / Surveys / bench marking
Incident investigation and reporting , Result analysis
Compliance verification
69
Implementation
Who, What, When, Where, Why and How questions relating to the frame work have been
answered.
For making the frame work sustainable following is done.
Integrated
Communicated
Checking
Self Assessment
Assisted Self Assessment
Internal Audit
Third Part Audit
An opinion from independent reviewer regarding the effectiveness of risk base control
frame work.
Recommendations for actions to strengthen and improve frame work.
A report which substantiate and communicates the opinion and recommendations.
70
SWOT Analysis
Strength
Weakness
Experienced staff
Assets
Hardware up-gradation
Financing
Threat
Opportunity
Systems
ISO and OHSAS certified
LP model, Hysys, RCM, DCS and
APC
SAP
Low cost operator
Product specs
Current hardware is not suitable
Government
Competition
Risk Assessment
Moderate
Major
Significant
Sustained
License to
Profitability
Operate
Medium
Succession
Planning
Zero LTI
License to
Operate
Loss
Control
Energy
Index
Man
Power
Low
Impact
High
1
0.9
High
0.8
0.7
0.6
0.5
0.4
0.3
0.2
Low
0.1
Operating
Cost
0
Low
Medium
Likelihood
71
High
HSEQ-MS Committees
In order to ensure effective functioning of HSEQ Management System, PRL has following
committees:
Engineering HSEQ
Committee
The Management HSEQ Committee meets at least bi-annually, under the chairmanship of
Managing Director-CEO and evaluates Health, Safety, Environment and Quality management
system based on the following inputs and takes appropriate decisions for implementation and
improvement in the system:
72
73
Minimizing liabilities
74
Assurance / Authenticity
PRLs Routine Surveillance Visit by BUREAU VERITAS against ISO 9001:2000 which is Quality
Management System, ISO 14001:2004 (Environmental Management System) and OHSAS 18001
(Occupational Health & Safety Assessment Series) certification was conducted during the month
of November, 2007.
No (minor / major) Non- Conformity (NCRs) was identified.
75
Demonstration of Commitment
76
Awards
PRL received following Awards in recognition of its HSEQ commitments during the fiscal year
2006-2007.
77
78
79
Identification
Assessment
Planning
Implement
Monitor
Reassess
Improve
80
81
Manageclosely
closely
Manage
Keepsatisfied
satisfied
Keep
4
12
17
Interest
22
36
16
11
10
21
33
20
24
35
26
32
1/ 16/ 3
29
30
15
Monitor
Monitor
(Minimum
effort)
(Minimum effort)
14
37
18
13
28
27
31
34
19
23
25
Power
Keepinformed
informed
Keep
82
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Stakeholder
Quadrant
ARL
Parco
Bosicor (refinery)
Shell (shareholder)
Chevron-Texaco
PSO
Direct Financial Institution (shareholder)
Private shareholders
Oil Companies Advisory Committee (OCAC)
Oil and Gas Regulatory Agency (OGRA)
Ministry of Petroleum and Natural
Resources (MP & NR)
Pakistan Standard Quality Authority
Power supplier company (KESC)
Natural gas supplier (SGSC)
Non Governmental Organisations (NGOs)
Shell Global Solutions
PRL employees
Environmental Protection Agency
Ministry of Industry and Production (MOI&P)
Financial institutions (for project financing)
Local community
Local contractors
International EPC contractor
Pipeline operator (includes shareholders in
PRL) of product distribution
Ministry of Port and Shipping (port
authorities)
Customers of refinery products (Fuel Oil,
HSD, Mogas)
Water supplier (KW & SB)
Local government
Current suppliers of HSD to Pakistan
Equipment manufacturers (including
suppliers of LLI)
Third party Licensors for new units
Ministry of Labour
Federal Board of Revenue (tax and import
authority)
Collective Bargaining Agency (CBA):
equivalent to trade union
Local, national, international media
Project Steering Committee
Securities and Exchange Commission/Stock
Exchange
"Monitor"
"Keep informed"
"Monitor"
"Manage closely"
"Manage closely"
"Manage closely"
"Manage closely"
"Manage closely"
"Monitor"
"Manage closely"
"Manage closely"
83
"Keep satisfied"
"Keep informed"
"Keep informed"
"Monitor"
"Manage closely"
"Manage closely"
"Keep informed"
"Keep informed"
"Manage closely"
"Keep satisfied"
"Keep satisfied"
"Keep informed"
"Manage closely"
"Monitor"
"Monitor"
"Keep informed"
"Keep informed"
"Monitor"
"Keep informed"
"Monitor"
"Monitor"
"Manage closely"
"Monitor"
"Monitor"
"Manage closely"
"Keep informed"
84
Environmental Reporting
Refinery emissions and effluents priority parameters are reported to Pakistan Environment
Protection Agency (PEPA) and Sindh EPA on monthly basis.
http://www.prl.com.pk/env_rep.html
Board of Directors Meetings
Board of Directors meeting is held on quarterly basis to asses the performance of PRL against
defined parameters.
85
86
87
Idea
Disposal
Recycle
Research
Consumers
PRODUCT
Product
Development
STEWARDSHIP
LIFE CYCLE
Customers
Customers
Process
Development
& Design
Suppliers
Marketing
& Sales
Toll
Processors
Customers
Warehouse
& Terminal
Package
Development
Manufacturing/
Refining
Transportation
Stewardship of our products is our goal. Process through which our products are produced is
certified against the system requirements of ISO 9001:2000, ISO 14001:2004 and OHSAS
18001:1999. We are focusing on the following areas:
Marshalling Process
In order to maintain product stewardship and our competitive edge in health, safety, environment
and quality system, we continuously communicate with our employees, contractors, suppliers, and
customers about product stewardship practices.
88
Emissions to Air
Discharges to Water
Organic Pollutants
Waste to Land
Hazardous and Non-Hazardous Waste (Landfill, Incinerated)
Resources Used
Fuel Consumed
Crude Oil
89
MEASURE ITEM
Environmental Investment/expenditures
Units
199.5
60
Million PKR
0.5
0.24
Tonnes
Methane (CH4)
22
6.24
Tonnes
Carbon Dioxide
152
127
Kilo Tonnes
0.55
0.225
Tonnes
1050
1078
Tonnes
95
71
Tonnes
340
202
Tonnes
1.2
1.29
Tonnes
Number
18.7
18.0
Million Units
56.1
44.43
Kilo Tonnes
110
127
Million Gallons
2177
1978
Kilo Tonnes
Manufacturing Loss
12.8
16.5
Kilo Tonnes
286
Tonnes
7.6
6.6
Tonnes
Exposure Hours-Company
0.9
0.98
Million hours
Exposure Hours-Contractor
1.3
1.47
Million hours
53
73
Number
Number
Number
Number
Number
Number
Spills>100 Kgs
90
MEASURE ITEM
Actual
Target value
Units
2006
2007
---
0.025x10-3
0.02x10-3
wt% of throughput
Methane (CH4)
0.001
0.001
0.0003
wt% of throughput
Carbon Dioxide
0.141
0.069
0.064
Tonnes /ton of
throughput
---
0.020x10-3
0.011x10-3
wt% of throughput
0.043
0.048
0.054
wt% of throughput
0.014
0.0043
0.0035
wt% of throughput
0.018
0.015
0.010
wt% of throughput
0.442
0.5
0.652
Grams /Ton of
throughput
Spills>100 Kgs
0.2
0.06
0.06
Number/Normaliz
ed Shift Position
158
157
152
---
---
0.30
0.35
Million
Gallons/Day
0.58
0.58
0.83
wt% of throughput
Manufacturing Loss
0.25
0.18
0.24
Potential
Incidents/Number
of Employees
0.41
LTI/Million Manhours
1.5
2.4
1.22
TRC/Million Manhours
TROI/Million Manhours
91
92
Emissions
PRL conducts monthly testing of all its emissions from Stacks of Boilers & Furnaces.
Emissions from stacks vs. NEQS limits are given below:
2500
2000
Emis s io n
fro m S ta c ks (in mg / Nm3)
(fro m Ja nuary to De c e mbe r 2 00 7)
17 0 0
N EQS
1500
T e s t R e s ult
800
1000
566
400
500
15 7
300
75
10
56
0
SOx
CO
NOx
H2S
PM10
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
Boilers
Furnaces Stack
415
572
409
512
451
450
595
728
532
310
577
430
702
230
617
560
554
940
422
790
625
890
525
740
93
CO
43
98
60
101
17
395
30
215
19
118
18
132
9
110
20
320
11
540
10
520
9
650
127
205
NOx
83
82
77
61
50
83
108
140
43
59
70
54
97
45
67
64
50
80
48
80
85
83
81
110
H2S
PM10
0.10
0.10
0.00
0.00
0.00
1.00
0.00
0.00
0.00
1.00
0.00
0.00
0.00
0.00
0.00
1.00
7.00
2.00
1.00
1.00
1.00
3.00
2.00
0.10
48
81
61
89
57
71
49
68
58
80
70
51
45
70
43
45
7
8
52
85
47
47
50
65
2004
2005
2006
0.12
0.080.052
2
0.767
0.04
1
S. East Corner
0.833
2004
2005
2006
N. West Corner
0.16
1.000
N. East Corner
S. East Corner
0.067
0.00
0.062
N. East Corner
0.833
0.054
S. West Corner
S. West Corner
2004
2005
2006
N. West Corner
0.16
20
0.12
15
0.063
0.08
10
0.04
S. East Corner
0.07
0.1130
0.185
0.141
S. East Corner
N. East Corner
0.070
0.00
0.076
0.067
S. West Corner
S. West Corner
Testing of ambient air for above pollutants in underway for the year 2007.
94
N. East Corner
Effluent Discharge
The entire Refinery effluent including sewage water is treated in the state of the art PRLs
wastewater treatment plant (Activated Sludge Process) before final discharge to the sea. It is
ensured that the water leaving the wastewater treatment plant is free of pollutants and
complies with NEQS limits to protect marine water habitat life and maintain the natural
ecosystem. The report of effluent discharge is sent to Pakistan Environmental Production
Agency & Sindh EPA on monthly basis under the Self Monitoring & Reporting Program. The
aggregate annual level of oils, grease, phenols; BOD & COD along with other parameters in
refinery effluent are as shown in the graph.
2003
450
Actual Results
NEQS Limit
20
375
15
300
2004
150
2007
2005
2006
Sulphides
Effluent Discharged to Aquatic Environment (in ppm)
2003
10
2006
2005
Actual Results
2003
250
NEQS Limit
200
150
2007
2004
75
2006
NEQS Limit
225
10
2007
Actual Results
2004
50
2006
95
NEQS Limit
100
2007
2005
Actual Results
2004
2005
pH
Effluent Discharged to Aquatic Environment
Phenols
Effluent Discharged to Aquatic Environment (in ppm)
2003
0.9
Actual Results
2003
12
NEQS Limit
Actual Results
NEQS Lower Limit
NEQS Upper Limit
0.6
0.3
2007
2004
2007
0.0
2006
2005
2006
2005
2004
2003
5000
Actual Results
Actual Results
NEQS Limit
NEQS Limit
4000
200
3000
2000
100
2007
2007
2004
2004
1000
0
2006
2006
2005
Ammonia
Effluent Discharge to Aquatic Environment (in ppm)
2003
50
2005
Chloride
Effluent Discharged to Aquatic Environment (in ppm)
2003
1600
Actual Results
NEQS Limit
Actual Results
NEQS Limit
40
1200
30
800
20
2007
2006
2004
2007
10
400
2005
2006
96
2004
2005
Iron
Effluent Discharge to Aquatic Environment (in ppm)
Lead
Effluent Discharge to Aquatic Environment (in ppm)
2003
0.8
2003
10
Actual Results
Actual Results
NEQS Limit
NEQS Limit
8
0.6
0.4
2007
2007
2004
0.2
2004
2
0
0.0
2006
2006
2005
Zinc
Effluent Discharge to Aquatic Environment (in ppm)
2003
8
2005
Manganese
Effluent Discharge to Aquatic Environment (in ppm)
2003
2.0
Actual Results
1.5
4
2007
1.0
2004
2007
0.0
2005
2006
Nickel
Effluent Discharge to Aquatic Environment (in ppm)
2003
1.2
2005
Boron
Effluent Discharge to Aquatic Environment (in ppm)
2003
8
Actual Results
0.9
0.6
4
2004
0.3
2007
2004
0.0
2006
Actual Results
NEQS Limit
NEQS Limit
2007
2004
0.5
2006
Actual Results
NEQS Limit
NEQS Limit
2005
2006
97
2005
Soil Monitoring
At PRL we ensure that leakages of hydrocarbons if any, are effectively controlled in order
to minimize oil losses, degradation of soil and under ground water. The following steps
have been taken in the recent years to reduce soil and water contamination:
All leakages are reported and corrective and preventive actions are taken promptly.
Lead
In soil (in mg/kg)
400
250
200
300
143
150
212
200
100
124
99
100
49
50
18
27
20
2004
2005
0
2002
2003
2004
2005
2002
2006
2006
Hydrocarbon
In soil (in mg/kg)
Aliphatic
In soil (in mg/kg)
2400
2003
15000
2193
12000
1800
8997
1377
9000
1204
1077
1200
6000
839
600
3000
1395
1390
1141
1019
2003
2004
2005
2006
0
2002
2003
2004
2005
2002
2006
Testing of the Soil and Underground water for the above parameters is
underway for the year 2007.
98
Mineral Oil
In underground water (in ppm)
Mineral Oil
In underground water (in ppm)
1.5
1.5
1.033
1.033
1.0
1.0
0.5
0.5
0.333
0.000
0.000
0.000
0.333
0.000
0.0
0.000
0.000
0.000
0.000
2002
2003
2004
2005
0.0
2001
2002
2003
2004
2005
2006
2001
Chloro Benzene
In underground water (in ppm)
Lead
In underground water (in ppm)
0.0008
1.5
1.2
0.0006
0.9
0.0004
0.70
0.6
2006
0.0004
0.56
0.42
0.0002
0.30
0.3
0.17
0.0000
0.0000
2002
2003
0.0000 0.0000
0.0000
0.0000
0.0
2002
2003
2004
2005
2001
2006
2004
2005
2006
Volatile Aromatics
In underground water (in ppm)
Zinc
In underground water (in ppm)
5
25
Volatile Aromatics
4
20
15
15.3
2.43
1.83
2
1.44
10
1.41
0.95
0.1
2002
2003
2004
2005
2006
2002
99
2003
0.2
0.7
1.1
2004
2005
2006
Chromiun
In underground water (in ppm)
0.4
0.12
Mercury
0.3
0.09
0.0684
0.186
0.2
0.06
0.159
0.1
0.03
0.076
0.010
0.001
0.0
0.0000
0.0000
0.0000
0.0000
2003
2004
2005
2006
0.00
2002
2003
2004
2005
2006
2002
Cadmium
In underground water (in ppm)
Arsenic
In underground water (in ppm)
0.10
Cadmium
0.08
0.25
Arsenic
0.20
0.2
0.062
0.06
0.15
0.04
0.10
0.024
0.02
0.05
0.008
0.001
0.000
0.00
0.0
0.0
0.0
0.0
0.0
2002
2003
2004
2005
2006
0.00
2002
2003
2004
2005
2006
2001
Nickel
In underground water (in ppm)
Copper
In underground water (in ppm)
0.90
6.0
Nickel
Copper
4.0
0.60
3.4
0.45
2.0
0.30
1.5
0.7
0.25
0.16
0.15
2004
2005
0.12
0.5
0.1
0.00
0.0
2002
2003
2004
2005
2006
2002
2003
2006
Illumination
at different locations in PRL (in lux)
300
240
2005
2006
192
170
180
2007
128
128 125
120
71
71
70
60
62
62
67
55
67
60
45
45
40
29
29
32
W
W
TP
Bo
il e
r
pr
es
so
rs
Pu
m
p
Ar
ea
Re
ac
to
rA
re
a
Fu
rn
ac
es
Co
m
G
en
e
ra
to
rs
Noise Monitoring
Noise is one of the major health hazard. At
Noise Level
at different locations in PRL (in dBA)
tank
farm
area
and
the
160
power
120
2005
2006
2007
103
104 105
88
91 89
88
89
87
80
80
81
89
87
85
82
82
80
ear
protection
while
working
in
close
proximity.
101
le
r
Bo
i
Fu
rn
ac
es
Ar
ea
Ar
ea
Re
ac
to
r
rs
Pu
m
p
pr
es
so
G
en
e
Co
m
ra
to
rs
83
Water Consumption
at reputable laboratories to ensure that it
Raw Water
Ground Water
The requirement of water is managed by
three tube wells. This water is used as fire
water after storing in a designated tank for
this purpose and for plant floor washing. The
well water is also treated in the Reverse
Osmosis Plant to produce low TDS permeate
and is used as boiler feed water and cooling
water make up.
Drinking water
To provide safe drinking water to employees
and
contractors
labor,
three
Water Consumption
Raw Water consumed (in million gallons/ month)
stage
15
Keamari
Terminal.
The
purification
9.9
10.0
2004
2005
10.6
9.2
0
2003
102
2006
2007
Waste Management
Hazardous/Non Hazardous waste is collected
10
6.6
5.9
categories
of
material
7.6
5.5
(steel
0
2003
2004
2005
2006
2007
Clinical Waste
Reusable Scrap
small-scale work.
Recyclable Waste
Oily Sludge
cables).
Trash
sludge quantity.
Disposal of Oily Sludge
in PRL Land Farming Site(in tons)
1000.0
934.4
900.0
800.0
700.0
600.0
909 tons.
500.0
400.0
284.7
300.0
200.0
215.6
100.0
0.0
2004
Su2005
stainab2006
ility Rep2007
or t 20 07
103
Plant Operations
Crude Throughput
(in Kilo Tonnes)
250
3000
2500
200
158
166
158
157.0
2049
2155
2177
1978
2000
152
150
2188
1500
100
1000
50
500
0
2003
2004
2005
2006
2007
2003
104
2004
2005
2006
2007
105
CO
(ppm)
Noise
(dBA)
85 -710
65 - 84
Walkthrough Inspection
As a proactive approach, a cross-functional team is formed to conduct HSEQ walk through
inspections in all the areas of Refinery and Keamari Terminal. Observations are circulated
to concerned section for effective actions.
Internal Audits
Each process comprising the HSEQ Management System is audited at least once every
year. The non conformities reported are dealt with effectively and corrective / preventive
actions are taken accordingly.
This years internal audit was carried out in July 2007, some non conformities were raised
by the internal auditors, which were dealt with and closed after taking corrective and
preventive actions.
106
Complaints
One from SPL/PSO for low F.P of HSD and second one from Chevron LPG regarding copper
corrosion during the month of March 2007.
107
Suppliers
All Suppliers are required to provide the Material Safety Data Sheet (MSDS) as mandatory
requirement of material purchase system for compliance by the users. The supplier of the
materials provides all information related to HSE hazards / risks associated with the materials as
follows:
Handling/Packing/Identification requirement
Competence/Training requirements
Contractors
Contractors are required to carry out their job without violating the prescribed HSEQ Management
system requirements. It is also ensured through routine checks by the company representative
during the entire phase of job that all necessary measures are undertaken by the contractors
which are necessary for performing the job in a safe & environment friendly manner.
The criteria of contractors/ suppliers performance monitoring & re-evaluation include the review of
their performance in at least the following areas to assess the ability of contractors/suppliers
according to the integrated HSEQ management.
Product quality
Delivery reliability
Warranty/Guarantee
Technical Strength
HSE Compliance
108
1. Product quality
2. Delivery reliability
3. Warranty/Guarantee
4. Technical Strength
5. HSE Compliance
109
Description
3.00
3.90
1.30
4.10
5,5
3.5
3.0
3.0
2.70
2.0
1.5
1.2
10
Replacement-Fire Extinguishers
0.9
11
New-Bund Pourers
0.5
12
0.4
13
0.4
14
15
16
17
18
19
New-fire Extinguisher
20
0.075
21
New- Minor OT
0.075
22
0.06
23
0.05
24
0.05
11.5
0.35
0.3
0.25
0.2
0.12
0.1
Total
10.00
110
60.00
111
S. No
Brief Description
Status
In progress
Achieved
Achieved
Achieved
In progress
In progress
Achieved
Achieved
112
S. No
Brief Description
113
Status
In progress
In progress
In progress
In progress
In Progress
In Progress
In Progress
The facilities include topping refinery plus catalytic reforming and hydro treating unit with utilities,
off site and tank age. The nameplate capacity is 47100 bbls/ day and the feedstock for producing
the petroleum is a diet of imported and indigenous crude oil.
FG
GAS
LPG
CAUSTIC
STAB
L
P
G
LN LIGHT NAPHTHA
M
O
G
A
S
H2
KERO HDT
KERO -
TCS
HEAVY NAPHTHA
PLT
H
V
Y
N
A
P
KEROSENE
CDU
AMINE
SR GASOIL
TCS
HDS
H2
SRU
S
GAS
NG
H2S
ADIP
GAS
L
S
F
G
LPG
AMINE/H2S
J
P
1
J
P
8
K
E
R
O
AMINE/
CAUSTIC
F
R
N
A
P
NAPHTHA
HMU
Feed
TGU NAP -
TGU GAS
L
S
H
S
D
DIESEL
TGU GASOIL
WASTE WATER
TGU
ETP
TGU RESIDUE
Yellow Existing
TREATED WATER
F
O
Green New
In July 2006, during the companys annual Business Strategy Workshop the business
requirements, profitability, products specifications and demand / supply was taken into
consideration through environmental scan and internal scrutiny.
The workshop was attended by PRLs management team (MTM) along with the senior managers.
114
115
Electricity Generation to provide a secure power supply to the refinery to meet the future
electricity demands.
Process control and safeguarding investment to support the new configuration.
The new (gasoil) HydroDeSulphurisation (HDS) unit produces gasoil which meets the 500 ppmw S
HSD specification with a reduced T90 boiling point. The HDS unit will process a mix of straight-run
(SR) and thermally cracked gasoils.
Design Capacities
The design capacities of the new and revamped process units shall be:
Unit
mtd
Feeds
TGU
3400
HDS
3000
SR LR from CDU
SR Gasoil from CDU, Naphtha and Gasoil from new
TGU
ADIP Unit
550
SRU
55
Sulphur Plant
50
HMU
20 (2)
Amine Wash/Caustic
70
300
Effluent Treatment
500
Waste Water
116
117
HSSE / SD
The PRL Upgrade Project will be designed in accordance with Health, Safety, Security,
Environment and Sustainable Development policies in line with the existing policies of PRL.
The PRL Upgrade Project will use Hazard and Effects Management Process and will undertake
full suite of studies to identify hazards, predict their consequences and manage risks in a
systematic way through out the design phases.
Recommendations from HEMP studies will be fed back into the design as a apart of the process to
demonstrate that all risks to people, asset, reputation and the environment will be reduced in
compliance with the principle of As Low As Reasonably Possible (ALARP) and will be managed
through continual improvement.
The execution (Construction) contractor will be required to continue the HEMP studies and
demonstration of ALARP. A construction HSSE/SD management Plan will be developed by the
contractor and will cover the activities and resource commitments required to deliver the Project
HSSE/SD objectives.
118
It is worthwhile to note that one Corrected Energy Index in number is equivalent to USD 100,000.
119
During 2007 PRL won People As Key Resource Award by Employees Federation of Pakistan.
No. of Employees
Technical Trainings
375
HSEQ Trainings
170
41
Total
120
586
Continuous Monitoring
As per the certification policy and IAF (International Accreditation Forum) Guidelines, it is
obligatory for organizations to undergo continuous monitoring by the certification body to ensure
compliance to requirements on an on0going basis. Bureau Veritas Certification has been
performing regular surveillance audits every year and found the implementation of the
requirements in full effect. Also major improvements were observed in the areas of health, safety
and environment, providing evidence to the core theme of the standards, which require
organization to continually improve its HSEQ Management System once it subscribes to
certification.
Verification Method
The assessment scheme is based on review of environmental aspects identified by PRL, which
have significant impact on environment, all health and safety hazards having associated significant
risks and interaction of the processes are reviewed. Representative samples are selected from
activities of PRL and audited for compliance against requirements of ISO 14001: 2004, OHSAS
18001: 1999 and ISO 9001: 2000.
A detailed site tour of Refinery and Storage Areas in Korangi and Keamari is also performed in
every visit to ensure that operational controls are effectively established and implemented. Crisis
Management / Emergency Preparedness and response plans are also tested to ensure that
organization is well equipped to respond to any untoward incident. The continuous monitoring of
PRLs HSEQ system has provided confidence to Bureau Veritas Certification that the system is
effectively and efficiently functioning in compliance to recognized regulatory and statutory
requirements as well as requirements of ISO 14001: 2001 and OHSAS 18001: 1999 and ISO
9001: 2000.
121
Opinion
Transparency and Completeness
The management system in response to requirements of ISO 14001: 2004, OHSAS 18001: 1999
and ISO 9001: 2000 intends to cover significant environmental impacts and health and safety risks
and quality issues. The management programs cover minute details to meet the objectives and
targets established by the organization in order to continually improve it HSEQ performance. The
objectives and targets are regularly assessed and management programs are reviewed and
audited by Bureau Veritas Certification to ensure progress towards meeting HSEQ commitments.
Sustainability Report 2007 clearly reports objectives, programs, and measures taken by
PRL to ensure its continued commitment and it is Bureau Veritas Certifications opinion
that the text and data have been presented in a fair and balanced manner.
The stakeholders are regularly informed through effective communication procedures about the
Health, Safety, Environmental and Quality performance and key issues which require their
attention. We look forward to stakeholders opinions on the issues covered in this written report
and the process for this being presented in a transparent manner.
Accuracy
The Health, Safety, Environment and Quality performance reporting system is effective, generating
data which when aggregated at a corporate level is generally accurate and reliable. The system is
well incorporated in the business processes, with a high level of commitment noted during the
assessment process.
122
M.S. Saqib
Certification Manager
Bureau Veritas Certification Pakistan
123
Feedback Form
All stakeholders are encouraged to fill in this questionnaire. This evaluation data will assist in
further improvement of this report.
For each statement, please indicate your response in the columns with the respective letters given
below and add your comments/suggestions where appropriate.
Sr. no
1
2
3
4
5
6
7
SA
SD
Comments/ suggestions
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Thank you for sparing your precious time to give your response. Your feedback will play a
significant role in improving the standard of this report.
Your Name:_____________________
Your Designation: ________________
Department: _____________________
Organizations Name: _____________
124