Petron Bataan Refinery Procedures PDF

## LEAP - Linking Environment and Petron ### Incident Management **LEAP** stands for **Linking** **Environment** **and** **Petron**. **LEAP** is an internal system Petron uses to manage environmental-related incidents. It has the following sections: * **Policies** * **Department** * **Laws** *...

## LEAP - Linking Environment and Petron ### Incident Management **LEAP** stands for **Linking** **Environment** **and** **Petron**. **LEAP** is an internal system Petron uses to manage environmental-related incidents. It has the following sections: * **Policies** * **Department** * **Laws** * **Facilities** * **Programs** * **Incident Management** * **Open Forum** Under **incident management**, there are two main categories: * **Odor Complaints** * **Oil Spill Response** ### Oil Spill Response Plan The **Oil Spill Response Plan** has the following components: * **Oil Spill Contingency Plan**: This plan aims to prevent and respond to Oil Spill that may occur in the area of Petron Bataan Refinery. Its goal is to minimize the devastating effects of untoward incidents, including employee casualties, damage to company assets, business interruption, damage to marine life, and the environment. * **Oil Spill Response Plan**: A flowchart describing the general alert and response procedures for oil spills. #### Flowchart: The **Oil Spill Response Plan** flowchart is as follows: 1. **Discovery of Oil Spill**: The person who discovers the oil spill reports it to the **Safety Supervisor** of the Area. 2. **Reports to SS of Area**: The **Safety Supervisor** then contacts the **On-Scene Commander** (**OSC**) 3. **Is there a fire?**: If there is no fire, the **OSC** informs **Key Personnel** (**SOSCO, OSCO, FPO, etc.**) 4. **Activate FF contingency plan**: The **On-Scene Commander** (**OSC**) assesses the situation and activates the appropriate personnel. 5. **OSC Mobilizes**: The **OSC** mobilizes the **Oil Spill Control Team** (**OSCT**). 6. **Needs PCG assistance?**: If the situation requires assistance, the **OSCT** contacts the **Philippine Coast Guard** (**PCG**). 7. **Contain spill, clean-up, apply corrective actions**: The **OSCT** will contain the spill, clean up the area, and apply corrective actions. 8. **OSCO prepares oil spill notification**: The **Offsite Commander** (**OSCO**) prepares the oil spill notification. 9. **Comrel reports to PCG**: The **Communications Officer** (**Comrel**) contacts the **PCG** for further assistance. 10. **PCG assumes OSC role**: The **PCG** takes over the role of **On-Scene Commander**. #### Oil Spill Control Team (OSCT) Composition **OSCT** consists of the following personnel: * **On-Scene Commander** * **Offshore Commander** * **Speedboat Operator** * **OSCT 1 - Tugboat / Oil Spill Boom Lead** * **OSCT 2 - Banca / Oil Spill Boom Rear** * **OSCT 3 - Anchor & Buoy Deployment** * **OSCT 4 - Chemical Dispersant Team** * **OSCT 5 - Oil Spill Recovery Team** * **OSCT 6 - Shore Clean-up Team** * **Security Speedboat** * **Terminaling Technicians (T5, T6, T7)** * **T1** * **SS-1 (Deputy OSC)** * **SSE-1 (Logistics)** **First Responders**: * **Advises T1 of spill** * **Contact tugboats and contractor boats** * **Advises SS-1 and SSE-1** * **Contact Seaborne Security to survey** * **Open and ready the OSGE** ### Odor Complaints The **Odor Complaints Handling** system utilizes a procedure to capture, monitor and mitigate complaints within the refinery, housing, and adjacent communities as part of PBR's odor management. This process applies to all internal and external complaints. #### Odor Complaint Procedure: 1. **Odor Complaint is received by Community Relations:** The Community Relations department receives the odor complaint. 2. **Assigned Env Engr surveys the affected area**: An assigned environmental engineer surveys the affected area, records the perceived odor, wind direction, and performs gas tests. 3. **Envi Engr records data**: The environmental engineer then records the data in the Odor Complaint Monitoring Log. 4. **Envi Engr generates a report to Area Superintendents**: The environmental engineer generates a report and sends it to the Area Superintendents. 5. **Area Superintendents check their areas for possible sources of odor**: Area Superintendents then identify the potential sources of odor and apply mitigating measures. 6. **Area Superintendents revert to Env Engr with information**: The Area Superintendents inform the environmental engineer regarding the mitigating measures implemented and any process changes. ### Job Safety Analysis (JSA) Petron Bataan Refinery uses an updated Job Safety Analysis (JSA) format. The new format incorporates environmental aspect identification and control. #### JSA Sections: The JSA has ten sections: 1. **Basic Details**: Includes the JSA number, work description, location, project number and title, work scope, dates from and to, and a list of the names of the personnel involved. 2. **Safety & Environment**: - Contains the emergency response plan, the required personal protective equipment, the expected hazardous waste generation and its required container, and the expected liquid discharge to sewer (if any). 3. **Job Steps & Risk Analysis**: - Includes a table with eight columns: Job Steps, Potential Hazard, Potential Environmental Impact, Potential Accident, Recommended Actions, Action By, Initials, and Date. ### Chemical Management Petron Bataan Refinery uses several measures to manage chemicals within the plant, including Chemical Control Orders (CCOs), the Pre-Manufacture Pre-Importation Notification (PMPIN) process, and the Priority Chemicals List (PCL). #### Chemical Control Orders (CCOs): * **Regulations**: CCOs are regulations issued by the Environmental Management Bureau (EMB) to ensure the safe handling and management of hazardous chemicals. #### Pre-Manufacture Pre-Importation Notification (PMPIN): * **Purpose:** This process aims to screen harmful substances before they enter Philippine commerce. It ensures new chemicals that may pose an unreasonable risk to human health and the environment are either denied manufacturing and imports or placed under strict control. #### Priority Chemicals List (PCL): * **Purpose:** The PCL is a list of existing and new chemicals that are likely to pose a substantial risk to public health, workplaces, and the environment. #### PCL Compliance: * **Requirement for permits**: For companies to import or use chemicals on the PCL, they are required to obtain a PCL compliance certificate from DENR-EMB. #### Chemical Management Requirements: * **General requirements**: For activities involving the use of chemicals that require permits from DENR, proponents must comply with the following requirements: - **Chemical Control Order**: Process flowchart, photos of the plant's operation, latest safety data sheet for the chemical, training certificate for chemical use, and a chemical management plan specific to the substance.. - **Pre-Manufacture / Pre-Importation Notification:** Latest safety data sheet for the chemical, weight declaration of the components/composition of the product, chemical and molecular structure, intended use of the chemical, the substance's physicochemical properties, and toxicological and environmental/ecological properties. - **Small Quantity Importation:** Latest safety data sheet for the chemical and weight declaration of the components/composition of the product. #### Reportorial Requirements for Permits: * **General requirements**: To comply with reportorial requirements and renewal applications for environmental permits, the following documents need to be provided: - **Priority Chemical List Certificate:** Usage data for perchloroethylene, usage data for benzene, and a summary of importation data, delivery reports, invoices, and bills of lading. - **PDEA License to Handle CPECs:** Usage data for sulfuric acid, hydrochloric acid, acetone, and toluene. ### **Waste Management** #### **Waste Disposal Procedure:** * **Procedure**: Petron Bataan Refinery classifies endorsed wastes as non-hazardous waste, hazardous waste, or as feed to the Circulating Fluidized Bed Boiler (CFB). #### **Types of Waste:** * **Hazardous Waste**: Includes spent caustic, spent liquid chemicals, used batteries and busted fluorescent lamps, lead and mercury laboratory wastes, solid sulfur wastes, used oil, oily sludge, oil-contaminated wastes, expired pharmaceuticals and drugs, and healthcare waste. * **Non-Hazardous Waste**: Includes castables, microfilters, insulations, used bag filters, and inert balls. * **Waste for CFB Processing**: Includes spent catalyst, spent clays, spent adsorbents, and activated carbon. #### **Waste Disposal Forms**: Proponents must provide the necessary forms for the disposal of waste, including: * **Request to Sell and Dispose Materials & Equipment Form** * **Non-Hazardous Waste Disposal Form** * **Hazardous Waste Disposal Form** #### **Turnover of Waste**: * **Procedure**: Petron follows a three-step procedure to transfer the waste for hauling and disposal. 1. **Direct Hauling:** Waste is temporarily staged in the current storage location, and then hauled directly by a truck. 2. **Hauling at Staging Area:** Waste is transferred from the current storage location to a dedicated staging area, then transported to a final disposal location. 3. **For Endorsement for Feeding to CFB**: The waste is evaluated to see if it is suitable for CFB processing, then transferred to the CFB facility for combustion. #### **Refinery Waste Classification Diagram:** The following diagram shows the general process of waste classification. * **Non-Hazardous Waste**: Can be disposed of through direct hauling or hauling at staging area. * **Hazardous Waste**: Can be disposed of through hauling at staging area or endorsed to CFB for evaluation. * **Acceptable Waste**: Can be sent for CFB processing. * **Not Acceptable Waste**: Should be disposed of by a third party. ### **Sustainability** Petron Bataan Refinery has committed to promoting sustainability initiatives. The primary focus is on water management, circular economy, and environmental health and safety. #### **Water Management:** * **SMC Water for All Project**: Reducing dependence on scarce groundwater and increasing the use of desalinated and recycled water. * **Desalination Plant**: Utilizing desalinated water for cooling and treated water for production units. * **Reverse Osmosis Reject Water Use**: Reducing groundwater consumption by utilizing RO reject water for piling works. * **Sink Urinals**: Improving water conservation through the installation of urinals at the administration building. #### **Circular Economy:** Petron Bataan Refinery promotes three main circular economy activities: * **Sludge Processing**: Using a dedicated facility to process sludge generated from coke drum quenching, reducing waste generation and operational expenses. * **RSFFPP Solid Waste Material Processing**: Maximizing the use of valuable spent materials as an alternative to coal, pet coke, and bed materials. * **Waste Segregation:** Promoting waste segregation in various areas of the refinery. #### **Waste Segregation:** Petron Bataan Refinery promotes waste segregation in various areas of the refinery. The following materials are classified: * **Biodegradable**: Includes food waste, leaves, and grasscuttings. * **Recyclable**: Includes plastic bottles, plastic cups, glass bottles, and aluminum cans. * **Residual Waste**: Includes plastic bags, used tissue papers, dirty papers, and candy wrappers. * **Oil Contaminated**: Includes oil contaminated gloves, oil contaminated rags, oil contaminated filters, and oil contaminated materials. #### **Waste Classification Diagram**: The waste classification diagram shows the four categories of waste and their respective areas. #### **Environmental Management:** * **Environmental Performance Indicators**: Petron Bataan Refinery monitors environmental performance metrics through energy consumption, environmental impact management, and environmental compliance. * **Greenhouse Gas (GHG) Accounting**: Petron Bataan Refinery follows a set of methods to measure and track their GHG emissions. #### **Environmental Programs and Initiatives:** Petron Bataan Refinery implements several ESG programs related to resource and waste management, process optimization, and energy and GHG reduction. * **SMC Water for All** * **Use of Waste Energy** * **Commissioning of Cogeneration Facility** * **Diversification to Petrochem** * **LED Conversion and Solar Power Usage** * **Hazardous Waste Recycling** * **Continuous to Batch Treatment at Spent Caustic Treater** * **Restoration of Superheater Coils** * **Puno ng Buhay Mangrove Reforestation** #### **Environmental Laws:** Petron Bataan Refinery follows several environmental laws, including: * **PD 1586: Philippine EIS System**: This law establishes an environmental impact statement system and is crucial for obtaining an environmental compliance certificate. * **RA 9003: Ecological Solid Waste Management Act**: Establishes the framework for a systematic, comprehensive, and ecological solid waste management program. * **RA 6969: Toxic Substances and Hazardous and Nuclear Wastes Control Act**: This law provides a framework for the effective implementation of regulations regarding hazardous waste generators, transporters, and treaters. * **RA 9275: Philippine Clean Water Act**: This act provides a legal framework for comprehensive water quality management. * **RA 8749: Philippine Clean Air Act**: This act provides the legal framework for comprehensive air pollution control. ### **Environmental Facilities** Petron Bataan Refinery operates several environmental facilities with the following functionalities: * **Air Pollution Control:** * **Baghouse Filters**: Reduce total suspended particulate levels. * **Limestone Injection:** Capture SOx from boiler flue gases. * **Flue Gas Treater:** Desulfurize flue gases exiting the FCC unit. * **Sour Water Facility:** Capture H2S and NH3 from sour water. * **Sulfur Recovery Unit**: Eliminate SOx from the flare by capturing and converting H2S to molten sulfur. * **Wastewater Management:** * **OWWTP-1:** Treats oily wastewater and sewage from Prod-A process area, tank farms, the administration building, PCR, and OM&S. * **WWTP-2:** Treats oily wastewater and sewage from Prod-B process area and MCB. * **WWTF-1/2:** Treats wastewater coming from RSFFPP Phase 1 and 2. ### **Integrated Management System** (**IMS**) Petron Bataan Refinery uses an integrated management system (IMS) for quality, environment, and safety. #### **IMS History**: This table shows the implementation history of Petron's IMS. * **1998**: ISO 9001 Certification (for one year only) * **2004**: ISO 14001 Certification * **2009**: IMS Certification * **2016**: RMP-2 inclusion * **2017**: Transition to ISO 9001:2015 and ISO 14001:2015 * **2019**: RSFFB inclusion * **2020**: IMS Certification (with ISO 45001 transition) * **2023**: Stage 1 and Stage 2 Certification #### **Other Management Systems**: Petron Bataan Refinery adheres to several other management systems in addition to the IMS: * **ISO 50001**: Energy Management * **ISO/IEC 27001**: Information Security * **ISO 22301**: Business Continuity * **ISO/IEC 17025**: Laboratory Management * **ISO 31000/ON 49001**: Risk Management * **ISO 55001**: Asset Management #### **Management System Process**: The IMS process has the following sections: * **Core Processes**: * Customer Requirements * Operations and Production Planning * Crude Processing * Oil Movement and Storage * Customer Satisfaction * **Support Processes**: * Operations (Utilities) * Product Quality and Testing * Engineering Services * Maintenance and Repair Services * Project Administration * Technical Training * Security * Safety * Environment * General Services * RSFFB Plant Services and Logistics * Refinery Finance * Human Resources * Community Relations * Medical Services * Procurement * Non-Refinery Groups * Business Plan and Objectives * Business and Resource * Planning * IMS Review and Improvement #### **IMS Policy**: Petron Bataan Refinery is "fully committed to be the center of operational excellence and a dependable producer of quality petroleum and petrochemical products, without compromising the environment, safety, and health". #### **Organizational Roles, Responsibilities, and Authorities**: The IMS has the following important roles: * **Vice President for Refinery**: Overall IMS Responsibility * **Vice President for Plant Operations**: Focuses on the plant's operations. * **Assistant Vice Presidents**: * Production A: Responsible for production unit A. * Production B: Responsible for production unit B. * Utilities and RSFFB: Responsible for utilities and the Refinery Support & Fuel Factory Plant. * Technical Services: Responsible for technical services. * **Support Services Manager**: Provides overall leadership for support services. * **Technical Training & Management Systems Manager**: Manages technical training and the implementation of IMS. * **IMS Audit Coordinator**: Responsible for conducting internal audits. * **Environment Manager/ Pollution Control Officer**: Manages environmental programs and facilities. * **Environment Engineer**: Responsible for environmental performance indicators and environmental compliance. * **Safety Manager/ Safety Officer (SO2, SO3)**: Responsible for safety programs in different production units. * **Radiation Safety Officer**: Responsible for managing radiation safety. * **Medical Officer**: Responsible for medical services. * **Business Process Area Managers**: Responsible for their assigned area. * **IMS Area Representatives**: Responsible for implementing IMS in their specific areas. * **CHIEF Reliability Engineer**: Provides expertise in reliability engineering. * **ERSE Chief**: Manages emergency preparedness and response. * **IMS & Audit Coordinator**: Coordinates the IMS and audit process. * **Environmental Engineers**: Conduct projects and audits related to the environment. * **IMS Internal Audit Team**: Works closely with the coordinator to ensure all IMS elements are actively implemented. * **IMS Engineers**: Contribute to IMS implementation and document related activities. #### **IMS Awareness Refresher:** Petron Bataan Refinery periodically conducts IMS awareness refresher sessions. Its objectives are: * **continuously improve the effectiveness** of programs and activities. * **apply the salient provisions of the IMS Policy and ISO standards**. * **gain awareness of ISO 9001:2015, ISO 14001:2015**, and **ISO 45001:2018**. #### **Understanding the Organization & Its Context:** Petron Bataan Refinery uses the following approach to identify and assess risks: * **Risk Identification and Management:** * **Internal Issues**: * Values * Culture * Knowledge * Performance * **External Issues**: * Legal * Technological * Competitive * Market * Cultural * Political * Social * Economic * Business Impact (per event): * Major toxic gas release * CDO (Cease and Desist Order) * Lost Work Day Injury * Large unit fire * Recordable Injury * Small contained fire * First aid injury * Near Miss * Spill (with no exceedance and not reportable) * Break-in work: Time required to complete is <3 days. Overtime is almost always justified. * Urgent: Action can be deferred by 7 days, and completed within 14 days. Overtime may be justified. * Normal: Action can be deferred by 7 days, and completed within 60 days. Overtime is not justified. * **Health/ Safety/ Company Reputation/ Environment/ Community:** * Fatality/ Extensive Adverse Attention * Multiple exceedances leading to SEC penalties. * Site-wide concern, multiple exceedances leading to public impact. * Some local and media attention. * Some public concern but not beyond local community. * No public concern or awareness. #### **Auditable Clauses:** The following clauses are subject to internal auditing: * **Clause 4: Context of the Organization** * **Clause 5: Leadership & Worker Participation** * **Clause 6: Planning** * **Clause 7: Support** * **Clause 8: Operation** * **Clause 9: Performance Evaluation** * **Clause 10: Improvement** #### **Structure of the IMS:** This diagram shows the overall structure of the IMS. The **IMS** is a cyclic process that starts by identifying the context of the organization, conducting risk assessments, and setting planning objectives. The process also includes leadership and worker participation, supporting those initiatives, implementing the chosen plan, conducting performance evaluations, and then finding opportunities for improvement. The organization's intended outcome is to achieve a high degree of compliance and continuous improvement within the IMS structure. #### **Process Approach:** The **IMS** is a systematic approach that applies concepts such as the "Plan-Do-Check-Act" (PDCA) cycle and risk-based thinking. #### **PDCA Cycle**: The **PDCA cycle** is a four-step iterative process that aims to achieve continual improvement: 1. **Plan** 2. **Do** 3. **Check** 4. **Act** #### **Risk-based Thinking:** The IMS incorporates **risk-based thinking**, which is a process to "determine and control possible factors that could cause processes and management systems to deviate from expected results". #### **Vision, Mission, and Values:** * **Vision:** "“To be the leading provider of total customer solutions in the energy sector and its derivative businesses””. * **Mission**: “To be a model department in the refinery committed to promote a clean, healthy and well protected environment and co-workers whilst supporting a synergistic company with the community, with competent and motivated employees." #### **Bloom's Taxonomy of Learning:** The **IMS awareness refresher** incorporates **Bloom's Taxonomy of Learning** to aid participant understanding. * **Creating:** Using information to create something new. * **Evaluating:** Examining information and making judgments. * **Analyzing:** Taking a known concept and identifying the relationships. * **Applying:** Putting information into practice. * **Understanding:** Recognizing and interpreting information. * **Remembering:** Recalling specific facts. <start_of_image>FOR TRAINING PURPOSES ONLY. NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT PRIOR WRITTEN PERMISSION FROM PETRON BATAAN REFINERY. ==End of OCR for page 77==