Untitled - Galp Energia

GALP ENERGIA 

2010 DATA BOOK ON HEALTH, 

SAFETY AND ENVIRONMENT 

MATOSINHOS REFINERY

01 • A Galp Energia 

4 

The Matosinhos refinery Data Book outlines 

the refinery performance in Health, Safety and 

Environment in a factual and direct manner, 

discussing and analysing various typical activity 

indicators as well as matters 

of interest to the public, stakeholders and 

public entities. We wish you a pleasant reading! 

MATOSINHOS REFINERY IN A GLANCE 

1969 

START YEAR OF 

OPERATION 

2010 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS REFINERY 

5.5Mt 

CAPACITY 

CRUDE/YEAR 

479 

NUMBER 

OF EMPLOYEES

400ha 

AREA 

GALP ENERGIA 

2010 DATA BOOK ON HEALTH, 

SAFETY AND ENVIRONMENT 

MATOSINHOS REFINERY 

A Galp Energia • 01 

01 • Message from the refi nery Management 

02 • Introduction 

03 • Framework 

• Health, safety and environmental policy 

• Introducing the refi nery 

• Operator details 

• Organizational model 

• Location and surroundings 

• Historical overview 

• Description of activity 

• Capacity 

• Description of the principal raw materials 

• Description of process 

04 • In detail – Hazop study to the existents units of the complex 

05 • Activities, actions and projects 

• Highlights of 2010 

• Revamping of unit 3000 - Distillation of Crude Oil & Furnace H3001 

• New acid water treatment plant - Un. 10775 

• Revamping of diesel desulphurisation plant - Un. 3700 

• New sulphur recovery treatment plant - Un. 10800 

• New Vacuum and visbreaker distillation plant – Un.10000 and Un. 10100 

• Costs and Investments 

• Training in health, safety and environment 

06 • In focus - Refi ney maintenance and 2010 technical shutdown 

07 • Activity Indicators 

• Level of activity 

• Production 

• Boa Nova Park 

08 • Environmental performance 

• Resource consumption 

• Water consumption 

• Energy consumption 

• Atmospheric emissions 

• Sulphur oxides 

• Nitrogen oxides 

• Total particulate matter 

• Carbon dioxide 

• Volatile organic compounds 

• Continuous monitoring 

• Impact on air quality 

• Liquid effl uents 

• Liquid effl uents production 

• Monitoring the quality of liquid effl uents 

• Waste 

• Noise 

• Soil and water resources 

09 • Safety and health performance 

• Accident rate 

• Occupational medicine 

• Industrial hygiene 

• Evaluation of occupational exposure to chemical agents 

• Hazard Identifi cation and risk assessment and monitoring 

• Safety management system for major accident prevention 

• Drill and training exercises 

• Annual verifi cation of the system requirements for a safety management system for 

major accident prevention 

• Management change – standard procedure 

• Internal emergency plan revision 

• Work permits audits 

• Preventive safety and environmental observations 

• Product safety 

• REACH regulation 

10 • Community relations 

11 • The faces behind health, safety and environmental aspects at the refi nery 

12 • Glossary 

13 • Statement of conformity 

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2010 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS REFINERY 5


6 

01 

MESSAGE 

FROM THE REFINERY 

MANAGEMENT 

2010 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS REFINERY

MESSAGE FROM THE REFINERY 

MANAGEMENT 

The 2010 Data Book on Health, Safety 

and Environment of the Matosinhos 

refi nery, that now is presented, refl ects 

our commitment and accomplishment 

that we have achieved, and they are a 

source of pride and satisfaction for all 

Galp Energia team and service providers. 

In fact, they were achieved in a 

particularly diffi cult context, marked 

by an unprecedented effort of 

construction and maintenance of 

facilities. In 2010 we operated in an 

environment of strong and focused 

investment, with over 2,500 employees 

from service providers and with the 

industrial complex in total operation. 

Furthermore, our Injury Rate of 

accidents resulting in workday losses 

had its lowest value ever, and this 

situation gave us a very favourable 

position in the best references for 

the European industry; we reached a 

value, unlikely at the outset, of four 

million and four hundred thousand 

hours without accidents resulting 

in no working day losses; the units 

startup, after the technical shutdown 

period in October, occurred without 

any safety incident; the environmental 

performance has always improved in a 

continuous and sustained process. 

These situations prove the maturity 

of our culture of Safety, Health and 

Environment, and we believe that they 

deserve a vote of confi dence (women 

and men), dedicated professionals 

who work in this industrial unit, by the 

local community, authorities and our 

stakeholders. A special appreciation to 

Direction of the refi nery of Matosinhos. 

the service providers who shared with 

us a year of hard work with excellent 

results. 

Our fi rst two values are: 

• all our activities and decisions are 

supported on a solid Safety culture; 

• our commitment to the Environment 

is beyond legal issues. We search 

a sustainable integration of our 

activities in the surroundings. 

Past performance is not, however, 

a guarantee of a good future 

performance. On the contrary, the 

future is grounded in our daily work, 

conducted with rigor and operational 

discipline, and therefore, it is also 

determinant on the ongoing alignment 

Message from the refinery management • 01 

THE MATOSINHOS REFINERY 

BOARD OF DIRECTORS 

IS COMMITED TO THESE 

MATTERS. 


01 • Message from the refinery management 

8 


of our suppliers of goods and services, 

with our culture. 

Our goals are zero personal accidents, 

zero serious industrial accidents, zero 

environmental incidents and an ever 

deeper integration of the Environment 

with Safety measures. We search, 

beyond that, integrating into the 

surrounding community, conscious of 

our social responsibility. 

Finally, the business plan and 

sustainability of Matosinhos refi nery 

will depend on how we use Energy, 

representing in 2010, about 69% 

of operating costs. Our goal is that 

in 2012 we can fi nally achieve a 

competitive cost structure in line with 

the best of what is done in Europe. 

The Environment will continue to win 

and we all win with lower emissions 

of carbon dioxide and with even lower 

emissions of sulphur dioxide and 

nitrogen oxides into the atmosphere. 

And so, our vision of “Cost Leadership 

in 2012” begins to take shape. The 

strategy pillars of our four businesses 

areas portfolio are: 

• fuels; 

• aromatics and solvents; 

• lubrifi cating Oils, Bitumen and 

Paraffi ns; 

• electricity, 

that will take us to achieve the 

goals set in 2008. In 2010, a year of 

intense realization of investments 

on energy integration, expansion of 

activity and replacement, that will be 

concluded in 2011 with the launch of 

Vacuum/Visbreaker units and the new 

Cogeneration Plant. This structured 

evolution is possible only because we 

remain committed, ever more fi rmly 

in the support of this development in 

a strong culture of Safety, Health and 

Environment. 

The Matosinhos refi nery Board of 

Directors.


02 

INTRODUCTION 

THE SUSTAINABILITY OF OUR ACTIVITY 

REQUIRES A CONCERN FOR PROTECTING 

THE ENVIRONMENT AND THE HEALTH AND 

SAFETY OF OUR STAFF, CONTRACTORS, 

CLIENTS AND COMUNITY, AS COMPANY 

VALUES AND ESSENTIAL PILLARS OF 

MANAGEMENT. 

2010 2010 DATA DATA BOOK BOOK ON ON HEALTH, SAFETY AND AND ENVIRONMENT • MATOSINHOS • MATOSINHOS REFINERY 9

02 • Introduction 

10 

INTRODUCTION 

We already have four editions of the Matosinhos Data Book. 

In these four years we have presented, with transparency and 

accuracy, the performance of Matosinhos refi nery and the guidelines 

that thread our way in Health, Safety and Environment performance. 

In this way, the editorial development 

and its content is remarkable. Today, 

the Data Book is a mature document 

capable of responding to the concerns 

and interests of stakeholders, not 

becoming exhausted on the traditional 

themes and trying to offer new 

perspectives on the refi nery and the 

strategies that have been developed. 

We maintain a logical and intuitive 

method in the consultation and reading 

of this document, and spread the 

historical data results of the refi nery 

to six years: 2005 – 2010, which 

provides, undoubtedly, a substantial 

and important overview on the 

performance evolution in Environment, 

Health and Safety, which allows to 

evaluate trends and the impact of the 

strategies adopted. 

With last year’s edition we expanded, 

both in number and in borders, the 

readers universe. We produced printed 

versions in English, commitment that 

we keep in this issue. In addition, we 

are pleased to consider suggestions 

and comments from our readers who 

promptly fi lled and sent to us the 

questionnaire that accompanied the 

2009 Data Books. 

In this edition, we have developed 

efforts to humanize the Data Book. It’s 


made for and about people, about and 

for the people that work in the refi nery, 

about and for the local Community. It 

is for all employees of Galp Energia. 

It is for investors and public entities. 

It is for all who are interested in the 

impact and performance of Matosinhos 

refi nery. Thus, we continue to 

understand that the external verifi cation 

of the Data Book is fundamental, as 

a way to demonstrate the confi dence 

that we have in the reported results, 

and so we pass to our readers that 

same confi dence. It is also why we call 

for their active participation, by fi lling 

the questionnaire that accompanies the 

Data Book, in the certainty that their 

voices will defi ne our way from today’s 

current status. 

Finally, we reaffi rm the message 

which we have been insisting on. The 

Data Book is a document which the 

purpose is being practical and having 

reliable information and data accurately 

presented. The data that we publish 

is reproducible and are appropriately 

framed through its defi nition in the 

Glossary section. Please, consider this 

document to satisfy your interest and 

curiosity or use it as a working tool. 

We are at your disposal to support you 

in these tasks and we wish you good 

reading. 

IN THIS EDITION, WE HAVE 

DEVELOPED EFFORTS TO 

HUMANIZE THE DATA BOOK. 

IT’S MADE FOR AND ABOUT 

PEOPLE, ABOUT AND FOR 

THE PEOPLE THAT WORK IN 

THE REFINERY, ABOUT AND 

FOR THE LOCAL COMMUNITY. 

IT IS FOR ALL EMPLOYEES 

OF GALP ENERGIA. IT IS FOR 

INVESTORS AND PUBLIC 

ENTITIES. IT IS FOR ALL WHO 

ARE INTERESTED IN THE 

IMPACT AND PERFORMANCE 

OF MATOSINHOS REFINERY.


03 

FRAMEWORK 

THE GROWING CONCERN 

REGARDING HEALTH, 

SAFETY AND THE 

ENVIRONMENT AT 

MATOSINHOS REFINERY 

IS POSITIVELY AND 

INEQUIVOCABLY REFLECTED 

IN THE RESULTS WE NOW 

PRESENT. 

2010 2010 DATA DATA BOOK BOOK ON ON HEALTH, SAFETY AND AND ENVIRONMENT • MATOSINHOS • MATOSINHOS REFINERY 11


12 


HEALTH, SAFETY 

AND ENVIRONMENTAL POLICY 

Galp Energia acknowledges that the protection of the Environment, 

Safety and Health of its employees, customers and community 

in general, are essential values for the Organization sustainability 

and is, therefore, aware of its responsibility in managing the impact 

of its activities, products and services within the society of which 

it takes part. 

Thus, establishes a commitment 

to integrate Health, Safety and the 

Environment (HSE) into the Company’s 

strategy and activities, as well as 

into the continuous improvement 

of its performance, making these 

it’s Management pillars and thereby 

contributing to achieving a sustainable 

development and corporate excellence. 

Galp Energia is committed to: 

• establish Health, Safety and 

Environmental Protection as 

fundamental values of the Company; 

• acknowledge that managing Health, 

Safety and the Environment is a direct 

leadership responsibility and risk 

prevention is a shared responsibility 

within the Organization; 

• promote training for all employees 

in these subjects, involving partners 

and other interested parties, 

committing them to Health, Safety 

and the Environmental matters 

in order to act proactively both 

within and outside the working 

environment; 

• apply the best management practices 

and technical solutions available, 

in addition to legal compliance, in 

continuous prevention strategies 

by identifying, controlling and 

monitoring risks to ensure Health, 

Safety and Environmental protection; 

• create conditions that allow the 

Organization as a whole to be 

permanently prepared to respond to 

emergencies; 

• ensure the sustainability of projects, 

ventures and products throughout 

their life cycle, through the use of 

technology, facilities, resources and 

best practices to prevent or minimize 

adverse consequences; 

• establish challenging targets and 

goals, measuring and evaluating 

the results obtained and taking the 

necessary action to pursue them; 

• ensure effi cient use of energy and 

resources and the incorporation of 

safe and innovative technologies 

when managing its activities, 

minimizing the impact, so as 

to guarantee the Company’s 

sustainability and Environmental 

protection; 

• make this Policy known and 

available, in a responsible and 

transparent way, to all interested 

parties, communicating regularly 

the Company’s Health, Safety and 

Environmental performance.

Galp Energia, therefore, assumes its 

role as a socially and environmentally 

responsible Company, operated by a 

motivated, competent and innovative 

team of people, committed to protect 

Matosinhos refi nery aerial view. 

INTRODUCING THE 

REFINERY 

OPERATOR DETAILS 

The Matosinhos refi nery is an asset of 

Petrogal, S.A., a company in the 

Galp Energia group. The following table 

shows some relevant details: 

the Environment, Health and Safety of 

its employees, customers, partners and 

the community, actively contributing to 

the wellbeing of the Society. 

Matosinhos refi nery, Apartado 3015 

Matosinhos, 4451-852 Leça da Palmeira 

Telephone: +351 229 982106 

Fax: +351 229 982196 

CAE: 19201 - Manufacture of Refi ned 

Petroleum Products 

Date of Incorporation: 26 March 1976 

Headquarters: Rua Tomás da Fonseca 

Torre C - 1600-209 Lisboa 

Telephone: +351 21 7242500 

Fax: 21 7240573 

Equity: €516,750,000 

Tax Registration Number: 500 697 370 

Registration Number at the Lisbon CRC: 523 

Framework • 03 



14 

Organization structure 

Monitoring Acompanhamento of Construction de 

Construção and Commissioning e Comissioning 

HSEQ AQS 

Environment Ambiente 

Qualidade Quality 

Segurança Safety 

Operations Operações 

Fabrica Fuelsde 

combustíveis Plant 

Fabrica Base Oil de 

óleos Plant base 

Fabrica Aromatics de 

aromáticos Plant 

Fábrica Utilities de 

Utilidades Plant 

Movimentação Storage 

produtos and oil 

movements 

Integridade Integrity e 

and conservação Conservation de 

activos Assets 

Paragens Shutdowns e 

and empreitadas activities 

Preservation 

Conservação 

de of activos assets 

Fiabilidade Reliability 

Project 

Management Gestão de 

projectos and Engineering e Eng.ª 


ORGANIZATIONAL MODEL 

As mentioned before, there are 479 

employees working in the Matosinhos 

refi nery, spread across different areas, 

whether procedural, technical support 

services or management. The following 

diagram shows the organizational 

structure of the refi nery. 

Refinaria Matosinhos de 

Matosinhos Refinery 

Technical Técnica 

Procedure Controlo 

processual Control 

Technology Tecnologia 

Laboratório Laboratory 

Inspection Inspecção 

for excellence in its HSE, based on 

the fundamental principle of line 

accountability. 

The management of HSE is 

participative with the involvement 

of all hierarchical levels, and the 

hierarchical responsibility in HSE is 

It is also important to present the 

Integrated Organization Structure of 

HSE of the refi nery. 

Through the Integrated Organization of 

HSE, the Matosinhos refi nery reiterates 

its commitment of the demand 

Performance e 

planeamento 

and Planning 

de Production produção 

Programming 

Programação 

Performance Análise de 

performance Analysis 

Transversal Projectos 

Transversais Projects 

Planning Planeamento Control de 

controlo and Management e serviços 

de Services gestão 

Management Controlo 

de Control gestão 

Commercial Movimento 

Movement comercial 

General Serviços Services gerais 

defi ned and applied at all levels 

and functions, were they assume 

functions of technical advisory in the 

Organization. 

In the diagram above the structure of 

the HSE organization is represented.

HSE Committee structure 

Group of Excellence 

for the Investigation 

of Accidents 

HSE SubC 

Aromatics Plant 

HSE SubC 

Fuels Plant 

The HSE Committee (HSEC) of the 

Matosinhos refi nery it’s constituted 

by the board members, Heads of the 

HSEQ Areas and by the Occupational 

Physician. The HSEC it’s also constituted 

by the responsible member for the 

Lubricants Plant and by the responsible 

member for the Boa Nova Park, to 

ensure the proper coordination of 

actions and information exchange with 

these units. 

Directly under the HSEC of the refi nery 

there are the HSE Sub-Committees 

(SubHSEC) for each Plant and for 

Storage and oil movements, which 

ensure the dissemination and 

alignment with the HSEC. In these 

subcommittees, there are usually the 

Responsible for the Area, the Deputy 

HSEC 

HSE SubC 

Oils Plant 

Chief, shift supervisor, two operators 

(at least one from outdoors), the 

Representative of the Maintenance 

Zone, the Representative of Zone 

Inspection, the HSE element for Zone 

support, and other elements may 

participate temporary or permanently. 

In 2010 the Groups for Excellence (GE) 

of the refi nery were active and they 

were dedicated to the Report, Events 

and Incident Investigations and the 

Group Policies and Procedures. 

In addition to the above structure 

represented, the Matosinhos refi nery 

also participates in corporate GE, 

particularly in the Process Safety GE, 

for which it is the leader, and the 

service providers GE. 

HSE SubC 

Utilities Plant 


Group of Excellence 

for Standards and 

Procedures 

Working Groups 

HSE SubC 

Storage and oil 

movements 



16 

LOCATION AND 

SURROUNDINGS 


The Matosinhos refi nery is located on 

the Douro Coast between Boa-Nova 

and Cabo do Mundo, in the parishes of 

Leça da Palmeira and Perafi ta, in the 

municipality of Matosinhos. It covers 

an area of approximately 400 ha, to 

the Northeast of the city of Porto, 

about 2 km North of Port of Leixões. 

The refi nery has good access roads 

and a link to the Oil Terminal and 

monobuoy, by which raw materials 

are received and fi nished products 

despatched. 

The following facilities in the refi nery 

surroundings warrant special mention: 

• Gas Perafi ta Park, with facilities for 

Liquid Petroleum Gas (LPG) storage 

and fi lling of tanker vehicles and 

bottles, situated to the Northeast of 

the refi nery; 

• Boa Nova Private Hospital; 

• canning factory, vehicle repair 

workshops and garages, about 150 

m from the refi nery fence; 

• urban spaces and population 

centres, namely Leca da Palmeira 

and Matosinhos to the South, Aldeia 

Nova, Poupas and Telheira to the 

North, and Almeiriga, Amorosa, 

Gonçalves and Avessada to the East; 

• forest, agricultural land and bush land; 

• dunes, with typical vegetation. 

There are no Nature conservation 

areas close to the refi nery. 

The following is a list of the 

land-planning schemes in force in the 

region bordering the refi nery: 

• Leça River Catchment Scheme (Plano 

de Bacia Hidrográfi ca do Rio Leça); 

• Caminha – Espinho Coastal Strip 

Land-use Plan (Plano de 

Ordenamento da Orla Costeira 

Caminha – Espinho); 

• the Forest Land-use Plan for the 

Porto Metropolitan Area and 

between Douro and Vouga (Plano 

Regional de Ordenamento Florestal 

da Area Metropolitana do Porto e 

Entre Douro e Vouga); 

• northern Region Land-use Plan 

(Plano Regional de Ordenamento do 

Território para a Região Norte); 

• management Scheme for the 

Municipality of Matosinhos (Plano 

Director Municipal de Matosinhos); 

• urbanisation Scheme for between 

Rua de Belchior Robles and Avenida 

dos Combatentes da Grande Guerra 

in Leça da Palmeira (Plano de 

Urbanização entre a Rua de Belchior 

Robles e a Avenida dos Combatentes 

da Grande Guerra em Leça da 

Palmeira). 

Although multiple operators contribute 

to the air and water quality in the 

region under the infl uence of the 

Matosinhos Industrial Complex, and

given that the refi nery monitors liquid 

and gas emissions to control the 

impact of its activity, it is relevant to 

provide information on the quality of 

these descriptors in the surroundings. 

The municipality of Matosinhos is part 

of a monitoring network of the air 

quality in the Northern Region and is 

included in the agglomeration of the 

Porto Coast. Of the 15 stations that 

compose the agglomeration of Porto 

Coast and that are spread between 

Espinho, Gondomar, Maia, Matosinhos, 

Porto, Vila do Conde and Valongo, fi ve 

are located in Matosinhos. 

The following graph shows the 

history of the Air Quality Index for 

the Porto Coast region. It can be seen 

that the quality of air has improved 

consistently. 

In terms of surface water, the region 

is the watershed between the Leça 

River and Onda River catchments. 

Watercourses are temporary, with 

natural drainage occurring only after 

signifi cant rainfall. 

In the last years the quality of the 

beaches in Matosinhos has improved 

signifi cantly, and in 2010, 13 beaches 

have received the Blue Flag (against 9 

Blue Flags in 2009). 

Aquifers are at low vulnerability of 

pollution. 

Air Quality Index - Porto Coast 

Number of days 

400 

350 

300 

250 

200 

150 

100 

50 

0 

Very good 

Good 

4 2 1 1 0 

113 

81 

89 

34 

67 

36 

75 

79 

157 

12 

2005 

Average 

Weak 

87 

188 

7 

2006 

Bad 

98 

158 

236 


208 

19 

28 

46 

2007 2008 2009 

Source: Link to the site of the Portuguese Environmental Agency: http://www.qualar.org/INDEX.PHP?page=1. 

Note: In the index shown above, the following pollutants are considered Nitrogene Dioxide (NO2), Sulphur Dioxide (SO2), 

Carbone Monoxide (CO) and Particulate Matter (PM10 – less than 10 μm diameter). 

The information above considers the available statistics. 



18 


HISTORICAL OVERVIEW 

1966 

1967 

1969 

1970 

1973 

1975 

1978 to 

1982 

1981 

1982 

1983 

1984 

1988 

1989 

1991 

1992 

The start of the construction project for the Matosinhos refi nery, with a crude oil 

processing capacity of 2Mtonnes/year. 

Construction work begins in September 1967. 

Progressive start-up of the processing facilities beginning in September. 

Matosinhos refi nery offi cially opens, 5th June. 

Between September and December – First renovation to give a capacity of 4.5 

Mtonnes/year, consisting of transforming the visbreaking and thermal cracking 

facility into a new visbreaking facility, with the equipment made available for a 

new atmospheric distiller. 

Second renovation with the construction of a new crude oil treatment line. 

Shutdown of various facilities of one of the lines as a consequence of the oil shock 

of 1973/74 and subsequent startup of the Sines refi nery, with a drastic reduction 

in the treatment of crude oil at the Matosinhos refi nery. 

Start of development of the Aromatics Plant, with a capacity of 350 thousand 

tonnes/year for Benzene, Toluene, Paraxylene, Orthoxylene and Aromatic and 

Aliphatic Solvents. 

The refi nery crude oil processing capacity rises to 4.5 Mtonnes/year. 

Transformation of a semi-regenerative Platforming facility into a CCR – Continuous 

Catalyst Regeneration Platforming facility, so that the quality and quantity of 

production of the catalytic regeneration plants is maintained. 

Modifi cation of the Base Oil Plant so as to increase its production capacity from 

100 thousand to 150 thousand tonees/year of base oils. The production of paraffi n 

and bitumen increases from 5 thousand and 30 thousand tonees/year to 10 

thousand and 130 thousand tonnes/year, respectively. 

Reactivation of the Unifning and Platforming plants due to contracting by third 

parties for treating crude oil. Renovation of the WWTP, so that treatment capacity 

increases from 150 to 450 m 3 /h. 

Changes to allow the Vacuum Distillation plant to be fed with external Atmospheric 

Residue. 

Modifi cations of the Unifi ning and Platforming plants to increase their capacity 

and decrease their energy consumption. Shutdown of Unifi ning line 3000. 

Modifi cations to the Parex, due to the demands of the international market 

regarding purity and growth in consumption, leading the total production of the 

Aromatics Plant to increase to 440 thousand tonnes/year.

HISTORICAL OVERVIEW 

1994 

1996 to 

1997 

1997 to 

1998 

2000 

2001 

2004 

2005 

2006 

2007 

2008 

2009 

2010 

Modernisation of the Vacuum distillation unit of the Base Oil Plant. 

Construction of the Road Tanker Filling Station with a Vapour Recovery Unit (VRU), 

construction of a new Diesel Desulphurisation Plant and associated plants: sulphur 

production plant and acid water stripper, and renovation of an amine plant. 

Installation of a monobuoy of the Port of Leixões in order to increase the refi nery’s 

operational preparedness and profi tability. 

Construction of a hydrogenation plant for oil paraffi n and waxes. 

New Hydrogen Purifi cation plant enters operation. 

Modernisation of the Waste Park. 

Issue of licence No.197.02 for emitting Greenhouse Gases. 

New pipelines connecting the refi nery to the Leixões Oil Terminal enters operation. 

The monobuoy enters operation. 

Issue of the Environmental Permit for the Matosinhos refi nery. New storm drains 

for the Wastewater Treatment Plant (WWTP) enter operation. General shutdown. 

Start of works to reconfi gure the Matosinhos refi nery. 

Upgrade of the old storm drains. 

Inspection and Renovation of the entire oil drainage network completed. 

Electrostatic Precipitators for reducing particulate emissions from the Utilities Plant 

enter into operation on boilers G and H. 

The system for removing chlorides from the LPG fl ow from the two reforming 

units, U1300 and U3300, enters operation. 

The system for removing hydrochloric acid from the hydrogen-rich fl ows from the 

two reforming units, U1300 and U3300, enters operation. 

Installation of Low-NO X burners in boiler H. 

Installation of a new nitrogen production plant. 

Replacement of the gas analysers in the fi xed emission sources. 

Installation of new production unit of nitrogen in the Aromatics Plant. 

Deep remodeling of the furnace H-3001. 

Remodeling of the train swap topping Un. 3000. 

Revamping unit Desulfurization of HDS Diesel II (increased capacity of the Unit). 

New storage tanks for diesel, TK-6117 TK-6117 A and B. 

Increase the capacity of recovering the water treated by WWTP 

New fi lter U-1500. 




20 


DESCRIPTION OF ACTIVITY 

CAPACITY 

Matosinhos refi nery has an installed 

refi ning capacity of 5.5 million 

tonnes of crude oil per year, 

producing a wide range of refi ned 

commercial products, namely: 

The crude oil storage capacity at the 

refi nery is 648,621 m3 , with a total 

storage capacity of 1,780,317 m3 . 

The refi nery management and 

production plans, that have an impact 

on the inventory management consider 

the need to assure a safe supply of 

Petroleum products to the market. 

DESCRIPTION OF THE PRINCIPAL RAW MATERIALS 

Matosinhos refi nery, refi nes two 

types of crude: SOUR and SWEET, the 

names deriving from their sulphur 

content. Crude comes mostly from 

Libya, Nigeria, Algeria, Saudi Arabia, 

Iran, Russia and the North Sea – 

Norway and the United Kingdom. 

The following table shows the 

TYPE OF LINE INDICATOR 2005 2006 2007 2008 2009 2010 

SWEET 

SOUR 

LIQUID PETROLEUM GAS; 

PETROL; 

NAPHTHA; 

JET/OIL; 

DIESELS; 

FUELS; 

BASE OILS; 

LUBRICATING OILS; 

PARAFFINS; 

ALIPHATIC AND AROMATIC, 

SOLVENTS, BENZENE, 

TOLUENE AND XYLENES; 

BITUMEN. 

proportions of each crude type, as well 

as its principal features. 

The selection of crude types depends 

on various commercial, technical and 

environmental factors, such as: quality, 

market availability, international 

market value, refi nery production 

plans, and the storage capacity. 

Proportion of use (%) 68.20% 66.90% 71.10% 69.80% 62.00% 56.61% 

Load Density (ºAPI) 43.33 42.46 41.02 40.67 40.69 40.35 

Sulphur (%m/m) 0.15 0.15 0.13 0.11 0.12 0.13 

Proportion of use (%) 31.80% 33.10% 28.90% 30.20% 38.00% 43.39% 

Load Density (º API) 33.21 33.17 32.94 33.23 33.18 35.52 

Sulphur (%m/m) 1.87 1.87 1.96 1.86 1.70 1.58

DESCRIPTION OF PROCESS 

Matosinhos refi nery carries out 

the following activities under the 

Integrated Pollution Protection and 

Control (IPPC) Regime. 

The fi gure below shows the 

arrangement of the refi nery and 

various units that support its operation. 

Matosinhos refinery configuration 

Aromatics 

Plant Fare 

Aromatics 

Plant 

Fuels 

Plant 

The following schematic shows the 

simplifi ed production process: 

Process diagram 

Arabian 

Light 

SB, EA, CPC, 

Forties,... 

FOB 

d.a. 

FCO 

atmospheric 

distillation 

of p.b. 

LPG 

Naphta 

Diesel 

Fuel 

FOB 

d.a. 

Transport 

Products 

Despatch 

IPPC IDENTIFIER DESCRIPTION 

1.1 Combustion facilities with combustion heat output over 50MW 

1.2 Oil and gas refi neries 

4.2 (a) Chemical plants intended to manufacture products based on organic chemicals. 

Thermoelectric 

Power Station 

Processing 

Lubricants 

Plant 

Base Oils 

Plant 

FAR 

Bitumens 

Paraffins 

Base Oils 

LPG 

Petrols 

Aromatics 

Diesels 

and Jet 

Fuel 



22 


04 

IN DETAIL 

HAZOP STUDY TO 

THE EXISTENTS 

UNITS OF THE 

COMPLEX. 


04 • In detail 

24 


HAZOP STUDY TO THE EXISTENTS UNITS 

OF THE COMPLEX 

Framed in the operationalization of the 

Health, Safety and Environment Policy 

(HSE) of Galp Energia, the Matosinhos 

refi nery defi ned a strategic initiative 

for the period between 2009 and 

2012, the Hazard and Operability study 

(HAZOP) Safety Review of process 

units that have never been submitted 

to a Process Hazard Analysis (PHA). 

The safety of the procedural facilities 

is one of the most important issues for 

this industrial complex operation. 

Regulations of organizations 

like the Occupational Safety and 

Health Administration (OSHA) and 

Environmental Protection Agency (EPA) 

determine the realization of the PHA 

to the process units of the petroleum 

refi ning industry, in order to reduce 

the likelihood and/or consequences 

of serious accidents with impact on 

employees, welfare of the population 

and the surrounding, internal and 

external assets, Environment, and the 

survival factor of the refi nery, with 

regard to its longevity of operation. 

Among the existing PHA techniques 

the HAZOP was the chosen one, due to 

the complexity of the existing process 

units at the refi nery. 

The purpose of the HAZOP study is to 

determine the deviations of process 

variables, in normal operation, that 

can cause procedural risks, with 

impact on people and equipment, or 

compromise the Company’s business. 

Simultaneously, it also allows the 

review of operational procedures 

to ensure that they are appropriate 

and are in accordance with the units 

projects conditions. 

The scope of this study includes all 

the equipment of the unit, based 

in the Process & Instrumentation 

Diagrams (P&ID), utility systems (and 

the equipment assigned to them) 

since they interfere with the causes, 

consequences or protection measures 

of any deviation studied, for normal 

operations, start-up and emergency. 

An action plan was developed for the 

realization of the HAZOP studies. For 

the elaboration of this plan, it was 

determined by the refi nery Board that 

it would begin from the Base Oil Plant, 

starting the analysis at Unit 2600. 

Until December 2010, HAZOP was 

performed to the following units: Unit 

2600 – Production of bitumen, and 

Unit 2400 - Base Oil Treatment with 

hydrogen. 

The continued success of this initiative 

depends on: 

• total commitment from the refi nery, 

involving the different areas; 

• collaboration and active participation 

of all involved; 

• the knowledge, commitment and 

technical experience of the refi nery 

technicians.

To carry out HAZOP studies, multidisciplinary teams are created. Among those 

elements it is chosen a “Team Leader” who: 

• defi nes the scope of analysis; 

• plans and prepares the study, indicating the location, date and time; 

• selects the team members and communicates, previously, the “we” that are 

considered for the study; 

• addresses the meeting, introducing the discussion using word guides. 

Amongst the team there is an element that is designated as a “Secretary” 

which makes use of the software available in the refi nery, to prepare the 

HAZOP worksheets. 

The “Secretary” notes the topics that are discussed in these meetings, 

prepares the draft and the fi nal version of the study report. This element 

should be of the technical area and being familiar with the computer 

application used for the HAZOP studies. 

The remaining “Team Members” are: 

• responsible for the Plant or Unit Operations; 

• process Engineer; 

• technical Operations Expert; 

• technical Expert in Assets Conservation; 

• instrumentation and Control Systems Engineer; 

• prevention and Safety Engineer. 

Depending on the complexity of the study, the team can be enriched with 

collaborators with other type of knowledge such as: 

• refi nery Operations Responsible; 

• assets Integrity and Preservation Responsible; 

• other experts who are appropriate for the study. 

In detail • 04 


26 


05 

ACTIVITIES, ACTIONS 

AND PROJECTS 

WE BELIEVE THAT THE SUSTAINABILITY 

OF OUR REFINERY IS CENTERED ON 

OUR BASIC VALUES: SUBJECTING 

OUR ACTIVITIES AND DECISIONS TO 

PROTECTING HEALTH, SAFETY AND THE 

ENVIRONMENT. 



28 


HIGHLIGHTS OF 2010 

The main goals to achieve with the reconfi guration of 

Matosinhos refi nery, called Masterplan, are: 

• improve diesel production due to the 

construction of vacuum distillation 

and Visbreaker units; 

• process heavier crude oils, allowing a 

better refi ning margin; 

• produce Fuel 1% for the local 

market, ensuring full supply 

coverage; 

• greater fl exibility of operation, 

enabling a better adaptation to 

demands in the fuel market; 

• diesel versus Petrol, maximizing 

diesel production throughout 

Galp Energia refi neries; 

• reduce energy consumption, with the 

modifi cations in the furnace and the 

exchange cart in Unit 3000 and other 

additional modifi cations; 

• improve the environmental 

performance through the construction 

of acidic waters treatment plants and 

sulphur recovery units. 

The following sections explain in detail 

the changes undertaken in this project. 

REVAMPING OF UNIT 3000 - 

DISTILLATION OF CRUDE OIL & FURNACE 

H3001 

Unit 3000 for the distillation of crude oil has undergone 

modifi cations to improve its energy performance and hence its 

environmental impact. 

These modifi cations also enabled to 

increase the processing capacity of 

crude oil and adapt this facility to 

crudes with different characteristics 

compared to the initial project. 

The most signifi cant changes occurred 

in the crude preheat cart furnace 

H-3001. 

The revamping is refl ected essentially 

by: 

• increasing the unit capacity from 

current 9,700 tonnes/day to 12,000 

tonnes/day; 

• the ability of processing acidic crude 

oils (TAN max = 1.0), enlarging the

ange of crude oils that could be 

handled; 

• increased energy integration through 

the increase in the heat transfer area 

and the upgrade of the exchange 

cart to the new crude oils; 

• increased energy effi ciency by 

reconfi guring the furnace H3001. 

This was rebuilt and fi tted with a 

preheating combustion air system 

enabling effi ciency increase from 

84% to 93% resulting in reduced 

energy consumption. The upgrade 

U3000 

In terms of the loads to treat the unit 

was designed for the following two 

cases of crude blends: 

Case A: Bonny Light + Marlim 

It is the reference case for setting up 

of the integrated operation including 

the new vacuum/visbreaker unit. 

These are heavier crude oils, with 

increased yield in the residue. Enable 

the process to obtain the load in the 

new vacuum unit. 

In this set-up the top product is 

reduced so that the petrol-fractionating 

column T-3004 remains out of service. 

Therefore all light petrol is conducted 

to the petrol desulphurization unit 

minimizing the sulphur content of the 

also enabled a signifi cant reduction 

in the furnace noise; 

• better energy integration obtaining 

a hot diesel oil stream conducted 

directly to the diesel desulphurization 

plant U3700. 

The energy performance of the Unit 

has been considerably improved 

comparing with the values of the 

Solomon study in 2006 and, with 

reference to the equivalent units in 

Europe, the new positioning of some 

key indicators, energy is the following: 

Average 

2006 

Average 

Solomon 

components to be incorporated in the 

lots of petrol. 

Case B: 100% Sarah Blend 

With 

Revamp 

T at Furnace entrance (ºC) 194 246 276 

T in the Flash Zone (ºC) 342 352 362 

Highest T product at Aero (ºC) 185 155 159 

Cart Available Area m2 /bbl capacity 0.055 0.099 0.091 

It is the reference case of operation, 

before the integration of the 

vacuum/visbreaker, using lighter crude 

oils. In this situation the unit maintains 

the operating mode prior to the 

project deployment, benefi ting only 

from the energy performance drivers. 

Activities, actions and projects • 05 



30 


NEW ACID WATER TREATMENT PLANT - 

UN. 10775 

Following the new Vacuum and Visbreaker units, it becomes 

necessary to design and build a new acid water treatment plant that 

can receive additional quantities of process water from these units. 

The unit purpose is to remove 

hydrogen sulphide (H S) and ammonia 

2 

(NH ) of acid water obtained as 

3 

effl uent in several units of the process. 

The planned capacity is 30.6 m3 /h and 

treats all process streams from the 

units mentioned above. 

As treatment products, it is obtained 

an acid gas stream that is sent to 

the sulphur recovery Units (Un. 3800 

and the new Un. 10 800) and treated 

water to be reused in other units. 

The treated water has the following 

characteristics: H S concentration

Alongside, a new fl ow composition 

equalization tank, with a capacity of 

800 m3 , was built. 

This equipment enables the storage 

of acid water equivalent for two 

days of normal production of the 

refi nery. Thereby, increasing the 

facilities reliability and reduces the 

environmental impact due by possible 

stops of the acid water units. 

With this new unit, designed with 

the best available techniques, the 

Fuel Plant will be able to reuse about 

REVAMPING OF DIESEL 

DESULPHURISATION PLANT - UN. 3700 

As a result of changes introduced in crude distillation unit and the 

construction of the vacuum unit and the Visbreaker, the ability to 

produce diesel with high sulphur content has increased. 

In order to avoid a shortfall in the 

desulphurization diesel capacity and 

increase fi nal diesel production, it 

became necessary to increase the 

capacity of diesel desulphurization 

installed to cope with additional 

production of distilled diesel. 

The revamping conducted at unit 

3700, focused mainly on the following 

points: 

• increased unit treatment capacity to 

4,200 tonnes / day (+21%); 

• increased energy integration through 

adjustments and incorporation 

of additional heat exchangers in 

500 tonnes per day of treated water 

as desalination water in Unit 3000, 

decreasing the consumption of raw 

water in the refi nery. 

There is also a reduction in the purges 

for drainage, reducing the fl ow to 

the wastewater treatment plant with 

the consequent reduction in the 

wastewater through the industrial 

emissary. 

exchange cart and the incorporation 

of a stream of hot diesel powered 

directly from the unit 3000. 

In this case the need for increased 

treatment capacity of diesel distilled, 

provided an opportunity to implement 

measures that impact on the reduction 

of energy consumption. 




32 

New sulphur recovery and tail gas treatment diagram 

SWS unit 

U-3775 

SWS unit 

U-10775 

AMINE 

Regent. Unit 

U-1500 

SWS 

acid 

gas 

Sour water 

Lean avine 

Rich avine 

Existing SRU 

U-3800 

Sulphur 

New SRU 

U-10800 

Sulphur 


NEW SULPHUR RECOVERY TREATMENT 

PLANT - UN. 10800 

The sulphur recovery from gaseous streams generated at 

desulphurisation units or derived from crude oil is a critical process at 

the refi nery. 

The regulation of air emissions of 

sulphur compounds requires the 

desulphurisation by the Sulphur 

Recovery Unit (Claus Unit). In addition, 

the recovery effi ciency of these units it 

is also a regulated value of 99.5% for 

the refi nery. 

Therefore a new Claus Unit and a 

exhaust gas (Tail Gas) treatment 

system joint with the existing unit was 

taken in consideration, following the 

adaptation recommended in the Best 

Available Techniques (BATs), as a result 

of the environmental licensing process 

and under the reformulation Project. 

The new Sulphur Recovery Unit 

(U-10800) allows a sulphur production 

Hydrogen 

TGT Unit 

U-10800 

[H 2 S] - 10mg/Nm 3 (max) 

[NO x ] - 150mg/Nm 3 (max) 

Existing 

Incineator 

U-3800 

Fuel 

Gas 

of 27 tonnes/day and can run in 

parallel with the existing unit. 

This will increase the reliability of the 

sulphur recovery process, allowing, 

in case of failure of one, the increase 

of treatment capacity in the other, in 

order to treat all acid gas produced in 

the complex. 

The tail gas (TGT) treatment system 

common to both units is an additional 

equipment for sulphur recovery. 

This ensures the sulphur dioxide 

(SO ) emissions reduction into the 

2 

atmosphere and the sulphur recovery 

capacity of 99.5%, in agreement with 

the refi nery Environmental Permit. 

The new Sulphur Recovery and Tail Gas 

Treatment unit are connected to the 

existing facility as on the diagram on 

the left: 

At the incinerator’s exit, the gas 

effl uent from the sulphur recovery 

system has the following design 

specifi cations: 

[H S] < 10 mg/Nm 2 3 (max) 

[NO ] < 150 mg/Nm X 3 (max)

NEW VACUUM AND VISBREAKER 

DISTILLATION PLANT – UN.10000 AND 

UN. 10100 

At the heart of all the reconfi guration of the Fuel Plant is the 

construction of the new vacuum unit and Visbreaker (VU / VB). 

This unit’s main function is to process 

the atmospheric residue of Unit 3000. 

The heavy diesel will be a load to the 

future Hidrocracker unit of the Sines 

refi nery, and is expected to represent 

40% of the total load of this unit. 

The Vacuum Distillation Unit and the 

Visbreaker are distinct units, even 

though they are interconnected in 

terms of location and in an operational 

and energetic point of view. 

The vacuum distillation unit 

(VU) is intended to separate the 

heavy fraction of crude, from the 

Atmospheric residue, originated from 

the atmospheric distillation. 

The capacity of the unit is 6,000 

tonnes/day of Atmospheric Residue. 

In this way, the production of currents 

to incorporate in more valuable 

distilled compounds is maximized, at 

the expense of fuel oil production. 

The intermediate products which are 

obtained from the vacuum distillation 

are: light vacuum diesel, heavy 

vacuum diesel, vacuum residue and 

non-condensable gases (methane, 

ethane and hydrogen sulphide). 

The heavy vacuum diesel is sent 

as load to the Sines refi nery, to the 

hydrocracker unit, and vacuum residue 

is sent to the Visbreaker or for storage. 

The process of visbreaking (VB) can 

be defi ned as an average thermal 

cracking and is intended to reduce 

the viscosity of vacuum residue and 

obtain components of gasoil and, 

consequently, decrease the production 

of fuel oil. The unit capacity is 2,400 

tonnes/day of vacuum residue. 

The intermediate products that 




34 

Costs and Investments concerning the protection of the environment (M€) 

Millions € 

30,0 

27,5 

25,0 

22,5 

20,0 

17,50 

15,0 

12,5 

10,0 

7,5 

5,0 

2,5 

0 

0,03 

0,60 

6,24 

1,41 

1,54 

2005 

Noise and Vibrations 

Protection 

Biodiversity and 

landscape 

0,09 

0,95 

5,38 

0,70 

1,52 

2006 

0,10 

7,18 

5,19 

2,33 

8,20 

2007 

Environment protection 

and management 

Air and climate protection 

0,77 

5,19 

3,16 

0,82 

11,39 

2008 


are obtained are: naphtha, gasoil, 

visbreaker residue and gases (C1 to 

C4 saturated and unsaturated and 

hydrogen sulfi de). 

It should be noted that with the expected 

energy integration foreseen in the 

project, these units, as compared with 

similar ones, will be the most effective in 

Europe in terms of energy consumption, 

according to the Solomon studies. 

COSTS AND INVESTMENTS 

82% 

increase 

since 2009 

3,68 

0,22 

2,11 

6,08 

1,19 

1,47 

2009 

Soil and groundwater 

protection 

Waste Management 

Water Protection 

Relationship between costs and environmental investments (M€) 

Costs 

1.98 

13.25 

2005 

2.12 

11.12 

2006 

Investments 

4.81 

22.45 

2007 

2.60 

18.72 

2008 

2.75 

12.00 

2009 

0,05 

0,14 

0,18 

18,63 

5,35 

0,73 

1,80 

2010 

2.18 

24.70 

2010 

Also as part of the reconfi guration, an 

expansion was made to the gas oil 

storage with the construction of two 

new tanks, each with a capacity of 

40,000 m3 , allowing that two tanks 

used for diesel storage returned to its 

original function of crude oil tanks. The 

reinforcement in this way, of the crude 

oil storage, has become necessary 

due to increased distillation capacity 

resulting from these projects. 


main environmental costs and 

investments. 

The annually reported amounts as 

Environmental Investments refl ect the 

cycle of the projects. Its development, 

consequently, must be seen in an 

integrated, cumulative manner, as 

constituting successive stages for 

consolidating investment plans. In this 

perspective, annual fl uctuations do not 

mean different levels of commitment 

in pursuing improved environmental 

performance. In the period under 

analysis (2005-2010) the total sum of 

environmental investments is €104 

million. 

The Safety investments resulted in a 

total of €2 million in 2010. 

Of the amounts shown above 

the following graph distinguishes 

operational costs from investments, 

demonstrating the refi nery´s 

concern for renovation and pollution 

prevention. 

Examining investments in matters 

of environmental protection and

management, one concludes that the 

refi nery’s greatest effort regards the 

choice of integrated technologies to 

prevent and reduce the generated 

pollution, avoiding investment in 

end-of-line measures that aim to 

reduce the impact of the produced 

TRAINING IN HEALTH, SAFETY 

AND ENVIRONMENT 

The training policy of Galp Energia seeks to ensure employees personal 

and professional development, with the aim of contributing to the 

consolidation of the Group’s culture, promote the development of 

strategic perspective on value creation, supporting the individual 

development plans. 

The themes of Safety, Health and 

Environment, especially in an industrial 

activity as the refi ning, are absolutely 

strategic, and over the past few 

years the cultural development of 

the Organization has made clear 

its commitment to training and 

qualifi cation as essential tools in 

ensuring sustainability of the activity in 

its various strands. Training plays a key 

role and therefore is taken with great 

pollution. It should be noted 

that the adopting of end-of-line 

technologies often means technical 

and structural constraints 

makingthe implementation of 

pollution-prevention technologies 

unviable. 

seriousness at the refi nery 

and between employees and service 

providers. 

The realization of this vision unfolds 

in two parts. The fi rst focuses on the 

training and qualifi cation of employees 

of the refi nery and takes several 

available formats: on-job, classroom 

or e-learning, packing various learning 

processes. 


Overview of environmental 

Investments in 2010 

53% 

End-of-line 

equipment 

Integrated 

equipment and 

technology 

47% 



36 


On-job training: 

Accumulation and transfer of knowledge acquired by more experienced 

employees in their function, leading to “see and make accompanied” and 

provide training skills necessary to tailor the performance to the requirement 

of very specifi c functions. 

Classroom training: 

Acquisition and development of expertise and/or behavioral skills, using 

methodologies of classroom training, monitoring and workshops necessary to 

the qualifi cation or development required to perform functions. 

E-learning: 

Stimulating the context of self-training, ensuring a culture of continuous 

learning by developing and providing innovative training tools to broaden the 

universe of students, encourage reciprocal investment between company and 

employee as well as reducing unit costs of training. 

In Regulatory Standard – Training, 2008 

Specifi cally within the Safety Program 

of Galp Energia, there was several 

specifi c training sessions, which 

were attended by 29 employees of 

Matosinhos refi nery, giving them 

knowledge and skills needed to 

implement various aspects of HSE 

Management System, namely: 

• motivation; 

• HSE Management of the Service 

Providers 

• audits to the HSE Management 

System; 

• risk Analysis Process; 

• operational Discipline. 

All these issues are important for 

the proper development of the HSE 

culture, essential for Galp Energia to 

fulfi l its ambition to operate with ZERO 

ACCIDENTS. 

In the training fi eld of audits of the 

HSE Management System a new 

cycle of assessment and monitoring 

of the evolution of the culture and 

the implementation of HSE processes 

and procedures management system 

at the refi nery was started, with the 

completion of the internal audit, which 

consisted of the practical component 

of training. 

The training in Process Risk Analysis, 

have a high relevance for the refi nery 

because of the diversity, complexity and 

risk of the operating procedures that 

allowed employees join the teams that 

should make the proper identifi cation, 

assessment and risk management 

to minimize the exposure of people,

facilities, environment and society in 

general to the risk of accidents derived 

from process. 

The training in HSE Management 

of the Service Providers and in 

Operational Discipline were written 

under “Train the Trainer”. The purpose 

and advantage of this method is 

that employees are now qualifi ed to 

transmit knowledge in their areas, 

providing training to other employees 

and subsequent refreshing training. 

Additionally, and because many 

service providers work daily on the 

premises of Matosinhos refi nery 

it is also essential to ensure their 

alignment with best practices in 

Health, Safety and Environment and 

with the procedures in force at the 

facility. It is in this sense that the 

areas of environment and safety of 

the refi nery provide safety induction 

activities to the service providers, with 

the following typifi cation: actions of 

hosting, notice actions, awareness 

campaigns and actions for Emergency 

Brigades. 

The graphs on the right show, for 

2008, 2009 and 2010, the number of 

training hours; the number of trainees 

and the number of training sessions 

regarding Health, Safety and the 

Environment attended by Matosinhos 

refi nery staff: 

The training costs in 2010 amounted to 

about €13,600. 

The graphs on the next page show 

the same indicators for the training 

provided by the refi nery. 

The Matosinhos refi nery annually 

gives a set of trainings distributed 

mainly by fi ve major groups: Training, 

Awareness, Warning, Induction and 

Emergency Brigade, whether to 

internal employees or to service 

provide employees. 

Training courses, in general, address 

issues related to internal procedures by 

focusing on the most relevant content. 

The analysis of HSE indicators shows, 

in some periods, certain weaknesses 

in some descriptors. Awareness 

campaigns are essential, by bridging 

these weaknesses, by focusing on the 

aspects that need improvement and 

actions to be taken to eliminate these 

deviations. 

Number of training programmes 

in Health, Safety and Environment 

21 

2008 

Number of trainees in training 

programmes in Health, Safety 

and Environment 

843 

2008 

68 

2009 

467 

2009 

97 

2010 

648 

2010 


Number of hours of training 

programmes in Health, Safety 

and the Environment 

7,854 

2008 

6,356 

2009 

4,254 

2010 



38 

Number of hours of training given in 

Security, Health and Environment 

Number of trainees in training 

programmes provided in Health, 

Safety and Environment 

2,986 

2008 

Total 

Emergency 

Brigade 

Induction 

4,305 

2009 

Warning 

Awareness 

Training 

849 

5,683 

66 

500 

306 

2010 

Number of training programmes 

provided in Health, Safety 

and Environment 

473 

2008 

473 

2008 

Total 

Emergency Brigade 

Induction 

Total 

Emergency 

Brigade 

Induction 

594 

2009 

594 

2009 

Warning 

Awareness 

Training 

265 

443 

8 

52 

69 

2010 

Warning 

Awareness 

Training 

187 

281 

15 

66 

72 

2010 


Whenever procedures are identifi ed, 

incorrect practices or unsafe actions, 

it’s triggered an action of notice to the 

team and to the company targeted 

by this observation. In the current 

year, the refi nery held 66 actions of 

warning, as illustrated in the following 

graph. 

All employees, to begin their activity 

within the facilities of Matosinhos 

refi nery, must take part in induction 

training. Throughout a period of 

approximately three hours are treated 

subjects such as Personal required 

protective equipment, Work permits, 

Assessment and Risk Management fact 

sheets, Procedures in case of general 

emergency and Waste, among others. 

In 2010, the induction trainings were 

responsible for about 45% of total 

trainings, contributing to that the 

Technical Shutdown that the refi nery 

was subject in this year. 

The fact that the Matosinhos refi nery, 

under Decree-Law No. 254/2007 

of 12 July, falls within the regime 

of establishments of high level 

of dangerousness, leads to the 

requirement of carrying out drill 

exercises and training as a way 

of preparing employees for real 

emergency situations. 

The training of Emergency Brigade 

prepares employees who belongs to 

the emergency response teams, from 

the practical and theoretical point of 

view, as regards to the prevention 

of serious accidents and their 

consequences. 

A practical training is held every week 

to the Emergency Brigade which, 

among other things, trains themselves 

in the refi nery training park. Real 

accident conditions are simulated, such 

as live-fi re exercises, use of installed 

barriers installed in the park, use of 

autonomous respiratory protective 

equipment and assembly/disassembly 

of emergency equipment. 

The theoretical sessions focuses 

on how one should establish 

communication in an emergency 

and how to liaise with the Safety 

Communications Central Unit, on 

chemistry of fi re, on processing units, 

on associated products and safety 

systems affected, and on the different 

rules and regulations applicable to 

prevention and safety of persons and 

facilities.

The training given by the refi nery is an additional requirement associated 

with services providers’ recruitment. Galp Energia has a Standard Procedure 

(NPG), published in early 2010, on the Management of Health, Safety and 

Environment of its service providers, which aims to: 

• minimize exposure of employees, facilities and environment in general to 

the risk of accidents; 

• promote the inclusion of HSE issues in the process of hiring of service 

providers; 

• require compliance with legal requirements and other HSE requirements of 

Galp Energia; 

• assess the HSE performance of service providers and establish clear 

principles, procedures and well-defi ned requirements for the maintenance of 

the contract; 

• promote the use of best practices and work methods on the execution of 

services. 

In NPG-029 – HSEQ requirements in the relationship with service providers, 

2010 review 

The established procedure involves the following steps: 

Pre-qualification Qualification 

Grant of 

contract 

Guidance 

and training 

Development 

of tender 

specifications 

Coordination 

and inspection 

Contract 

review 

There is an HSE component of the pre-qualifi cation survey, with minimum and 

recommended requirements for bidders to a given contract, whose results 

are worked out in the form of an HSE rating index for service providers. It 

settles a degree of risk associated with the contract, according to which the 

requirements (the qualifying standard) has an increasing demand. Apart from 

a wide range of requirements and assessments, it is given a strong emphasis 

to HSE training programs in the Company to hire. 




40 


The Data Book more and more 

refl ects a joint work, which equate 

and consider the service providers 

and employees contributions. The 

confi rmation of this is the testimonies 

from two employees who were 

interviewed for this document. 

By the refi nery, the responsible for 

the maintenance of the fuel Plant 

was interviewed and by the service 

providers the responsible for the 

gardening maintenance contract. 

During the interviews were discussed 

issues like: 

• induction training, issues presented 

in this training, and how important is 

this training in the performance of 

duties by the employees; 

• strengths and weaknesses of HSE 

trainings that Matosinhos refinery 

minister to their service providers 

and degree of satisfaction with 

regard to these training; 

• annual training plan and focus on 

HSE content, number and quality of 

training sessions, importance of 

training to the job tasks; 

• preventive Safety and Environmental 

Observations; 

• responsible for Safety of Matosinhos 

refinery. 

Identifi cation of the person 

responsible for Gardening 

maintenance: 

Name: Rui Abreu Vaz Guimarães 

Age: 36 years 

Company: Fitonovo Lda 

Nature of services: Gardening 

Experience: 11 years 

Duration of Contract: 4 years 

Identifi cation of the person 

responsible for the maintenance of 

the fuel Plant: 

Name: Hélder Dias 

Age: 32 years 

Department: Assets Maintenance 

Functions: responsible for the 

maintenance of the fuel Plant 

Matosinhos refi nery experience: 7 

years 

The set of interviews shows that, 

with regard to Induction training, both 

consider the action quite important, 

and that issues covered are enough, 

noting that this exercise enables each 

internalize on their activities, their role 

in prevention and safety. 

HSE training is considered a positive 

feature for the role of employees since 

it allows better understanding of the 

risk associated with individual’s job 

tasks improving the critical capability 

for self development. Consider the 

training sessions should be extended 

and more specifi c in opposition to the 

current generalist approach. 

Further use of multimedia solutions

and more interactive sessions were 

other features mentioned that need to 

improve in the training sessions. 

The subject of communication was 

considered to have signifi cant room 

for improvement. It was identifi ed 

the need to improve the engagement 

between the different areas of the 

refi nery, for example, Maintenance, 

Operation and Safety in order to 

streamline/ease practices in which 

these areas are involved. 

The OPAS, initiatives to help identifying 

misbehaviours, incorrect postures 

and working practices, are a regular 

practice of the Maintenance 

co-ordinator, who was never subjected 

to this approach. 

These practices, if carried 

out by people who are 

not involved in their every day activity, 

are considered, by the responsible 

of the gardening maintenance 

contract, to provide fi ndings 

that foster improvements on how jobs 

are carried: 

“Procedures executed and assessed 

through the same angle always 

provide the same reading; you 

need new lenses so that the image 

displayed is different. Out of the set 

of two or more alternative views there 

are always results if not better, at least 

more complete.” 

Both responded they considered to be 

the primary responsible for their 

own safety, showing workers 

engagement with one of the strongest 

elements of commitment. 




42 

2010 2010 DATA DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS • MATOSINHOS REFINERY


06 

IN FOCUS: REFINERY 

MAINTENANCE AND 2010 

TECHNICAL SHUTDOWN 

WE ARE AWARE THAT THE ACTIVITIES 

ASSOCIATED WITH MAINTENANCE ARE 

A RISK FACTOR IN THE OCCURRENCE 

OF SEVERE PERSONAL ACCIDENTS, 

OCCUPATIONAL DISEASES AND 

INDUSTRIAL ACCIDENTS. 

2010 2010 DATA DATA BOOK BOOK ON ON HEALTH, SAFETY AND AND ENVIRONMENT • • MATOSINHOS REFINERY 43

06 • In focus 

44 


IN FOCUS: REFINERY MAINTENANCE 

AND TECNICHAL SHUTDOWN 

The hiring of service providers, in 

various specialties, to perform routine 

maintenance activities, deep repairs or 

the construction of new facilities is a 

necessary reality, particularly for 

companies operating in the 

petrochemical business, such as the 

Matosinhos refinery. 

Furthermore, the activities associated 

with maintenance are a risk factor in 

the occurrence of severe personal 

accidents, occupational diseases and 

industrial accidents, estimating that 

between 10% to 15% of fatal 

accidents and 15% to 20% of personal 

accidents are related to maintenance 

activities (1) . 

So, for the biennium 2010/2011 the 

European Agency for Safety and Health 

at Work, following this perspective, 

launched the campaign themed “Safe 

Maintenance in Practice”. 

The Matosinhos refi nery has developed 

a systematic approach to this issue as 

part of a similar strategy, now 

advocated by the European Agency, 

Evolution of number of contracts and working days 

57 

723 

2006 

Contracts 

63 

7,718 

2007 

Working days 

85 

14,823 

2008 

given that the component of the 

provision of service providers 

represents more than double of the 

Galp Energia employees in terms of 

work hours. 

The hiring of service providers is 

characterized in two ways, one being 

multi-year oriented maintenance 

contracts, covering 14 entities 

specialized in various activities, from 

engineering, electrical and 

instrumentation, construction and 

household and industrial cleaning, 

among others. The other, results from 

the implementation of the Matosinhos 

refinery Investment Plan, whose scope 

may address general or deep 

equipment rehabilitation work or 

implementation of new facilities. 

The evolution of the number of 

contracts and total working days is 

shown in the chart (this does not 

include works performed during the 

General Shutdown, in 2007, nor the 

Technical Shutdown, carried out this 

year). 

72 

12,289 

2009 

(1) See on edition “ Working Environment Information”, from European Agency for Safety and Health at Work (EU-OSHA). 

80 

10,176 

2010

The number of contracts per week, 

running concurrently, whose 

coordination was always assured by 

Number of contracts per week 

In 2010, with the implementation of the 

Matosinhos refi nery Conversion Project, 

there was a signifi cant expansion of this 

components impact, since during this 

year, there were more intense activities 

and complex work execution in an 

environment characterized by the 

constraints inherent to the facility’s 

normal operation. 

During the period from September 28 

to November 17, maintenance works 

were carried out associated with the 

2010 Technical Shutdown. 

2010 was the year that recorded a 

larger and more complex activity, on 

an industrial complex in full operation 

and with the highest requirements 

performance standards in the various 

activity strands. 

On average, per day, during Technical 

Shutdown period, the employees 

number was 2,641, amounting to a 

peak of 3,500 employees in October 13. 

The following chart shows the daily 

variation in the number of staff 

present on premises throughout the 

maintenance intervention period. 

In focus • 06 

40 

35 

30 

25 

20 

15 

10 

5 

0 

26 

24 25 

25 25 25 

23 23 23 

25 24 23 

24 

32 33 

31 

29 29 

27 28 28 

29 

30 31 

26 26 

29 28 29 

25 

25 26 26 

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 

36 

24 24 24 

24 23 

21 22 

20 21 

20 

24 24 24 25 25 

22 22 

23 

21 

22 21 22 

22 

19 

26 

Number of workers at Matosinhos refinery - Technical shutdown - 4 th Oct - 16 th Nov 

4,000 

3,500 

3,000 

2,500 

2,000 

1,500 

1,000 

500 

0 

Matosinhos refinery, are showed in the 

following chart: 

04-10-10 1,976 2,874 

05-10-10 1,592 2,363 

06-10-10 1,888 3,285 

07-10-10 2,193 3,349 

08-10-10 2,168 3,297 

09-10-10 1,382 1,907 

10-10-10 764 914 

11-10-10 2,184 3,320 

12-10-10 2,293 3,394 

13-10-10 2,358 3,483 

14-10-10 2,310 3,476 

15-10-10 2,351 3,494 

16-10-10 1,653 2,446 

17-10-10 871 1,010 

18-10-10 2,348 3,456 

19-10-10 2,327 3,500 

20-10-10 2,324 3,475 

21-10-10 2,217 3,418 

22-10-10 2281 3,337 

23-10-10 1,595 2,210 

24-10-10 755 874 

25-10-10 2,343 3,339 

26-10-10 2,258 3,360 

27-10-10 2,426 3,359 

28-10-10 2,313 3,366 

29-10-10 2,170 3,136 

30-10-10 1,295 1,859 

31-10-10 711 832 

01-11-10 1121 1,516 

02-11-10 2,128 3,115 

03-11-10 2,237 3,122 

04-11-10 2,265 3,084 

05-11-10 2,126 3,136 

06-11-10 1,471 2,008 

07-11-10 674 781 

08-11-10 2,005 2,746 

09-11-10 1,838 2,828 

10-11-10 1,899 2,894 

11-11-10 1,901 2,806 

12-11-10 1,830 2,794 

13-11-10 901 1,473 

14-11-10455 

556 

15-11-10 1,878 2,686 

16-11-10 1,733 2,556 

Zone II Galp (PP + ed. admind) Total (Galp + PS) ZI + ZII + COG 



46 

Characterisation 

of Matosinhos refinery population 

- SEVESO Zone (Zone II) 

34.7% 

1.3% 

Galp total (PP + P4) 

PS RM (s/ COG) 

(2) API - American Petroleum Institute. 

(3) NFPA - National Fire Protection Association. 

21.0% 

43.1% 

PS Cogeneration 

PS PCRP 


Zone II is understood as an area in 

which work required the emission of 

work permits, thus ensuring the proper 

coordination and cooperation among 

the crew, and the refinery’s 

Operational and Safety Areas. 

It should also be noted the 

involvement of 337 companies, 

including contracted entities and 

subcontracted. 

On average, the active population in 

Matosinhos refinery characterization is 

shown in the chart below. The 

Galp Energia employees represents 

21% and the remaining service 

providers, which in turn are spread by 

activities related to the facility 

(43.1%), the Conversion Project 

activities (34.7%) and Cogeneration 

Project activities (1.3%). 

The performance achieved in 2010 in 

terms of safety and health indicators is 

comparable with international 

references levels, despite the 

complexity of the environment, in the 

undertaking activities constraints and 

the risk that they account for the 

complex itself. 

The risk management associated with 

the performing entities activities 

assumes a set of initiatives that are 

triggered systematically, at the various 

phases, from initial design, 

procurement, planning and execution. 

The aim, through this process, is 

ensuring not only the requirements 

established in Decree-Law No. 

273/2003 on Safety and Health at 

Work in Construction Sites as also 

Decree-Law No. 254/2007 (Seveso II 

Directive), but also, integrate the best 

practices associated for this type of 

industries, including API (2) and NFPA (3) . 

Of the various pillars of this process, 

we highlight the following: 

• HAZARDS IDENTIFICATION - After 

selecting the Performing Entity, it’s its 

responsibility for the transition of the 

Project Health and Safety Plan (SSP) 

to the Work Health and Safety Plan. 

To ensure the participation and 

commitment of all involved in the 

works, multidisciplinary team is 

formed, consisting of the Performing 

Entity, the Safety, Health and Safety 

at Work technicians (TSHT), Work 

Supervision, the Investment 

Manager, Head of the Facility where 

the work is done, the Safety 

Coordinator (CSO) and other experts 

that are deemed critical by the 

specifics of the contract. 

In this activity we identify the 

constraints that the methodology and 

Work Planning must take in 

consideration, as well as impacts to 

the facility, resulting from the tasks 

to be developed. 

The information resulting from this 

activity is formalized in a document 

that, after validation, is incorporated 

into the Execution of Work PSS. 

• HEALTH AND SAFETY PLAN FOR 

EXECUTION OF WORK - 

standardization of the PSS structure 

took place in January 2010, with 

verification, registration, control and 

management tools of all activities 

associated with the implementation 

of the contract. 

• SAFETY PROCEDURE DOCUMENT (FPS) 

- for all undertaken activities, its 

developed a FPS, which is prepared 

by the Performing Entity TSH,

approved by the Project Manager, 

verified by the Operational Area and 

validated by the Safety Coordinator. 

This document identifies the dangers 

associated with the activity and the 

resulting risks to people and 

installation. Furthermore, it describes 

control measures and risk 

management, to be checked during 

the execution of works. 

The FPS is annexed to a Work Permit 

(WP), which guarantees the safety 

conditions to be observed for the 

commencement of work. 

• THE 5 MINUTES OF GOLD (Rules) - at 

the beginning of work, a initiative 

takes place to remind the most 

critical aspects and rules for the 

activity in question. This initiative 

involves all elements of the team 

and is preferably conducted by a 

team leader, which is guided by TSHT. 

It aims to focus on all the team 

members in working methods and to 

keep in mind, all risk factors and 

preventive measures to be taken. 

These actions are formally registered. 

• WEEKLY / MONTHLY REUNIONS WITH 

PERFORMING ENTITIES - weekly 

meetings are held with the 

Performing Entities TSHT, where they 

discuss key aspects of the week 

occurrences and published safety 

alerts and lessons learned. In 

addition, a monthly meeting is hold, 

in which, apart from TSHT, are also 

present the Work Supervisors, or 

companies representatives, 

promoting their involvement and 

commitment in implementing these 

recommendations and best practices 

in Health, Safety and Environment. 

The 4,025,620 hours worked in 2010 

and 4,406,713 hours without accidents 

resulting in lost working days, 

involving about 337 companies, 

reflects the size and dynamics of 

activity and demonstrate a remarkable 

level of performance. 

The Matosinhos refinery has begun to 

draw up and implement its program to 

“implement the safe maintenance” 

(Safe Maintenance in Practice). 

During the Technical Shutdown of 

2010, 20 relevant contracts were 

carried out. Several challenges were 

surpassed, including: handling over 40 

large equipments; execution of 

approximately 640 tie-in’s; about 5.5 

km of open drains; blockage of roads, 

with the need for alternative circuits 

definition for the event of an 

emergency; work done at different 

levels (overlapping activities), among 

others. 

The Technical Shutdown has, excluding 

personal accidents, a total of 20 

events, distributed as follows: 

2010 Technical shutdown incidents 

0 

HSE Non 

compliances 

1 

Near 

accidents 

2 

Road 

accidents 

9 

Environmental 

accidents 

(spills) 

In focus • 06 

Material 

accidents 

2010 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS REFINERY 47 

8


48 

Total number of vehicles/day (shutdown period) 

172 

167 

174 

180 

28-09-10 

30-09-10 

70 35 

02-10-10 

124 

108 

04-10-10 

177 

194 

197 

06-10-10 

08-10-10 

110 

10-10-10 62 

188 

196 

208 

203 

201 


12-10-10 

14-10-10 

The total number of vehicles present 

in the refinery, distributed by the 

General Shutdown period are in the 

graph below. 

On average, per day, within the 

refinery, there are about 153 cars 

circulating. 

If, on one hand, the performance 

reached reference levels, on the other 

135 

70 

16-10-10 

197 

210 

214 

211 

211 

18-10-10 

20-10-10 

22-10-10 

128 

24-10-10 63 

203 

197 

197 

208 

187 

26-10-10 

28-10-10 

30-10-10 103 

57 

01-11-10 82 

side, all the momentum continues to 

impose an effective control process 

and risk management. Indeed, the 

impacts of these activities, as 

recognized by the European Agency for 

Safety at Work, can take an 

unacceptable impact in the areas of 

Health, Safety and Environment, and 

so, these issues deserve and will 

continue to receive the higher 

attention. 

194 

187 

196 

189 

03-11-10 

92 

56 

05-11-10 

175 

181 

178 

178 

176 

07-11-10 

09-11-10 

11-11-10 

13-11-10 64 

26 

157 

155 

15-11-10 

160 

17-11-10

07 

ACTIVITY INDICATORS 

BEYOND THE IMPORTANCE 

OF THE ACTIVITY INDICATORS 

THEMSELVES, WE UNDERSTAND 

THE THE CONCERN FOR SAFETY 

AND THE ENVIROMENT SHOULD 

BE SEEN AS LINKED TO THE 

LEVEL OF ACTIVITY. 

WE BEGIN BY PRESENTING THE 

ACTIVITY INDICATORS. 


07 • Activity indicators 

50 

Level of activity (10 6 t) 

4.1 

2005 

3.6 

4.0 

2006 

3.5 

Load processed Crude oil processed 

Production volume (10 3 t) 

122 

1,041 

112 

414 

152 

1,477 

757 

195 

2005 

Gases 

Gasolines 

113 

902 

122 

397 

140 

1,655 

737 

154 

2006 

Jet/Pet 

Aromatic oils 

Petrols 

Diesel Oils 


98 

830 

145 

425 

124 

1,472 

686 

123 

2007 

LEVEL OF ACTIVITY 

The graph below shows the load 

processed and the crude oil 

processed in the refinery. The load 

processed includes not only crude oil, but 

also the raw materials and components 

processed, weighted by a conversion 

factor that considers the amount of crude 

oil equivalent to the level of processing 

for the respective load. 

3.8 

127 

829 

151 

380 

155 

1,780 

736 

193 

2008 

2007 

3.4 

Fuels 

Bitumens 

105 

869 

133 

325 

137 

1,504 

577 

183 

2009 

4.9 

2008 

4.2 

99 

638 

164 

276 

126 

1,182 

615 

164 

2010 

The activity decrease in 2010 

compared with 2009, due to the 

maintenance stop and also by 

strategic shutdowns of processing 

plants which were influenced by 

supply and demand, resulting from 

the global economic situation. 

4.1 

2009 

3.3 

3.8 

PRODUCTIO N 

2010 

3.0 

The graph on the left shows the 

Matosinhos refinery’s production over 

the last few years. The sulphur and 

paraffin are excluded as these are 

considerably less significant than the 

remaining products. 

The decrease of the production 

compared with the previous years can 

be explained by the technical shut 

down for maintenance and for the 

strategic shutdowns of some process 

units.

BOA NOVA DEPOT 

The expeditions area of Matosinhos 

refinery has a set of 46 tanks, where 

products are stored and dispatched 

to all over the country, supplying 

approximately one third of the 

national market needs, and also, 

from where part of the petroleum 

products produced at the Matosinhos 

refinery complex are exported to 

Europe. 

This activity covers the receiving, 

subdivision and shipment by road 

tankers of several product families, 

such as: 

• aromatic and solvents, for national 

and international chemical and 

petrochemical industries; 

• petrol and Diesel, to supply fuel for 

the entire North Area of the 

Country. In these facilities, they are 

coloured and additives are added 

according to performance 

requirements and legal marking; 

• fuels, for the energy supply of part 

of the Portuguese industry; 

• paraffins, which are used in several 

industries , e.g. candles, cosmetics, 

molds, food, etc.; 

• bitumen of various grades, as a 

component for industrial adhesives, 

binders and insulation wire but 

essentially for road paving; 

• JET A1 (in cases of contingency, it is 

possible to supply aviation fuel to 

domestic airports from this facility). 

The graph below shows the quantity 

of products delivered by road tanker. 

Quantity of products delivered by road tanker (10 3 t) 

196 

152 

596 

1,417 

2005 

Bitumens 

Chemicals 

154 

149 

552 

1,374 

2006 

Blacks 

Whites 

Road tanker delivery orders 

Bitumens 

Chemicals 

Blacks 

Whites 

126 

160 

492 

1,405 

2007 

The graph below shows the number 

of deliveries by road tanker for each 

type of product: 

8,220 

6,466 

28,744 

61,667 

2005 

6,362 

6,663 

26,267 

58,924 

2006 

4,866 

7,297 

23,593 

60,020 

2007 

179 

156 

404 

1,255 

2008 

7,894 

6,239 

19,815 

53,479 

2008 

Activity indicators • 07 

169 

90 

375 

1,303 

2009 

7,027 

4,124 

18,807 

55,417 

2009 

162 

121 

334 

1,274 

2010 

6,997 

5,138 

17,794 

53,173 

2010 


08 

ENVIRONMENTAL 

PERFORMANCE 

WE HAVE MADE AN AMAZING 

PROGRESS. 

COME AND ANALYSE THE 

DATA WE NOW PRESENT. 

52 2010 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS REFINERY

Under the Decree-Law No. 194/2000 

- Integrated Pollution Prevention and 

Control Integrated Pollution (IPPC 

Directive) - the Matosinhos refinery 

holds an Environmental Permit 

(No. 190/2008) which organizes and 

gathers all the legal environmental 

requirements. Additionally, the refinery 

holds a greenhouse gas emission 

permit (TEGEE 193.04.II) in the amount 

of 1,098,095 allowances of CO2 annually. 

This chapter presents information 

and indicators concerning Matosinhos 

refinery’s environmental performance, 

including compliance with IPPC 

Directive and other best practices. 

Besides absolute indicators, the 

performance also considers normalized 

indicators, that is, disregarding scale 

effects resulting from the different 

levels of activity intensity. Indeed, 

the level of activity of the facility 

inevitably interferes with the value 

of the absolute indicators, but 

sometimes the absolute evolution 

does not constitute a good picture 

of performance and progress of the 

facility. 

Water consumption and recycled water (10 3 m 3 ) 

2.920 

2005 

279 

2.634 

2006 

Water consumption Recycled water 

460 

Moreover, normalized indicators 

allow a comparison of the refinery’s 

performance with its European peers 

reference sector. 

RESOURCE 

CONSUMPTION 

Due to its significant use and 

environmental relevance, this chapter 

contains information and indicators on 

water and energy consumption. 

WATER CONSUMPTION 

The water for industrial purposes 

consumed in the Matosinhos refinery 

comes from the Matosinhos Municipal 

Water and Sanitation Services (Águas 

do Noroeste), Indáqua Matosinhos and 

Ave River. The two first sources are 

considered to be potable. 


total water consumption, as well as 

recycled water. 

2.890 

2007 

469 

2.893 

2008 

458 

Environmental performance • 08 

2.689 

2009 

478 

2.508 

2010 

896 



54 


2010 was a year of change in the 

management of water resources in 

the Matosinhos refi nery, as indeed 

observed in the previous chart. The 

commissioning of the water tank for 

the Fire Service network – TK4504, 

investment made in 2009, and the 

investment that allowed storing more 

recovered water from the wastewater 

treatment plant (WWTP) were the 

main reasons. 

The reuse of treated wastewater from 

the WWTP allowed the decrease of 

Water consumption per level of activity (m 3 /t) 

0.70 

2005 

0.65 

2006 

0.76 

2007 

It is important to note that the 

attainment of various hydraulic tests, 

arising from intervention works on 

tanks, the technical shutdown and 

the construction of new units, had a 

ENERGY CONSUMPTION 

With regards to the energy indicators, 

the fuel and electricity consumption 

are considered. 

The fuels consumed in the refi nery 

are the Residual Fuel Oil (known as 

RFO) and Gas, a mixture of Fuel Gas 

makeup water consumption and, hence, 

a reduction of treated water sent to the 

receiving environment, the sea. 

It can be seen that in absolute terms 

there has been a reduction in water 

consumption. However, since the 

refinery technical shutdown implies 

a reduction in the activity, in terms 

of data normalization concerning 

the level of activity, there are no 

noticeable changes compared with 

2009, as shown by the following 

graph: 

0.60 

2008 

0.66 

2009 

0.66 

2010 

significant contribution to the overall 

consumption of water, although water 

consumption by activity level is equal 

to 2009. 

enriched with Natural Gas. This allows 

an increased amount of gas available 

for consumption, making it possible 

to reduce consumption of a less clean 

fuel, as the RFO. The Matosinhos 

refinery has progressively privileged 

consumption of clean fuels.

The graphs on the right show the 

consumption of these fuels at the 

refinery. 

Since the entry of Natural Gas into the 

Refinery’s fuel pool, in 2008, it has 

been observed a significant decrease 

in the consumption of RFO. The Natural 

Gas consumption in 2010 was 45,338 

tonnes, in contrast with the 29,612 

tonnes in 2009. 

With regards to electricity, the refinery 

sells or acquires electricity from the 

grid, depending on whether it has a 

surplus or shortfall. 

The graph below shows the electricity 

produced and consumed. 

RFO consumption (10 3 t) 

226 

2005 

224 

2006 

Gas consumption (10 3 t) 

121 

2005 

Electrical energy (10 3 toe) (Consumed and produced) 

60 57 

2005 

61 

2006 

Electrical energy consumed Electrical energy produced 

53 

56 

2007 

ATMOSPHERIC EMISSIONS 

This chapter focuses on atmospheric 

emission of relevant pollutants in terms of 

environmental air quality. 

SULPHUR OXIDES 

The graph on the right presents 

absolute sulphur oxide emissions, on 

the basis of its equivalent in sulphur 

dioxide, SO . 2 

45 

104 

2006 

SO2 emissions (10 3 t) 

9.54 

2005 

9.75 

2006 

66 

2008 

211 

2007 

99 

2007 

52 

9.89 

2007 


218 

2008 

141 

2008 

59 

2009 

5.96 

2008 

46 

158 

2009 

134 

2009 

2009 

27% drop 

in RFO 

consumption 

143 

2010 

115 

2010 

1MWh = 0,29 toe 

2010 


54 

42 

13% drop in 

SO2 emissions 

from 2009 to 

2010 

4.05 

3.51 

2010


56 

SO2 emission per level of activity (kg/t) 

2,411 

2006 

2,591 

2,301 7% drop in SO2 

emissions per 

level of activity 

from 2009 to 

2010 

2005 

2007 

Percentage of sulphur in the RFO (%) 

2.06 

2005 

2.12 

2006 

SO2 Bubble (mg/Nm 3) 

1,170 

2005 

1,251 

2006 

2.28 

2007 

1,453 

2007 

1,226 

2008 

1.23 

2008 

885 

2008 


0,994 

2009 

1.29 

2009 

650 

2009 

0,924 

2010 

3.0 

1.48 

2010 

1,700 

610 

2010 

The graph on the left normalized 

absolute emissions based on the level 

of activity. 

Sulphur is a natural component of 

crude and during the refining process 

it is possible to recover part of this 

element, the other part inevitably 

being emitted into the atmosphere 

or retained in the refined products. 

When these are used as fuel, sulphur 

is released into the atmosphere. 

In order to reduce SO emissions, the 

2 

refinery has made efforts that are 

having a notable impact, as shown 

by the two graphs given on the left. 

On the one hand, it added natural 

gas to the portfolio of fuels used and 

increased the consumption of fuel 

gas, incontestably contributing to the 

reduction in emissions. On the other 

hand, there is a clear and consistent 

trend of reduction in the level of 

sulphur in the RFO, well below the 

limit stipulated in our licence (3%), 

which also impacts SO emissions: 

2 

Finally, the evolution of the SO2 “bubble” is illustrated on the left. This 

indicator represents the concentration 

of sulphur oxide in a virtual chimney, 

pondering the smoke flow and the 

pollutant concentrations in different 

sources. 

The Matosinhos refinery has made 

a significant effort in the continual 

improvement of its performance in this 

area, as illustrated in the chart. Also, 

through this indicator, it’s visible the 

result from the use of cleaner fuels, 

including the privilege given to the 

consumption of Gas and RFO with low 

sulphur content.

NITROGEN OXIDES 

The graph on the right shows absolute 

nitrogen oxide emissions. 

The graph on the right shows NO X 

emissions per level of activity. 

The effort made by Matosinhos 

refinery towards continued 

improvement of its environmental 

performance is also visible with regard 

to NO emissions. This was possible 

x 

due to the increased consumption 

of Gas against RFO and by installing 

low-NO burners on the main firing 

X 

facilities. 

TOTAL PARTICULATE 

MATTER 

The graph on the right shows the 

values of total Particulate Matter 

emissions for the study period: 

The graph below allows to evaluate 

the specific emissions of Particulate 

Matter at Matosinhos refinery: 

Once again, it can be seen that the 

quality of fuels burned and particularly 

the preference for cleaner fuels, such 

as gas, has been a determining factor 

in reducing the atmospheric emissions. 

NO x emissions (t) 

2,606 

2005 

NO x emissions per level of activity (kg/t) 

0.629 

2005 

0.608 

2006 

0.609 

Particulate matter emissions (t) 

595 

2005 

573 

2006 

2007 

544 

2007 


0.543 

2008 

426 

2008 

Particulate matter emissions per level of activity (kg/t) 

0.144 

2005 

2,458 

2006 

0.142 

2006 

2,323 

2007 

0.143 

2007 

2,639 

2008 

0.088 

2008 

1,823 

2009 

0.447 

2009 

215 

2009 

0.053 

2009 

1,365 

2010 

20% drop in the 

NOx emission per 


from 2009 to 

2010 

0.359 

2010 

65% drop in 

Particulate 

Matter 

emissions from 

2009 to 2010 

76 

2010 

63% drop 

Particulate 

Matter 

emissions per 


from 2009 to 

2010 

0.020 

2010 



58 

CO 2 emissions (10 3 t) 

1,155.93 

2005 

Emissions allowances 

CARBON DIOXIDE 


The graph below identifies CO2 emissions deriving from Matosinhos 

refinery’s activity and illustrates 

the compliance with the allocated 

emission ceiling in 2010 (EU-ETS). 

1,121.77 

941.21 952 1,098 

842.97 

887.86 

781.42 

2006 

2007 

2008 

2009 

We are currently in the third year 

of the second compliance period of 

the Portuguese National Emission 

Allocation Plan, PNALE II – 2008-2012. 

The change in the number of Emission 

Allowances recorded from 2007 to 

2008 does not reflect the generalized 

reduction in all of the sectors covered 

by this regime because since 2008 

the collective ceiling includes the 

Aromatics Plant. 

The increase in Gas consumption in 

place of consumption of RFO, which 

has a higher level of carbon, and the 

reduction in the level of activity in 

2010, due to the technical shutdown, 

was the main factors contributing to 

the reduction of CO emissions. 

2 

VOLATILE ORGANIC 

COMPOUNDS 

2010 

Matosinhos refinery’s Volatile Organic 

Compound (VOC´s) emissions come 

from various sources: product storage, 

process (including the drainage 

network) and effluent treatment. 

The Matosinhos refinery conducts 

VOC´s monitoring campaigns, under its 

Leak Detection and Repair programme, 

which measurements allow the 

minimisation of fugitive emissions. In 

these campaigns, the total emission of 

VOC´s resulting from the operation of 

the refinery, taking into consideration 

the fugitive emissions that results from 

leakages in manual and control valves, 

pumps, exchangers, flanges, sampling 

points, vent, purges and other 

end-of-line equipments. 

The VOC’s emissions also include the 

drainage network and equipments 

placed in the storage area (such as 

fugitive emissions) and the fugitive 

emissions of the different treatment 

equipments of the WWTP. 

The European standard EN15446:2008 

is being used to quantify the escaping 

emissions, associated with the different 

process equipments and the drain 

pipe system - “Fugitive and diffuse 

emissions of common concern to 

industry sectors. Measurement of 

fugitive emission of vapours generating 

from equipment and piping leaks”. 

To estimate diffuse emissions from the 

WWTP the EPA programme Water9 is 

being used. 

These procedures, implemented under 

the Leak Detection Repair programme, 

follow the techniques defined in the 

reference document under the IPPC: 

Reference Document on Best Available 

Techniques for Mineral Oil and Gas 

Refineries (BREF 4.23.6.1.)

CONTINUOUS MONITORING 

The Matosinhos refinery conducts 

continuous monitoring of SO , NO 2 X 

and Particulate Matter at certain 

fixed sources. Nevertheless, under 

the Environmental Permit it is only 

mandatory to continuously monitor the 

process furnaces fed with RFO and gas 

– mixed sources. 

The graphs on the right present the 

results for the SO , NO and Particulate 

2 X 

Matter, over the analysis period, for 

the self control of three fixed sources. 

The commitment of the facility to 

reduce the impact of its operations 

and ensure sustainable integration in 

its surroundings is clear from analyzing 

the above graphs. 

The technical shutdown of the refinery 

explains October and November 

values. 

Since 2008, that Large Combustion 

Plants (LCP’s) have been subject to 

a mass ceiling, as defined in the 

National Emission Reduction Plan 

(PNRE). The changes in recent years in 

pollutants mass emissions are visible 

in the graph below. 

Continuous monitoring - SO2 (mg/Nm 3 @ 8% O 2 ) 

1800 

1500 

1200 

900 

600 

300 

0 



ELV ST0601 ST2001 ST3001 

Continuous monitoring - NOx (mg/Nm 3 @ 8% O 2 ) 

450 

375 

300 

225 

150 

75 

0 

ELV ST0601 ST2001 ST3001 

1,700 


Continuous monitoring - Particulates (mg/Nm 3 @ 8% O 2 ) 

300 

250 

200 

150 

100 

50 

0 


ELV ST0601 ST2001 ST3001 

LCP’s emissions (t) 

3,500 

3,000 

2,500 

2,000 

1,500 

1,000 

500 

0 

Ceiling SO2 - 3,385 t/year 

Ceiling NOx - 896 t/year 

SO2 NOx Particulates 

2008 2009 2010 Plafonds 

450 

250 

Particulates - 100 t/year 



60 


IMPACT ON AIR QUALITY 

The Matosinhos refinery focuses 

heavily on minimizing the 

environmental impact of its business. 

The trend of its key indicators and the 

high level of investment that the plant 

is undergoing show those efforts. 

In 2010 it was conducted a study 

to assess the air quality in nearby 

surroundings, meeting the desire 

of local authorities and monitoring 

plans defined in the installation. 

This study was scheduled for 2011, 

immediately after the completion 

of ongoing investments, having its 

implementation been anticipate. 

The Benzene monitoring is carried 

as an indicative measurement which 

consists in carrying out a regular set 

of campaigns to determine the annual 

average concentration of benzene and 

comparing the value obtained with 

the annual limit value. The study also 

foresees the monitoring of atmospheric 

levels of Toluene, Xylenes, NO and SO . 

2 2 

In accordance with Annex X of the 

Decree Law No. 111/2002 of April 

16, the minimum period for a sample 

measurement for it to be indicative is 

14% of a calendar year. 

The ongoing study is being conducted 

with the support of the Institute 

for Environment and Development 

(IDAD) from Aveiro University. The 

study foresees the execution of 13 

weeks for air quality measurement, 

from April 2010 to November 

2011, thus ensuring the results 

representativeness. 

The sampling grid covers a total of 57 

measuring points distributed in the 

nearby surroundings of the refinery 

within a radius of 5 km. 

LIQUID EFFLUENTS 

LIQUID EFFLUENTS 

PRODUCTION 

Relationship between liquid effluents produced and average precipitation in the area of the refinery 

Wastewater production (m 3 ) 

300.000 

250.000 

200.000 

150.000 

100.000 

50.000 

0 

As mentioned in previous editions of the 

Data Book, the liquid effl uents production 

is inherent to operations, but is strongly 

influenced by the meteorological 

conditions, as rainwater in the processing 

and storage zones is collected and 

conducted to the refinery’s WWTP. 

The graph below relates effluents 

production with average rainfall for 

the region of the Matosinhos refinery 

in 2010 (data from the Portuguese 

Institute of Meteorology). 


Wastewater production Average rainfall 

500 

450 

400 

350 

300 

250 

200 

150 

100 

50 

0 

Average rainfall (mm)

As in previous years, also in 2010 it is 

apparent the influence of rainfall with 

the amount of effluents produced in 

Matosinhos refinery. The exception is 

visible in October, where due to the 

Liquid effluents produced (10 3 m 3 ) 

1.59 

2005 

1.94 

2006 

The following graph normalises 

effluents production by level of 

activity. 

2.45 

2007 

2.30 

2008 

Liquid effluents produced per level of activity (m 3 /t) 

0.38 

2005 

0.48 

2006 

0.64 

2007 

MONITORING THE QUALITY 

OF LIQUID EFFLUENTS 

The Matosinho’s Environmental Permit 

also defines the limits for discharge 

of treated wastewater in the WWTP. 

The following graphs show the 

concentration of pollutants discharged 

into the aquatic environment, 

demonstrating compliance with 

the requirements set out in the 

Environmental Permit. 

Technical Shutdown for maintenance 

there was no production of effluents. 

How liquid effluents production has 

changed over recent years is clear 

from the following graph. 

0.47 

2008 

Wastewater pH 

10 

9 

8 

7 

6 

5 

4 

1.73 

2009 

0.42 

2009 

18% drop in the 

liquid effluents 

produced from 

2009 to 2010 

1.42 

2010 

12% drop in 

liquid effluents 

produced per 


from 2009 to 

2010 

0.37 

2010 

pH Range permited by the license 


7.35 7.20 7.37 7.33 7.32 7.50 

2005 2006 2007 2008 2009 2010 


9 

6


62 

Waste Hydrocarbons in the effluents 

Hydrocarbons (mg/l) 

Concentration of total solids, biochemical oxygen demand and oils and grease in the effluent (mg/l) 

mg/l 

12.0 

10.0 

8.0 

6.0 

4.0 

2.0 

0 

2.89 

1.11 

4.4 

2005 

Waste hydrocarbons 

Concentration limit 

defined by the permit 

9.5 

2005 

2.86 

1.37 

2006 

9.4 

ELV TSS = 60mg/l 

3.7 

3.84 

2.46 

11.2 

2006 

Oils and greases TSS BOD 5 

2007 

0.82 

ELV BOD 5 = 40mg/l 

ELV O&G = 15mg/l 

9.8 

1.74 

2008 

Waste hydrocarbons per 


5.4 

12.5 

2007 


2.10 

0.81 

2009 

12.1 

Concentration of phenols and cyanides in the wastewater (mg/l) 

0.041 0.02 

2005 

0.078 0.03 

2006 

0.037 0.04 

2007 

Phenols Cyanides Limit defined by the permit 

2.43 

3.1 

10 

0.84 

2010 

10 

8 

6 

4 

2 

0 

14.5 

11.5 10.6 

9.5 11.1 

6.4 

3.0 

3.9 

2008 

0.035 0.03 

2008 

Hydrocarbons rejected per level 

of activity (g/t) 

On the previous page, the graph of the 

pH of wastewater. 

The graph on the left shows the 

performance of the refinery in relation 

to hydrocarbons. 

The graph below shows the 

concentration of the wastewater 

in terms of Oils and Grease (O&G), 

Total Suspended Solids (TSS) and 

Biochemical Oxygen Demand at 5 

days (BOD5), indicators associated to 

the presence of organic matter in the 

wastewater. 

ELV TSS = 50mg/l 

ELV BOD 5 = 25mg/l 

2009 

0.051 0.01 

2009 

2010 

The refinery has also stayed within 

the limits defined in the Permit for 

phenols and cyanides. 

0.048 0.01 

2010 

0.5

Finally, the concentration of Total Iron 

in the wastewater is shown in the 

graph on the right. 

The performance indicators relating to 

the WWTP demonstrate a consolidated 

improvement which is a result of 

the adoption of measures at the 

operational level to minimize the 

impact of some pollutants in the 

WWTP treatment processes. 

WASTE 

The Matosinhos refinery, conscious 

of its responsibility for managing 

the impact of its activities on 

the environment, with a view of 

implementing the policy of the 

3 R’s - Reduce, Reuse and Recycling - 

seeks to minimize waste production 

mainly from the appropriate waste 

and materials segregation. 

Industrial waste produced (10 3 t) 

5.2 

2005 

1.1 

3.8 

2006 

8.4 

Concentration of Total Iron in the wastewater (mg/l) 

1.02 

2005 

Permit limit 

0.71 

2006 

0.78 

2007 

This chapter presents the evolution of 

waste generation over time by type. 

The graph below shows the change 

over time of the industrial waste 

produced. 

9.2 

2007 

12.7 

Hazardous industrial waste Non-hazardous industrial waste 

The graph below illustrates the production of waste against the level of activity: 

Industrial waste produced per level of activity (kg/t) 

1.25 

2005 

0.27 

0.93 

2006 

2.09 

2.42 

2007 

3.33 

Hazardous industrial waste Non-hazardous industrial waste 

6.4 

1.32 

2008 

2008 

1.8 

0.36 


0.66 

7.4 

2008 

1.81 

2009 

2009 

0.2 

0.05 

0.31 

2009 

6.7 

1.78 

2010 

2010 

0.45 

0.1 

2010 

0.04 

2.0 



64 

174.3 

2005 


The waste handled by the municipal waste system is presented in the graph 

below. 

Production of waste similar to solid urban waste (t) 

Tons of recovered materials 

159.3 

2006 

Recovered materials (t) 

2,500 

2,250 

2,000 

1,750 

1,500 

1,250 

1,000 

750 

500 

250 

0 

0.092 

579 

2005 

1,263 

0.104 

2006 

Quantity of recovered material 

171.2 

2007 

The following chart illustrates the 

evolution of material recovery in 

the refinery. This indicator should 

1,996 

0.091 

2007 

As can be deduced from the graphs above, 

it is notable the effort of the refinery to 

reduce production of waste that is not 

likely to be recyclable compared to the 

amount of recyclable waste. 

However, it is important to note that, 

regarding the amount of industrial 

waste that can be recovered, the 

178.6 

2008 

2008 

1,134 

0.139 

381 

2009 

173.1 

2009 

0.313 

0.050 

Recovered material per quantity of 

industrial waste produced 

2,159 

2010 

171.4 

2010 

be understood in its relation to the 

amount of waste produced. 

0.350 

0.300 

0.250 

0.200 

0.150 

0.100 

0.050 

0.000 

Tons of recovered materials per tons of 

industrial waste produced 

performance of the refinery depends 

on work performed by third parties 

and the activities undertaken. Indeed, 

the large material recovery in 2010, 

as in 2007, was due to a Technical 

Shutdown for maintenance, when 

significant quantities of metal scrap 

were produced as equipment was 

replaced.

NOISE 

The Matosinhos refinery is located in 

an area with diverse characteristics of 

occupation, both urban and industrial, 

and with different noise sensitivity 

levels. A concern of the refinery is to 

identify, reduce or eliminate nuisance 

sources, which affect the wellbeing of 

the community, since its surroundings 

consist mostly of residential areas. 

Indeed, the proximity to major 

population areas and busy seashore 

leads to the refi nery’s excellence 

environmental performance. 

The control and minimisation of 

environmental noise is a challenge set 

by Matosinhos refi nery, that it must 

achieve. A noise assessment was 

performed with sensitive receptors 

that are exposed to noise from the 

refi nery, accordingly to the Noise 

Regulation. The Noise Regulation 

(attached to Decree-Law No. 9/2007, 

as amended per Decree-Law no. 

278/2007) establishes criteria to apply 

to both planned and under operation 

activities. 

The noise assessment concluded an 

overall good result for Matosinhos 

refi nery. The study highlighted car 

traffi c as the main noise factor in 

locations adjacent to the refi nery. 

Regarding the inconvenience at night 

criteria, the assessment has also 

identifi ed certain aspects requiring 

further improvements, for which an 

improvement plan was established. 

SOIL AND WATER 

RESOURCES 

The Matosinhos refi nery’s concern 

with regards to soil and groundwater 

quality derives from the 

self-awareness of the risk involved in 

activity. 

To monitor the groundwater quality, 

the Matosinhos refi nery is equipped 

with 55 piezometers consisting of 

short drainage boxes in contact with 

the hydrological units, suitable to 

ensure the groundwater samples are 

representative. Every six months the 

groundwater monitoring is conducted. 

The following diagram illustrates the 

location of piezometers in the refi nery. 

Piezometers distribution 

Piezometers 




66 


In the environmental liability context, 

the Matosinhos refi nery, aware of the 

impacts associated with its activity, 

carried out a Quantitative Risk Analysis 

study aiming to identify and assess 

the potential risk for human health 

and ecosystems and support decision 

making on risk management. 

This study was carried out according to 

the following criteria: 

• quantifying the potential risk to 

human health and / or ecosystem 

due to the use of the facility subsoil; 

• calculation of the concentrations 

indicative of risk, both in soil and in 

groundwater, whose potential risk 

is acceptable from the standpoint of 

human health and ecosystems; 

• the compliance assessment with 

applicable laws concerning liability 

for environmental damage, including 

Decree-Law No. 147/2008 of 29 July 

(as amended by Decree-Law No. 

245/2009 of 22 September). 

During risk analysis the potential risk 

associated with established scenarios 

was assessed, defined from the 

maximum concentrations detected in 

the subsoil, for potential receptors and 

pathways that are active according to 

the current land use at the refinery 

and its nearest surroundings. 

Reference values were set 

accordingly to the “Guideline 

for Use at Contaminated Sites in 

Ontario” published by the Ministry of 

Environment of Ontario, in Canada. This 

Guideline defines assessments criteria 

of the effect on soils depending on the 

land use, namely, surface/subsurface 

soil and potable groundwater in an 

industrial area. 

The study completed in 2010, 

consisted of drilling surveys to 

collect soil samples at various depths 

in addition to regular monitoring 

campaigns conducted through the 

piezometric network installed in the 

refinery. For this purpose, 14 new 

piezometers were installed to improve 

data of the hydro geological features 

and the quality of the aquifer. 

Taking into account the results from 

the Quantitative Risk Analysis study, 

there is no sign of environmental 

damage caused to water, protected 

species and natural habitats, or 

soil, according to the principles 

and provisions of Decree-Law No. 

147/2008 of 29 July, resulting from 

activity at the facility.


09 

SAFETY AND HEALTH 

PERFORMANCE 

THE AIM IS TO ACHIEVE A 

SUSTAINABLE CULTURE OF 

PREVENTION BASED ON 

HIGHLY COMMITED HSE 

MANAGEMENT. 

2010 2010 DATA DATA BOOK BOOK ON ON HEALTH, SAFETY AND ENVIRONMENT • • MATOSINHOS MATOSINHOS REFINERY REFINERY 67


68 

ACCIDENT RATE 


Work accidents are a cause for 

concern, so it’s a prime task of 

Matosinhos refi nery Management to 

ensure the existence of the conditions, 

procedures and practices designed to 

prevent occurrences and implement all 

preventive and corrective measures to 

prevent recurrences. 

Within the implementation of 

Health, Safety and Environment 

Systems of Galp Energia group, all 

accidents occurring to own or to 

third party employees during the 

execution of services assigned to 

them, are investigated in order to 

identify corrective and appropriate 

preventative actions to prevent them. 

In 2010, there were 60 accidents, 

involving own and third party workers, 

as illustrated in the following graph. 

Total accidents 2010 

60 

MR+ SP 

25 

Occured during Technical 

shutdown (MR + SP) 

MR 

Total personal accidents Matosinhos refinery colaborators 2005 - 2010 (No.) 

11 

2005 

8 

2006 

5 

2007 

27 

2008 

14 

2009 

20 

20 

2010 

Of the 60 accidents, there were 25 

during the stop period, comprising 

approximately 40% of the total 

refi nery accidents. 

Of all accidents, 33% relate to direct 

employees of the refi nery and 

the remaining to external service 

providers. 

Analyzing the universe of the company 

employees, it is apparent that in 

the 2010 there were 20 reported 

accidents. 

Through the comparative analysis 

of charts, it can be seen that the 

total number of accidents increased 

compared to the number recorded a 

year earlier. 

The justifi cation for this result lies in 

the fact that the refi nery was subject 

of a technical shutdown in the period 

from September 28 to November 17 

where, either due to the nature of 

the work (working at height, work 

carried out at different levels, work 

in the interior of equipment, high 

mechanical loads) or because the 

number of employees present at the 

facility during the period, the risk 

for the occurrence of incidents was 

considerably higher.

Of the 20 accidents, 15 were cases 

of fi rst aid, 5 were cases of medical 

treatment and there were no lost 

workday injuries, as can be seen in the 

graph on the right. 

With a view to continuous 

improvement and increasingly 

stricter demands and accuracy in 

reporting occurrences, the following 

graph shows not only the number of 

personal accidents among our own 

staff but also the personal accidents 

involving contractors. 

The graph below shows the 

evolution of the lost workday injury 

frequency (number of accidents 

per million hours worked) This 

chart displays the continued effort 

to align with international best 

practices in communication indicators 

performance. 

As mentioned earlier, in 2010 the 

refi nery had no working day losses, in 

terms of its own staff, therefore the lost 

workday injury frequency was zero. 

Personal accidents 

(own staff) 

1 

4 

2007 

Lost 

workdays 

injuries 

6 

3 

18 

2008 

1 

3 

10 

Medical 

treatment 

cases 

2009 

5 

15 

2010 

First aid 

Personal accidents 2010 (No.) 

5 

15 

Galp Energia 

Injury Rate 

Medical 

treatment 

cases 

1 

19 

40 

Galp Energia 

+ Contractors 

First Aid 

Lost workday injury (No.) and Lost workday injury frequency (own staff) 

Accidents with workday losses (No.) 

20 

18 

16 

14 

12 

10 

8 

6 

4 

2 

0 

9.62 

8 

2005 

Lost workday injury 

2 

2006 

2.40 

1.17 

1 

2007 

6.41 

6 

2008 

Lost workday injury frequency 

1.35 

1 

2009 

0.00 

2010 

10.00 

9.00 

8.00 

7.00 

6.00 

5.00 

4.00 

3.00 

2.00 

1.00 

0 

Safety and health performance • 09 

lost workday injury frequency 



70 

Lost workday injury (No.) 

and Lost workday injury frequency 

(Contractors + Own staff) 

Lost workday injuries (No.) 

5 

5 

4 

4 

3 

3 

3 

2 

2 

1 

1.31 

1 

0 

2009 


1 


0.25 

2010 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 



Considering not only our own staff but 

also showing the aggregated overall 

losses (our own staff and contractors), 

the rate value is 0.2, due to an 

accident that resulted in a workday 

loss from a service provider. 

The value of 0.2 is the refl ection of 

the excellent performance achieved 

in 2010, in terms of Safety and 

Health at Work indicators, whose 

expression is equivalent to international 

benchmarks, despite the complexity 

of the environment, constraints on the 

undertaking of the activities and the 

risk they posed for the complex itself. 

Comparing this value, showed above, 

Lost workday injury (No.) and Lost workday injury severity (own staff) 

Lost workdays injuries (No.) 

Lost workdays injuries (No.) 

40 

35 

30 

25 

20 

15 

10 

5 

0 

40 

8 

2005 

Lost workdays injury 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

54 

3 

2009 

55 

2 

2006 

Lost workdays injury 

Lost workday injury severity 

185 

1 

2007 

Lost workday injury (No.) 

and Lost workday injury severity 

(Contractors + Own staff) 

6 

68 

2008 


1 

18 

2010 

100 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 


with a reference to the European sector, 

Concawe (4) , for which the 2009 value 

is 1.8 (own staff and contractors), it 

demonstrates the major efforts being 

developed, especially on what concerns 

raising awareness and training. 

The fact that no accidents resulting 

in lost workday injury of own staff 

implies that no work days were lost, 

and this fact translates on the Lost 

workday injury severity (total number 

of days lost/number of lost workday 

injuries) that is shown in the graph 

below. 

1 

2009 

63 

0 

0 

2010 

200 

180 

160 

140 

120 

100 

80 

60 

40 

20 

0 

(4) European downstream oil industry safety performance - Statistical summary of reported incidents – 2008; Prepared for the CONCAWE 

Safety Management Group by: A. Burton (Awaken Consulting) and K.H. den Haan (Technical Coordinator). 


If the statistics for contractors are 

included, the severity level raises to 

18, as the graph on the left shows:

Overall, in 2010 there were 193 

incidents reported and investigated, 

whether from the result of activities of 

own staff or conducted by contractors. 

It is necessary to emphasize that the 

seemingly high number of accidents of 

environmental nature is explained by 

the fact that it is policy of the facility, 

since 2010, to communicate, report 

and investigate any type of spillage 

that occurs. In fact, the policy that 

only spills greater than or equal to 150 

litres are reported and investigated 

was abandoned. The criteria for 

reporting has changed since 2010, and 

all spills, regardless of the quantity 

or existence of contact or not of the 

product with the environment, are 

reported and investigated. 

This also explains the increase in 

incidents of class 1, as showed in the 

chart on the right, as most part of 

environmental occurrences fall on this 

category. 

According to NPI-RP-348.00 - 

Communication and Incident 

Investigation for Safety, Health and 

Environment - the incidents are 

divided into four classes according to 

its gravity. 

The chart below shows the total 

percentage of accidents, for 2010, by 

class. 

Types of accidents 

Process Safety Indicators 

Following the industry trend driven by recent events, Galp Energia in general 

and Matosinhos refi nery in particular, have adopted, like other counterparts 

represented in CONCAWE, the methodology defi ned in API 754 - Process 

Safety Performance Indicators for the Refi ning and Petrochemical Industries - 

for the establishment of these indicators. 2010 is the fi rst year of reporting to 

CONCAWE, so there is no mature data for benchmark, and is a milestone in 

the management of Process Safety. 

90 

80 

70 

60 

50 

40 

30 

20 

10 

0 

1 

HSE Non 

compliances 

Total accidents 

0 

4 

9 

Near 

accidents 

10 

51 

4 

Road 

accidents 

Class 1 Class 2 Class 3 Class 4 


85 

Environmental 

accidents 

(spills) 

2009 2010 


34 

Material 

accidents 

0 

1 

24 

60 

Work 

accidents 

168


72 

Medical examination undertaken (No.) 

1,561 

2005 

Admission 

examinations 

1,365 

2006 

1,455 

2007 

Periodic 

examinations 


OCCUPATIONAL 

MEDICINE 


number of medical examinations 

conducted at the Matosinhos refinery 

during the period 2005 to 2010. 

34 

263 

865 

2008 

Occasional 

examinations 

21 

255 

696 

2009 

19 

323 

525 

2010 

Total 

examinations 

In total, in 2010, there were 867 

medical exams performed, and these 

examinations include admission 

examinations, periodic examinations 

and occasional examinations (for 

medical reasons and at the request of 

the worker). 

With the objective of identifying 

situations that put staff’s health at risk, 

the Occupational Medicine service 

conducts frequent visits to work 

stations and plants, seeking to 

implement measures that minimise 

the risks to which employees are 

exposed. 

In the course of all the efforts 

undertaken, no case of occupational 

diseases was registered amongst the 

Matosinhos refinery staff in the period 

under analysis. 

INDUSTRIAL 

HYGIENE 

Industrial hygiene is an important 

aspect with a significant weight in the 

overall activity of Matosinhos refinery 

Safety Department. This is seen as a 

priority when acting on various 

chemicals and contaminants (or 

pollutants) associated with the work 

environment, with the purpose of 

preventing occupational diseases in 

individuals exposed to them. 

The Safety Prevention area from 

Matosinhos refinery carries out every 

year a number of initiatives and other 

legal arrangements in order to prevent 

and control the incidence of 

occupational diseases. 

Subsequently, it is described in more 

detail some of these initiatives. 

EVALUATION OF 

OCCUPATIONAL EXPOSURE 

TO CHEMICAL AGENTS 

In 2010, between July 12th and August 

13th , took place the campaign for the 

assessment of occupational exposure to 

chemicals, on the WWTP and 

Laboratories of Matosinhos refinery. 

The fact that this initiative has been 

performed since 2007, allowed the 

campaign to be singled out. In fact, the 

2010 campaign was different from 

previous ones regarding the number of 

short duration (SD) samples performed.

In 2010, approximately 70 short 

duration samples were performed, 

including agents such as Benzene, 

Toluene, Xylene, H S, Furfural, 1.3 - 

2 

Butadiene, N-Hexane, N-Heptane, 

among others, in the operational 

areas, laboratories and WWTP. 

These samples were obtained in 

clearly identified activities and 

selected from each area where either 

the concentration of the current 

proceedings, or by the agent in 

question, or working procedure 

adopted, the employee could possibly 

be more exposed and existing 

potential risk to his health. 

The results of these samples are 

compared, according to the American 

Conference of Governmental Industrial 

Hygienists (ACGIH), with the Threshold 

Limit Value - Short-Term Exposure Limit 

(TLV-STEL), the equivalent, by the 

Portuguese Standard NP 1796:2007 

designation - valor limite de exposição 

– curta duração (VLE-CD) - 

corresponding to the maximum 

concentration to which workers may 

be subject to a period of 15 minutes. 

Simultaneously, corresponding samples 

were carried out based on a weighted 

average for a typical day of eight 

hours of work, to which workers may 

be repeatedly exposed, day after day, 

without adverse health effects, were 

compared, according to the reference 

Portuguese Standard NP 1796:2007, 

with the valor limite de exposição 

– média ponderada (VLE-MP), 

equivalent according to the ACGIH 

Threshold Limit Value - Time-weighted 

Average - TLV-TWA. 

Of the approximately 500 samples 

taken, it was observed that in none of 

the workplaces were recorded values 

above the benchmark values , 

translating into 100% of the values 

below the legally established limit. 

In summary, between 2007 and 2010 

there were 23 chemicals monitored, 

comprising a total of approximately 

3,600 samples. 




74 


These campaigns follow the next legal regimes: 

• Law No. 7/2009, of 12th February, approving the Labour Code revision, in 

relation to the duties of the employer on the general principles of safety and 

health at work; 

• Law No. 102/2009, of September 10, which regulates the legal regime for 

the Promotion of Safety and Health at Work in regard to its prevention; 

• Decree-Law No. 290/2001, of November 16, regarding protecting staff’s 

health and safety against risks related to exposure to chemical agents at the 

workstation; 

• Decree-Law No. 305/2007, of August 24, establishing a second list of limit 

values for occupational exposure; 

• Decree-Law No. 301/2000, on the protection of workers from risks related to 

exposure to carcinogens or mutagens substances at work; 

• 2009/161/EU Directive, of 17th December 2009, establishing a third list 

of values – indicative of exposure limits for the implementation of Council 

Directive 98/24/EC and amending Directive 2000/39/EC. 

HAZARD IDENTIFICATION 

AND RISK ASSESSMENT 

AND MONITORING 

In order to comply with Article 15 of 

Law no. 102/2009, which revoked 

the Decree-Law No. 441/91 of 

14th November and in relation to 

the employer general obligations, 

the Safety Area has been updating 

and characterizing the different 

jobs through the identifi cation of 

foreseeable dangers arising from 

the activities, processes, substances 

and products handled, among other 

things, to reduce the impact on the 

health of workers and the adoption of 

appropriate protective measures. 

In this sense, given that prevention 

requires the establishment of 

documents, procedures and actions to 

facilitate the identifi cation of hazards 

and risk assessment at various stages 

of work processes as well as the 

adoption of preventive measures 

and/or remedial action in order to 

ensure acceptable levels of exposure 

to the risks, a specifi c software for risk 

management was acquired this year. 

In this software hazards are identifi ed, 

assessed the occurrence probability, 

possible consequences, using a 

valuation methodology, which 

allows to decide what risks should 

be eliminated or controlled by the

creation of action plans, according to a 

signifi cance level. 

An Identifi cation Hazard Map, Risk 

Assessment and Control (IPACR), 

Action Plan and Risk Chart, were 

obtained from this procedure, as 

illustrated in the following schedule: 

The IPACR Map allows complying with the following principles of prevention 

laid down in Article 15 of Law no. 102/2009, September 10th : 

• identify the hazards and their risks in the design or construction of facilities, 

locations and the various stages of the production process including 

preparatory, maintenance and repair activities; 

• identify the equipment, substances, materials and products; 

• identify the preventive measures implemented to control risks; 

• eliminate the hazards and associated risks; 

• assess the hazards / risks that cannot be avoided (matrix method); 

• identify the legal requirements for each risk (Signifi cance Filter); 

• identify control measures to reduce or eliminate risks in order to comply with 

legal and regulatory requirements, based on the following principles: 

• avoiding risks at source; 

• to adapt the work to the man; 

• attending the state of technique evolution; 

• replacing what is dangerous by the non-dangerous or less dangerous; 

• prevention plan with a coherent system; 

Risk management 

Hazards and Risk identification 

Risk Analysis 

Treatment, Controls 

and Risk Monitorization 

Risk Communication 

• to give priority to collective protective measures with regard to 

personal protection. 


IPACAR 

Map 

Action 

Plan 

Risk 

Chart 



76 


The Action Plan leads to the 

implementation of control measures 

for prevention and protection, 

to reduce or eliminate the risks 

previously identifi ed on the IPACR 

map by controlling and monitoring the 

same. 

The employer, through the Risk Chart, 

communicates the risks that arise 

from the activities/tasks and their 

control measures for prevention and 

protection to be taken to reduce risks, 

both in terms of equipment/process/ 

job or workspace. 

SAFETY MANAGEMENT 

SYSTEM FOR MAJOR 

ACCIDENT PREVENTION 

The safe operation of a given 

establishment depends on its 

overall management, in particular 

the defi nition of a system to defi ne 

the implementation of structures, 

responsibilities and procedures, 

allocating the appropriate resources 

and technological solutions available. 

Decree-Law No. 254/2007, 12th July 

2007, known as Seveso II, transposed 

the Directive No. 2003/105/EC of the 

European Parliament and Council, of 

16th of December 2003, into national 

law amending Directive No. 96/82/EC 

(Seveso II). 

This law establishes a scheme 

that aims to preserve and protect 

environmental quality and human 

health, ensuring the prevention of 

major accidents and limiting their 

consequences through the adoption of 

preventive measures, appropriate to 

the risk level and emergency response 

procedure. To this end, it lays down 

a special scheme applicable to all 

establishments where dangerous 

substances are present in quantities 

exceeding those indicated in the 

decree. 

In this context, for establishments with 

higher rate of danger, as is the case of 

Matosinhos refi nery, it is mandatory 

to adopt a Safety Management 

System for Major Accident Prevention 

(SGSPAG). 

DRILL AND TRAINING 

EXERCISES 

Emergency scenarios of Matosinhos 

refi nery are fully characterized in terms 

of the Internal Emergency Plan (PEI). 

The completion of regularly training 

exercises and drill, in addition to legal 

compliance, has as main objective 

to evaluate the effectiveness of the 

PEI, to train those involved in the 

emergency response, and assess the 

training needs based on proven teams 

performance.

For 2010, the refi nery planned and 

carried out 8 training exercises and a 

drill exercise, testing the responses to 

various scenarios defi ned in PEI. 

The emergency drill was held in the 

Fuels Plant, on the 16th of August, by 

17:00 pm, more specifi cally in Unit 

1400 – Diesel Desulphurization, as 

illustrated in the fi gure on the right: 

The tested scenario is included in the Matosinhos refi nery Safety Notice. The 

exercise focused on reactor, R-1401 (fl uidised-bed reactor), equipment that 

aims to convert the Sulphur compounds (S) and nitrogen (N) to hydrogen 

sulphide (H S) and ammonia (NH ), also converting olefi ns and aromatics in 

2 3 

saturated compounds. 

This exercise considered the loss of containment due to a rupture of a 100 

mm output pipe from R-1401, with immediate auto ignition of the formed gas 

cloud. In the simulated accident scenario, due pressure, the fl ames of the 

jet-fl ame type would involve the entire reactor and would reach the 

surrounding structures. 

In this type of leak, if appropriate measures are not taken in a timely manner 

for the circumscription and leakage termination, there could be serious 

consequences, as it could quickly affect other areas and potentially impact 

the air quality in the surrounding environment, with possible implications for 

public health. This would necessarily lead to the External Emergency Plan (EEP) 

activation, involving the Relief Operations District Command (CDOS) of Porto, 

stating the type of alert and location. 

However, the fact that the units have permanent human presence and are 

fi tted with security cameras, this type of occurrence, would be readily detected 

and the alert immediately triggered. 

On the other hand, the loss of containment, which induces instability in to the 

unit, would require a series of procedural alarms that identify the existence an 

emergency. 




78 


This, in itself, will activate safety procedures, not depending on the actions of 

the process operator, which will trigger the stopping of equipment, allowing 

pressure to decrease, and immediately allowing the intensity of the fl ames 

and thermal radiation to reduce. Emergency situations like this also imply that 

the movement of processes are interrupted. 

Panoramas has described trigger the following behaviour, or from the 

procedural area or the preventive safety area of the facility, as a way to 

respond to emergencies: 

• the operational area immediately opens the curtain of water protection for 

the furnaces, with the cannon located south of the unit, and simultaneously 

projects foam to the ground through the foam generator that is in the area; 

• the Intervention Responsible (Head of Safety), when viewing the event, 

assess the situation and defi nes the strategy based on the following points: 

• leakage control through the sectioning of valves within the limits of the 

installation; 

• promotion of water curtains to allow the presence and safety intervention 

of human resources, in the vicinity; 

• protection of the building of the technical installations of the effect of 

thermal radiation; 

• equipment protection, use in the reactor, through the interposition of 

sheets of water, minimizing the effects of exposure to fl ame; 

• preventing the spread of fi re to equipments in the vicinity, especially to 

fans, who could suck the fl ames through the activation of the gun turret; 

• notifi cation of the WWTP/FAR of the possible arrival of large amounts of 

water/product.

The graph on the right refl ects the 

number of exercises conducted 

between 2005 and 2010. 

ANNUAL VERIFICATION 

OF THE SYSTEM 

REQUIREMENTS FOR A 

SAFETY MANAGEMENT 

SYSTEM FOR MAJOR 

ACCIDENT PREVENTION 

The Matosinhos refi nery, in 

accordance with Article 16. 

Decree-Law n. º 254/2007, 

must submit to the Portuguese 

Environmental Agency (APA), until 

March 31 of each year , an audit 

report on the - System Requirements 

for a Safety Management System for 

Major Accident Prevention – SGSPAG, 

to be held by qualifi ed verifi ers under 

Ordinance No. 966/2007. 

This audit aims to ensure that the 

facility developed, implemented 

and maintains a SGSPAG, as well 

as convey the improvements in the 

system performance, in accordance 

with Annex III of the article, taking into 

account as reference document in the 

SGSPAG (APA, March 2008). 

Since 2008, the refi nery has been 

subject of these audits. Subsequently 

we present the number of 

non-compliance and opportunity 

for improvement that have been 

identifi ed in the period between 2008 

and 2010. 

MANAGEMENT OF CHANGE 

- STANDARD PROCEDURE 

The Matosinhos refi nery, under 

Decree-Law No. 254/2007, which 

Drill exercises (No.) 

7 

2005 

establishes a regime of prevention 

of major accidents involving 

dangerous substances and limiting 

their consequences for man and 

environment, is characterized as 

facility with an higher level of 

dangerousness, and so has an 

obligation of constituting a Safety 

Notifi cation (NS), Policy for the 

Prevention of Accident (PPAG) 

involving dangerous substances and its 

Safety Report (RS). 

The above referred documents, in 

accordance with articles Article 7, 9 

and 13 of Decree-Law No. 254/2007, 

whenever there is a “substantial 

change”, should go through a revision 

so that modifi cations/changes are 

refl ected. 

7 

2006 

SGSPAG Audits Findings 

4 4 

2008 

7 

2007 


10 

2009 

Improvement opportunities Non compliance 

0 

8 

2008 

2009 


10 

3 3 

2010 

9 

2010


80 


“Substantial Change” under Article 2 of Decree-Law No. 254/2007, is defi ned 

as “signifi cant increase in the quantity or signifi cant change in the nature or 

physical state of dangerous substances present in the establishment indicated 

in the notifi cation as well as change in the processes used or modifi cations to 

an establishment or facility which may have signifi cant repercussions in the 

fi eld of major hazards accident involving dangerous substances.” 

On this topic, Galp Energia has 

developed a standard procedure - 

NPG-031 – Management of Change, 

which ensures compliance with 

the above, and which defi nes the 

minimum requirements to ensure 

that any changes/amendments, 

temporary, permanent or emergent, 

whether technological, process, 

facilities/equipment, or even people 

and surroundings, are evaluated on 

the aspects of HSE, ensuring that all 

potential risks associated with changes 

are identifi ed and controlled and if the 

merger should be considered in the 

documents described above, leading 

to a revision. 

This standard procedure is refl ected 

in Matosinhos refi nery’s Internal 

standard Procedure - NPI-090.06 – 

Amendments Management. 

So, whenever a 

modifi cation/amendment is 

recommended, such as, improving 

the accessibility to equipments, 

dismantling of lines, drains removal, 

among other examples, a standard 

procedure is followed.

Management of Change Procedures: 

1. The area that wants to perform a modifi cation/change, regardless of its 

end, starts this process by requesting a study, justifying the reason for the 

change; 

2. The Area Director, where the change will be made, decides on the drafting 

of a Request for Study (RS) and carries an cost estimate and/or economic 

assessment; 

3. After the RS approval, the technological area prepares a technical study, 

recommending the changes in a basic engineering level; 

4. After the study completion, a team is appointed, that produces an 

assessment of the modifi cation/amendment in question, based on a 

matrix, to assess what kind of risk analysis the planned change requires; 

5. The Risk Analysis, depending on the type of change and its implications 

on issues relating to Safety and Environment can lead to the realization of 

a Preliminary Risk Analysis (PRA) or, if appropriate, the development of a 

HAZOP (Hazard and operability study); 

6. The RS resolution and risk analysis follow to the Area Director for approval; 

7. Subsequently, the Matosinhos refi nery Management decides on the 

implementation, amendment/modifi cation, funds expenditure, its 

budgetary framework and appoints the manager for the change 

implementation; 

8. The change manager, responsible for preparing detailed engineering, 

promotes its internal approval (with the collaboration of other areas of the 

refi nery); 

9. The manager is responsible for the change/modifi cation implementing; 

10. The Area that submitted the RS accepts the implemented work; 

11. The change manager proposes terminating the RS and the destruction of 

disabled equipment, if applicable, and provides for the licensing of new, if 

applicable. 

When the implementation of change/ 

modifi cation is fi nished, the process is 

delivered to the Project Management 

and Engineering area, to be part of the 

Matosinhos refi nery technical archive. 

INTERNAL EMERGENCY 

PLAN REVISION 

Due to a conversion project, which 

involves the construction of two new 

process units and the reconfi guration 

of existing units at the Fuels Plant, 

Matosinhos refi nery produced a 

revision of the Internal Emergency 

Plan (PEI) which also refl ects the new 

Natural Gas Cogeneration Plant, which 

construction Galp Power, SGPS, S.A., is 

responsible. 

Among the changes listed above, the 

document has also undergone a slight 

adjustment to the production units 




82 


current scenario, introducing some 

concepts which have been updated 

since the last review, in the aspect of 

major accidents prevention involving 

dangerous substances and the 

incorporation of the current refi ner’s 

organizational chart, among other 

things. 

WORK PERMIT 

AUDITS 

Under the NPI - RP-338.20 standard, 

Work Permit (WP)/Certifi cate of 

Scaffolding Approval and entrance in 

equipments Permit, having introduced 

models for the Scaffolding Approval 

and Authorization for entry into 

confi ned spaces, it was necessary to 

develop a tool to assess whether the 

recommended changes were being 

implemented properly and have the 

desired effect and, accordingly, this 

procedure requires that audits to the 

involved procedures are carried out. 

These audits are conducted according 

to a plan established on the NPI, 

together with the operational area 

shift manager and safety area shift 

manager, where they evaluate how 

the procedures are implemented. 

These audits apply to all jobs 

conducted on the premises of the 

refi nery, and are refl ected in reports, 

and the original remains at the Safety 

department and a copy is sent to the 

Audited area. 

Those reports include the number of 

WP/Certifi cate of Scaffolding Approval 

and entrance in equipments Permit 

evaluated, the amount of 

non-compliance identifi ed, and a fi eld 

for comments and recommendations, 

if applicable. 

It’s the audited area responsibility to 

implement the corrective measures 

present in these reports, arising from 

this exercise. 

In 2010, there were a total of 514 

audits, assessed 2768 Work Permits 

and identifi ed six non-compliances 

PREVENTIVE 

SAFETY AND 

ENVIRONMENTAL 

OBSERVATIONS 

Implementing a Management System 

for Safety, Health and Environment 

requires, among other guidelines, 

the means to measure its outcomes, 

such as: Internal and External 

Audits, Inspections and as simple 

as the Preventive Observations for 

Environment and Safety (OPAS). 

According to the Internal Standard 

Procedure - NPI-RP-334.20 - Preventive 

Observations for Environment and 

Safety, refers to the act of to observe, 

talk, record and correct actions or 

dangerous conditions in the fi eld of 

Environment and Safety.

Matosinhos refi nery established for 

2010 the goal of 840 hours, however, 

that goal was exceeded and 1,017 

hours of OPAS were completed, carried 

out by qualifi ed Galp Energia workers, 

adequately trained and for whom 

monthly goals are established. 

The chart on the right illustrates the 

evolution of the indicator for the years 

2009 and 2010, and it’s expected to 

continue to follow in future years. 

PRODUCT SAFETY 

REACH REGULATION 

REACH Regulation (Registration, Evaluation, Authorisation and Restriction of 

Chemicals) came into force on June 1st 2007, with the aim of simplifying and 

improving the legal framework for chemical substances in the European Union. 

REACH appeared with the intention to improve the protection of human health 

and the environment through the better and earlier identifi cation of the 

intrinsic properties of chemical substances. 

Following up the work of the last few 

years, in 2010 the Matosinhos refi nery 

maintained its commitment to the tasks 

necessary to effectively comply with 

the Regulation. 

The most relevant actions took place 

in the fi eld of identifi cation and 

characterization of substances in terms 

of composition. 

Therefore most of the tests 

were performed, following the 

recommendations by the European 

Associations and Consortiums in which 

Galp Energia participates, 

No. of OPAS hours undertaken 

1,143 

2009 

These Regulations place greater responsibility on the industry in managing 

the risks that chemical substances may represent for human health and the 

environment. 

in order to reach this purpose. 

1,017 

2010 

Due to the variety of products produced 

in this refi nery, its laboratory was 

required to conduct dozens of trials, 

and in some situations, develop specifi c 

methodologies. 

In 2010, Galp Energia registered 

successfully with the European 

Chemicals Agency substances that are 

produced in quantities exceeding 1,000 

tonnes per year, totalling 58, of which, 

45 substances are produced in the 

Matosinhos refi nery. 



84 

10 

COMMUNITY 

RELATIONS 

WE CONSIDER THE 

INTEGRATION OF MATOSINHOS 

REFINERY ACTIVITIES WITH 

THE COMMUNITY A PRIORITY. 


The refi nery is fi rmly committed 

in the approximation with the 

surrounding local residents in order to 

meet their needs and concerns. 

For this purpose, an email 

address was created, 

refi nariamatosinhos@galpenergia.com, 

which allows treating situations like 

complaints, suggestions, among 

others, in a more expeditious and 

methodical way. In 2010, there 

weren’t any records at this address. 

This initiative aims to give an 

appropriately response to the 

progressive enrichment of the 

population of Matosinhos with 

particular emphasis to the 

surrounding of the refi nery, ensuring 

that this installation does not 

introduce factors that jeopardize 

the quality of life of the city and its 

residents. 

Community relations • 10 


86 

11 

THE FACES BEHIND 

HEALTH, SAFETY AND 

ENVIRONMENTAL ASPECTS 

AT THE REFINERY 

COME AND GET TO KNOW US! 


The faces behind health, safety and environmental aspects at the refinery • 11 

To be fair, this chapter should 

introduce all those who work in or for 

the refi nery, because it’s everyone’s 

responsibility for the performance in 

health, safety and environmental. 

However, there are employees who 

work daily and constantly with these 

issues, ensuring the adoption of best 

practices and guaranteeing that the 

refi nery and its employees have the 

necessaries resources and conditions 

to verify that the activity arises in 

safety and in full respect to the 

environment and in the protection of 

health and well-being of Employees, 

service providers and Community. 

This is the area devoted to introduce 

them. 



88 88 

2010 2010 DATA DATA BOOK BOOK ON HEALTH, ON HEALTH, SAFETY SAFETY AND AND ENVIRONMENT • MATOSINHOS • MATOSINHOS REFINERY REFINERY

12 

GLOSSARY 

THIS CHAPTER AIMS TO MAKE 

THIS REPORT COMPLETELY 

TRANSPARENT. 


89


90 

TERM DEFINITION UNITY 

Accidents in itinerae 

AP 

API Density 

Biochemical Oxygen 

Demand 5 (BOD 5 ) 

Represent accidents occurring on the route normally taken by the worker, whichever direction he or she is 

heading in, between the workplace or training location linked to said worker’s professional activity and his or 

her main or secondary residence, the place he or she normally has meals or the premises where he or she 

normally receives wages, resulting in death or bodily harm. Considers only the own staff. 

Represents the Aromatics Plant, a plant within the Matosinhos refi nery used for the production of solvents 

and aromatic compounds (toluene, xylene and benzene). 

Unit of density according to the indicator of the American Institute of Petroleum 

(°API = (141.5/ specifi c weight at 60° F) - 131.5). 

Corresponds to the oxygen consumed in the degradation of organic material at a mean temperature of 

20ºC over 5 days in the wastewater, in accordance with the laboratory analyses conducted in the refi nery 

Laboratory. 

Claus Unit This is the unit used for recovering Sulphur. 

CO 2 Emissions under 

EU-ETS 

Costs 

Cyanides 

Represents the total carbon dioxide emissions accounted for in accordance with the provisions of refi nery’s 

Greenhouse Gas Emission Permit. 

Total operating expenditure for operations related to each of the environmental categories (protection 

of water resources; waste management; soil and groundwater protection; air and climate protection). 

Classifi cation is made in accordance with the defi nitions of the National Statistical Institute. 

Corresponds to the concentration of Cyanides in wastewater in accordance with the laboratory analyses 

conducted in the refi nery Laboratory. 

Electricity production Represents electricity production measured on the boiler counters. 

End-of-line equipment 

Environmental 

Accidents 

First Aid 

Fuel Gas Consumption 

Facilities, equipment and identifi able machinery parts, as well as construction, that operate at the end of the 

production process, aimed at treating, preventing or measuring pollution. 

Refers to the total number of accidents causing damage to the refi nery’s surroundings, including air, water, 

soil, natural resources, fl ora, fauna, people and their interrelations. 

Refers to the total number of work accidents (excluding accidents on the way to or from work), requiring the 

worker to be attended, but not by a doctor. 

Fuel gas consumption, for burning in Large Combustion Plants and process furnaces. Consumption by Flares 

(only regarding the pilots, excluding losses) is also associated with the Process. 

Gas Consumption Consumption of Fuel Gas enriched with Natural Gas, burned in the LCPs and process furnaces. 

Hazardous industrial 

waste produced 

Hydrocarbons in 

efl uents per level of 

activity 

Hydrocarbons in 

wastewater 

Industrial waste 

(hazardous and 

nonhazardous) 

produced per level of 

activity 

Integrated Technologies 

Investments 

Represents the quantity of industrial waste that does represent a hazard to 

health and the environment, according to the applicable legislation and the 

European Waste List. The Lubricants Plant is not included. 

Represents the ratio between the total mass of hydrocarbons in effl uents (determined from the 

concentrations and volume of effl uents produced) and the load processed. 

Corresponds to the concentration of hydrocarbons in effl uents in accordance with the laboratory analyses 


Means the ratio between the quantity of industrial waste (hazardous or non-hazardous) and the load 

processed. 

Equipment and/or facilities or parts of equipment and/or facilities, that have been modifi ed to reduce 

pollution, integrated into the production process. Includes studies involving integrated analysis of solutions to 

improve environmental performance. 

Total of the amounts of investment in the various environmental categories 

(Protection of water resource; Waste Management; Soil and groundwater protection; Air and climate 

protection) and Safety, Health and Hygiene at Work. 

The classifi cation is made according to the provisions supplied by the National Statistical Institute. 

LCP’s Large Combustion Facilities used in energy production, with thermal power greater than 50 MWt. 

Liquid effl uents 

per level of activity 

Effl uents 

produced 

Load processed 

(Level of activity) 

Lost Workday injury 


severity 

Means the ratio between liquid effl uents produced, accounted for according to the contents of “Liquid 

effl uents produced” and the load processed. 

Involves the volume of wastewater produced m 3 

The load processed is a measure of the refi nery’s production intensity and Level 

of Activity, and is provided by the quantity, in mass, of raw materials that are processed, weighted by a 

conversion factor for crude oil equivalent. 

The conversion factor depends on the level of treatment that the raw materials and components are 

subjected. 

This weighting was introduced in 2008 to understand better the load processed. 

Refers to the total number of work accidents (does not include accidents in itinerae), in which there were 

days or shifts in which the worker did not perform his or her duties, due to any inability to carry out his or her 

work. 

Number of total days lost per Number of Lost workdays injuries 


Number of accidents 

º API 

mg/l 

t 

€ 

mg/l 

Number of tonnes of oil 

equivalent (toe) 



t 

g/t 

mg/l 

kg/t 

€ 

m 3 /t 

t 


Number of total days 

lost/ number of lost 

workdays injuries


Medical examinations 

Medical treatment 

cases 

Refers to of the number of admission examinations (obligatory medical examinations when a worker is hired, 

in order to evaluate the employee’s physical and psychological ability to carry out the function for which they 

are contracted); 

the number of periodic examinations (conducted at intervals prescribed by law, 

according to the worker’s age group); the number of occasional examinations 

(conducted for specifi c reasons, or on a doctor’s request/initiative, or at the request of the worker). Only 

Petrogral workers are considered. 

Refers to the total number of work accidents (excluding accidents on the way to or from work), requiring the 

worker to be attended by a doctor. 

Natural gas consumption Consumption of natural gas burned in the LCP´s and process furnaces. t 

Non-hazardous 

industrial waste 

produced 

NO X emissions 

NO x Emissions 

per level of activity 

Number of trainees in 

training programmes 

in Health, Safety and 

Environment 

Number of trainees in 

training programmes 

provided in Health, 

Safety and 

Environment 

Number of training 

programmes provided 

in Health and Safety 

Number of training 

programmes in 

Health, Safety and the 

Environment 

Occupational diseases 

Oils and grease 

Represents the quantity of industrial waste that does not represent a hazard 

to health and the environment, according to the applicable legislation and the 

European Waste List. It does not include recovered materials. The Lubricants 

Plant is not included. 

Represents nitrogen oxide emissions (nitrogen monoxide and nitrogen dioxide), deriving from combustion of 

RFO, fuel gas and natural gas, in boilers, Cogeneration and process furnaces. 

NO x = NO x RPC + NO x FG + NO x GN 

NO x RPC (t) = Consumption RPC (t) x F emission RPC x PCI RPC (TJ/t) x 10 -3 

NO x FG (t) = Consumo FG (t) x F emission FG x PCI FG (TJ/t) x 10 -3 

NO according to the “Air Pollutant Emission estimation methods for EPER and PRTR reporting by refi neries, 

x GN 

Concawe, report number 3/07R: 

NO = NO + NO xGN x thermal x fuel 

NO x thermal (kg) = 10 -3 x Consumption GN (t) x 1.11 x PCI (MJ/t) x 

F Base x F H2 x F Control x F Preheat x F H20 x F Load x F Burn 

NO x fuel = given that the percentage of combustible nitrogen in the Natural gas is zero. 

The formulas for RFO and Fuel Gas are applied to the combustion emissions, in accordance with the emission 

factors relating to combustion equipment having a thermal power greater or less than 50 MWt. 

Number of examinations 


COMBUSTION UNITS TYPE OF FUEL EMISSION FACTOR (g/GJ) 

With thermal power < 50MWt 

With thermal power > 50MWt 

RFO 180 

Fuel gas 1740 

RFO 190 

Fuel gas 140 

From 1 st April for fi xed sources with continuous monitoring, the calculation of emissions switched to being 

conducted by the Centralised Environmental Information System (SIAC - Sistema Informacao Ambiental 

Centralizada). 

Means the ratio between NO X emissions, counted according to the contents of 

“NO X Emissions” and the load processed. 

Represents the total number of Petrogal trainees that attended the internal and external training activities 

regarding matters of Health, Safety and the Environment. 

Represents the total number of trainees (Petrogal employees and service providers), who attended training 

activities regarding matters of Health, Safety and the Environment provided by the Safety and Environment 

departments. 

Represents the total number of training sessions regarding matters of Health and Safety provided by the 

Safety Department to employees and service providers. 

Represents the total number of different internal and external training activities 

regarding matters of Health, Safety and the Environment attended by employees, such as courses, seminars 

and other activities. 

Refers to as illnesses caused by the activity performed by the worker or included on the list of occupational 

illnesses (Dec-Reg 12/80 and Decree-Law No. 248/99). 

Corresponds to the concentration of Oils and Grease in wastewater, in accordance with the laboratory analyses 



t 

t 

kg/t 

Number of trainees 

Number of trainees 

Number of activities 

Number of activities 

Number of cases 

mg/L 

Glossary • 12


92 

TERM DEFINITION 

Represents the total particulate emissions (unburned fuel, soot and incondensable matter in suspension in gas 

fl ows), deriving from the RFO, natural gas and fuel gas combustion in the LCP´s, in process furnaces and the 

AP. 

UNITY 

Particulate matter 

emissions 

Particulate matter 

emissions per level of 

activity 

Personal accidents 

pH in effl uents 

The emissions are determined in accordance with the formulas in the EPA Manual: 

Particules = EmissionsRFO + EmissionsFG + EmissionsGN 

Emissions RFO = (9,19 x %S RFO + 3,22) + 1,5) x 0,1195 x Consumption RFO (t) 

P RFO (g/cm 3 ) 

Emissions = FG Consumption x 7,6 x 16 

FG 

P (g/cm FG 3 ) x 10 

Emissions GN = Consumption GN x 7,6 x 16 GN 

P GN (g/cm 3 ) x 10 6 

Beginning April 1 st , for fi xed sources with continuous monitoring, the calculation 

of emissions will be switched to being conducted by the Centralised Environmental Information System (SIAC - 

Sistema Informação Ambiental Centralizada). 

Means the ratio between the particulate matter emissions, accounted for according to the contents of 

“Particulate matter emissions” and the load processed. 

Refers to the total number of accidents suffered by employees excluding in itinerate. Includes accidents 

involving fi rst aid, cases of medical treatment and accidents leading to working day losses. 

Refers to the potential hydrogen in the wastewater from the refi nery WWTP, through laboratory analyses 

conducted on them. 

Phenols Represents the concentration of Phenols in wastewater in accordance with the laboratory analyses conducted 

in the refi nery Laboratory. 


t 

kg/t 


Sorensen Scale 

Process 

The process includes the plant activities involving fuel consumption. The Flares and Claus Unit are included in 

this description. 

Processed crude Represents the quantity of crude oil processed in the refi nery, supplying the units. t 

Production Represents the quantity of each type of product produced in the refi nery. Number of t/product 

Property damaging 

accidents 

Quantity of recovered 

materials 

Recovered sulphur 

Recovered sulphur per 

load processed 

Recycled water 

RFO consumption 

SO 2 emissions 

SO 2 Emissions per level 

of activity 

SO 2 ”bubble” 

Sulphur content in the 

RFO 

Total iron 

Total suspended solids 

Refers to the total number of accidents causing damage to material goods, namely, assets, equipment, 

product, productivity, stoppage of production, fi nes for non-compliance with legislation or expenses of another 

nature, related to the accident or the person involved in the accident. 

Corresponds to the quantity of materials sent for recycling, such as scrap metal, 

packaging, paper, plastic and used oil. The Lubricants Plant is not included. 

Represents in terms of mass the sulphur recovered in sulphur recovery units. 

This value is determined based on the refi nery mass balances, according to the 

load of H S in the units and its purifi cation effi ciency. 

2 

This is provided by the ratio between recovered sulphur, accounted for as described in the contents of 

“Recovered sulphur”, and the load processed. 

Represents the quantity of treated water in the WWTP of refi nery that is reuse in the water fi re network and 

in the service water network. m 3 

Consumption of Combustible Process Waste (Fuel-oil for internal consumption), for burning in LCP´s and 

process furnaces. 

This indicator represents the sulphur dioxide emissions arising from RFO combustion LCP´s and in process 

furnaces, in the AP and in the Claus Unit. The combustion emissions are calculated using the following 

formula: 

SO 2 = SO 2 RFO (t) = Consumption RFO (t) x % S RFO x 0,02 

% S RFO represents the level of Sulphur in the RFO (See “Sulphur content in the RFO”). Emissions of SO 2 from 

the fuel gas and natural gas are not considered as the level of Sulphur is very close to zero. 

Beginning April 1st, for fi xed sources with continuous monitoring, the calculation of emissions switched to 

being conducted by the Centralised Environmental Information System (SIAC - Sistema Informação Ambiental 

Centralizada). 

Means the ratio between SO 2 emissions, accounted for according to the contents of “SO 2 Emissions” and the 

treated load. 

Represents the concentration of sulphur oxides in the form of sulphur dioxide, a virtual stack, weighing the 

various fl ow rates and concentrations of different sources, as well as their sulphur content. The formula was 

approved by the Portuguese Agency for the Environment, and excludes emissions from the Claus unit and 

Flares. 

Means the percentage value of sulphur content in RFO. This value is determined in the laboratory, through 

weekly analyses on compound samples, the annual value constituting a weighted average of the mean 

monthly values. 

Represents the concentration of Iron in wastewater in accordance with the laboratory analyses conducted in 

the refi nery Laboratory. 

Corresponds to the concentration of Suspended Solids in the wastewater, in accordance with the laboratory 

analyses conducted in the refi nery Laboratory. 

mg/l 


t 

t 

kg/t 

t 

t 

kg/t 

mg/Nm 3 

% 

mg/l 

mg/l


Waste produced 

considered solid urban 

waste 

Water consumption 

Water consumption per 


Means the quantity of domestic or similar waste produced, due to its nature or composition t 

Represents the consumption of process water in the plant (captured from the Ave River), as well as water for 

human consumption from the Matosinhos Municipal Water and Sanitation Service 

This indicator is provided by the ratio between raw water consumed and the load processed in the refi nery. It 

represents the specifi c consumption of water. 

Glossary • 12 


m 3 

m 3 /t


94 2010 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT • MATOSINHOS REFINERY

13 

STATEMENT OF CONFORMITY 


NOTICE THAT THE DATA 

WE HERE PRESENT WAS 

SUBJECTED TO THIRD PARTY 

VERIFICATION. 


95

13 • Statement of conformity 

96 


Statement of conformity • 13 


EDITION 

REVISION 

DESIGN AND CREATION 

PHOTOS 

Galp Energia - Manuel Aguiar

Untitled - Galp Energia

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