TOTAL UK Limited Lindsey Oil Refinery Fast Facts

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Site Profile TOTAL Lindsey Oil Refinery

The TOTAL Lindsey Oil Refinery (TOTAL LOR) takes its name from its location within the
historic district of Lindsey in Lincolnshire.
TOTAL LOR is Britains third largest oil refinery with a processing capacity of up to 10
million tonnes of crude oil per year (over 200,000 barrels per day).
It was the first refinery to process North Sea Oil and came on stream in 1968. It has since
grown and developed into one of the most complex and technically advanced refineries in
Europe with the capability to process over forty different types of crude oil.
The 500, acre Refinery consists of processing units, a tank farm, loading bays (rail and
road), rail sidings, a laboratory and offices. In detail this means the site has the following:
- 145 liquid product tanks, including 11 for crude oil storage.
- 13 spheres for Liquefied Petroleum Gas (LPG)
- 38 loading bays supplying up to 400 road tankers a day.
- 13 miles of rail track and 5 loading bays supplying up to 10 trains a day. It is the
largest private rail complex in the UK.
- 225 km of underground pipeline to the Buncefield Storage Terminal at Hemel
Hempstead (See Fast Facts HOSL and Fina-Line).
- 7 pipelines supply the Immingham Oil Terminal and 5 others supply the South
Killingholme Jetty and Immingham Gas Terminal.
- The three marine oil terminals supply approx. 250 vessels a month. Between
them the terminals can handle, for example, 60,000 tonne LPG ships to Very
Large Crude Carriers of up to 300,000 tonnes

Site and Operational Detail

TOTAL LOR is a self-contained site. There is a gas fired co-generation unit on site owned
by Innogy Cogen. TOTAL LOR operates the unit, which supplies the site with steam and
electricity. This makes the site independent of the National Grid electricity supply offering
security of supply in the event of grid interruption. The Refinerys high-pressure steam
requirements are being met by a Combined Heat and Power Plant constructed and
operated by ConocoPhillips ICHP at the south eastern border of the Refinery. This
started production in October 2004.
The adjacent ConocoPhillips Humber Refinery is on TOTAL LORs southern boundary
and is separated from TOTAL LOR by the rail network supply for both refineries. Some
facilities are shared, for example, Associated Petroleum Terminals (Immingham) Ltd.
(APT) and its associated pipelines.

Product

90% of crude oil supply comes from the North Sea, the other 10% is from the rest of the
world.
Petrol and Diesel fuels are blended by state-of-the-art computerised systems, which use
on-line analysers to accurately control product quality to the highest specifications.
In addition to the 31 standard UK products produced, such as ultra low sulphur petrol and
diesel, TOTAL LOR also supplies 10 products for the overseas market including export
motor spirit, gasoil grades and fuel oil. TOTAL LOR also frequently makes batches to
special order.
Specifications are constantly being updated to comply with the latest environmental,
safety and quality requirements.
Tank levels are displayed on VDU screens in the Blending Control Room and are
constantly monitored.

Distribution

Distribution of oil product from the Refinery is by four methods.

The 38 loading bays supply up to 400 road tankers a day distributing 17% of
TOTAL LORs product.
Rail distributes 23% of output
The pipeline to the Buncefield complex carries 28%

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32% of TOTAL LORs product is transported by sea via the Associated Petroleum
Terminals (Immingham) Limited (APT) which operates three marine terminals:
Immingham Oil Terminal, South Killingholme Jetty and Immingham Gas Terminal.

Geography

TOTAL Lindsey Oil Refinery Limited, North Killingholme, Immingham, North Lincolnshire,
DN40 3LW.
The nearest villages are North and South Killingholme, both approx. 1 mile from TOTAL
LOR and with a joint population of around 2,200. The next nearest village is:
East Halton 4.8km (3 miles)
The next nearest Towns are:
Immingham 6.4km (4 miles)
Grimsby 17.6km (11 miles)
The River Humber is approximately 3.2 km (2 miles) east of the refinery
TOTAL LORs industrial neighbours include: the Associate Petroleum Terminals Limited
(APT) 3.2km (2 miles) east of Immingham, the ConocoPhillips Humber Refinery on
TOTAL LORs southern border, two large gas fired power stations owned by Powergen
and Innogy on its northern border, and a soon to be completed ICHP plant owned by
ConocoPhillips on its south eastern border (completion expected early 2004).
There are four on site contractors (see personnel section).

Personnel

The refinery is operational 24 hours a day 365 days a year.

TOTAL LOR has an establishment figure of 464 employees, 164 are day staff and the
remaining 300 are shift staff.
Between the hours of 0830-1630 Monday to Friday there are approx. 400 people on site.
Outside these hours the number stands at around 65. The site operates on a pattern of
three shifts within a 24 hour period.
TOTAL LOR also employs approximately 250 contractors on a permanent basis. For
special projects and Turnaround and Inspections (T & Is) TOTAL LOR can employ an
additional 800 people on a temporary basis. The next major T & I is due in September
2005, on average major T & Is occur every three years.
The main contractors provide a variety of maintenance and support, for example, cleaning
and scaffolding. On site contractors include: Mitsui Babcock (Mechanical) employs (130) /
(Control and Power)(40) / Grant Rail(maintenance and tracks) (3) / Jefco (20) /Flowserve
(3) / Sodexho (catering) (16)
CONTRACTOR SAFETY REQUIREMENTS - The main responsibility for ensuring that
contractors (tradesmen) are competent in both technical and safety aspects, rests with
their employer, however, whilst working on the TOTAL LOR site they are subject to the
same rules and regulations inherent within TOTAL LORs Safety Management System.
They also receive specialist training where appropriate.
For example: All contractors must possess a Client Contractor National Safety Group
(CCNSG) qualification called a safety passport. The scheme is becoming widely used
within the UK and is followed by all the major industries on the Humber Bank. The
scheme provides two days classroom training, including a written examination. TOTAL
LOR has been one of the driving forces in the establishment of this scheme locally and
nationally
TRACKING - Entry to the operating site is restricted to entry pass holders, employees,
contractors and authorised visitors. Entry to the external administration building is
controlled by a swipe card security system. The movement of people between locations is
registered using a tag board system. In the event of an emergency, a reconciliation is
carried out to identify location of people.

Safety and Security

TOTAL LOR has an excellent safety record. Since the process plant started operation in
1968 there has not been a single fatality or offsite emergency.
In April 1995 TOTAL LOR achieved a Level 8 rating on the International Safety Rating
System (ISRS). ISRS is the group standard for safety management systems with a target

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level 8 for refineries. This is an internationally recognised leader in safety management

systems and is followed by, the nuclear energy industry, chemical and petrochemical
companies. Only 10% of the companies who follow the system achieve level 8.
In June 2004 TOTAL LOR were recognised by RoSPA (Royal Society for the Prevention
of Accidents) and were awarded the RoSPA Gold Award for Safety performance during
2003. TOTAL LORs intention is to retain this award with their future safety performances
and initiatives.
TOTAL LOR is also a top tier COMAH site. COMAH stands for Control of Major Accident
Hazards Regulations 1999.
In addition to induction training, the companys ISRS programme also regularly exposes
all employees to health and safety issues through involvement in incident analysis,
regular group safety meetings, task analysis and promotion of safety topics.
Training forms an integral part of TOTAL LORs working practices, examples of
professional training include: fire-fighting training for all, including office based staff;
breathing apparatus training; first aid; and defibrillator use.
General site rules specify safety helmets, eye protection, safety footwear and fireretardant overalls. Specialised equipment with appropriate training is also supplied when
required, for example breathing apparatus and respirator protection masks.
TOTAL LOR incorporates the highest safety engineering standards into the design,
construction, operation and maintenance of all equipment in order to protect the health
and safety of staff and contractors.
The site conforms to the Fire Certificates, special premises and Petroleum Regulation
Acts in addition to other regulatory requirements including the Health and Safety at Work
Act.
A substance abuse Policy was introduced at the end of 2003.

Environment

TOTAL LOR adheres to a strict environmental code, represented in our Policy Statement,
which aims to ensure that stringent care has been and is taken in the design, construction
and operation of our plants to ensure that any risks are minimised throughout the refining
process from receipt of the crude oil to the loading and delivery of product.
With this in mind TOTAL LOR provides on-going investment in sophisticated monitoring
and control equipment, noise monitoring, water treatment, gas cleaning and sulphur
recovery plant. Some examples include:
Investment in a Water Bio treatment plant to significantly improve the quality of
effluent water leaving the refinery to a quality that supports aquatic life;
Installation of Vapour recovery facilities on road, rail and ship loading facilities to
virtually eliminate displacement of hydrocarbons vapour into the atmosphere
during loading operations
Specialised anti-pollution equipment is provided at both TOTAL LOR and APT,
including a rapid response vehicle equipped with oil boom, oil skimmers,
dispersants etc. TOTAL LOR and APT provide mutual support backup in the
event of an external oil contamination.
TOTAL UK Ltd is a participant in Oil Spill Response Ltd. (OSRL) based in Southampton.
This internationally recognised organisation provides specialised personnel equipment to
assist in dealing with oil spills.
All employees receive environmental awareness training, initially on induction and, where
appropriate, to meet job description requirements. Relevant personnel (Fire, Safety and
Tank Farm supervision) receive specialist training in dealing with water effluent pollution.
The site conforms to Waste Duty of Care Regulations and has an Environment Agency
Authorisation, which includes strict emission limits for Air and Water.
All effluent and surface waters pass through the effluent treatment plant before discharge
into the River Humber
TOTAL LOR also conforms to the Environmental Protection Act 1990 Part 1:
Authorisation of Process and the Petrol Vapour Recovery Regulations of 1996.
There are a total of 10 environmentally significant sites in the surrounding area including
six aquatic Sites of Special Scientific Interest.
We actively support a variety of local organisations to develop and protect the historical,
cultural and natural environment of Lincolnshire. For example, TOTAL LOR is
represented on the Advisory Environmental Group (EA Committee for Lincolnshire) and

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the Humber Estuary Shoreline Management Plan Committee. TOTAL LOR is also a
corporate member of the Lincolnshire Wildlife Trust.

Fire fighting

RESOURCES - Our fire fighting resources are shared jointly with the neighbouring
ConocoPhillips Refinery with the equipment, water storage and pumps on the TOTAL
LOR site.
A fire crew of 10 fully trained personnel mans each shift. Among the 10 strong team is
incorporated a professional fire fighter and a safety officer who have the responsibility of
leading the team. In total there are 5 teams of 10 personnel to cover all shift patterns.
All Shifts receive basic first intervention fire training.
TOTAL LOR maintains an up-to-date extensive range of fire-fighting equipment including:
2 foam tenders, 4 rapid deployment self contained foam storage delivery units, 1
water/foam tender, 1 initial response vehicle equipped with fire and emergency
equipment, including breathing apparatus, fire hoses, rescue equipment, additional foam
and specialised personal protective equipment.
ALARMS - There are a variety of alarms on site including fire, gas and all clear alarms. In
addition there are local alarms adjacent to specific areas warning of local gas escapes.
The alarms are tested weekly.
Both TOTAL LOR and ConocoPhillips also have a community alarm which is designed to
alert the villages of North and South Killingholme to any emergency situation, which may
affect them. This alarm can be initiated by either ConocoPhillips or TOTAL LOR and
sounds the alarms installed on both refineries. This alarm is tested twice per year.
As part of COMAH regulations information is provided to the local public on what actions
to take in the event of an offsite emergency. Both refineries have also established a free
phone 0800 number from which emergency community information can be obtained. Up
to 2000 people can access this recorded information at any one time.
HUMBERSIDE FIRE BRIGADE - has a station 2.5 km (1.5 miles) from TOTAL LOR with
a response time of approximately four minutes. Additional support would be provided by
their cascade system. Road access links to the refinery are very good
EMERGENCY PLAN AND EVACUATION PROCEDURE TOTAL LOR has an onsite
emergency plan detailing the actions to be taken by individuals in the event of various
envisaged site emergencies. These instructions cover site evacuation. Depending upon
location, there are 3 alternative evacuation routes each with safe refuges at the boundary
of the refinery. It is estimated that evacuation could be achieved within 10 minutes.
On average, staff carry out 2 emergency drills per annum. Regular exercises are carried
out involving the local fire brigade. The onsite emergency plan is tested annually.

Medical

A full-time Occupational Health Adviser, and a part time nurse and doctor are employed.
They are available on call outside office hours.
TOTAL LOR has two ambulances on site, which are driven by qualified first aid staff when
required.
There are 140 qualified first aid trained staff, at TOTAL LOR. The minimum number, for
example, on a night shift is between 20-25. Retraining and independent certification is
carried out every three years.
The nearest hospitals are the Diana, Princess of Wales in Grimsby 12 miles away and
Scunthorpe Hospital 25 miles away.

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