Occupational Hygiene in the Oil Gas Industry Day

Occupational Hygiene in the Oil & Gas Industry Day 3 – Section 12 Distribution to the supply network Terminals, Lube Oil Blend Plants, Depots 1. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Distribution Terminal 2. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Bottom loading – fill lines and vapour line 3. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Vapour Recovery Unit - VRU 4. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Drum Loading Fuel & Solvent Drum Filling 200 litre drum nominal standard size, formerly 44 Imperial gallon drum, or in the US known as the 50 (or 55) US Gallon drum. ) 5. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Drum filling using a stub High potential exposure via inhalation and skin contact. Note: no vapour extraction 6. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Vapour extraction systems 7. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Drum fill (200 L) line 8. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Packaged Goods • Small containers 20 L, 5 L, 1 L, for domestic market • Usually automated line, mostly lubes and solvents, pre-labelled containers • Little exposure to VOC, • Noise of empty cans or pneumatic handling systems Air silencer 9. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Rail Tank Car Loading • Daily loading schedules vary considerably; operators generally do this task for only several hours per day. • During top or bottom loading of rail cars, operators exposure to gasoline vapours at gantry level during opening /closing hatches and checking fill levels. • At the track level, exposures can occur in the connection/disconnection of hoses. • Exposures varies greatly depending on degree of enclosure and automation, volumes filled, ambient weather conditions, and any occasional spills. • Every effort should be made to avoid standing in the vapour plume. 10. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Marine Loading/Discharge – Ships, Barges • Wharf operations – loading by hose or Chiksan arm • “Open” Loading - tank tops, ullage ports, dip hatches are left open. Displaced hydrocarbon vapours are vented near the deck level. Crew can be exposed during connection/disconnection of product lines, or when leaning over open hatches to check fill levels, and during tank dipping • “Closed” Loading - automatic ullage measurement installed, ullage ports and hatches kept closed. Displaced vapours are vented at a remote point. Manual ullage measurements, and tank samples taken through open hatch. 11. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Lube Oil Blend Plant (LOBP) • Base oils are mixed with additives to produce finished Lube Oils – Castrol, BP, Mobil, Valvoline • LOBP - blend troughs (with or without extraction), heating ovens for additives, filling lines, warehouse, forklifts. • Some lube additives can decompose with excessive heat and produce noxious sulphur compounds 12. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Lube Oil Blend Plant (LOBP) • Issues – Noise, manual handling, skin exposure to additives, fumes, dust, oil mist during air blowing of lines, insulated lines, steam. • Product sold in 200 L drums for large industrial uses, 20 L for small industrial users, 5 L for domestic users and retail market 13. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Grease Manufacture • Grease manufactured in pressurised, heated kettles. • Raw materials - base lube oils, additives, thickeners, Calcium Base, Soda Base, Aluminium Base, Lithium Base, Complex Soaps. • Main issues – – manual handling of the additives (usually in 200 L drums), handling of heavy hoses, fugitive emissions from the kettles. additives and their decomposition products (refer to suppliers’ MSDS). – noise from the pumps, heat from the kettles 14. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Waste Product Recovery • Terminal Waste Treatment Facilities • All terminals and depots have stormwater runoff and oil recovery facilities to treat waste petroleum products from spills, overflows, wash-downs, tank bottom draining, etc. • Similar to refinery but on a smaller scale, waste oil recovery skimmer and water treatment. The waste oil is pumped to the slops tank. 15. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Waste Product Recovery • Waste recovery- emptying road tanker contents for change of service • Emptying damaged or leaking drums • Return of product from pump-out of customers tanks e. g. service station tanks (due to leakage, contamination, change of service). • Slops are blended off into finished products, returned to refinery for reprocessing, or sold off to waste recovery/recycling companies. 16. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

LPG Terminal and Filling Plants • LPG receiving bay, storage bullets or spheres, a cylinder filling carousel and a loading bay. • Filling line may contain radiation (gamma) level gauges for the filling operation. • Gas cylinder refurbishing operations - includes grit blasting and spray painting. • Utilities - pumps and compressors 17. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Coastal Bulk Plant (CBP) 18. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Depots 19. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Depot fill stand Top Spear Loading Gasoline & Diesel 20. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Other Potential Hazards Moisture forming ice on LPG line due to cooling of line from expanding LPG Liquid 21. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Bad products, working conditions, and supervision 22. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Poor work conditions 23. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Poor work conditions – bad design 24. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Occupational Hygiene Issues a) Hazardous Substances – Finished petroleum products this requires a chemical inventory and MSDS information – Purchased chemicals and products – treatment chemicals, additives, cleaning agents - this requires a chemical inventory and MSDS information – Generated hazardous substances such as welding fume, oil mists – Generated waste and waste disposal b) Thermal Environment - general environment & location [Grease plants use heated pressurised kettles] 25. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Occupational Hygiene Issues c) Noise - fire pumps, filling lines, pumps, vehicles, maintenance activities. Utilities boilers, compressors, and generators. d) Asbestos and Other Fibres: Insulation (acoustic and thermal) e) Ergonomic hazards associated with any facility f) Radiation: Ionizing, Non-ionizing, Lighting g) Maintenance Hazards. includes confined spaces hazards. h) Other Hazards – Generally terminals and depots are located in populated areas close to customers i) Environmental hazards 26. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Health Hazards of Some Petroleum Operations Tank Cleaning - Hydrocarbons, Noise, lead (alky lead), PAH (oils), confined spaces, ergonomics (manual handling), hydro blasting and water washing tanks. Use of compressed air (breathing air) Tank repairs - Hydrocarbons, Noise, lead (alky lead), lead based paints, epoxy paints, confined spaces, welding fumes, dust Repair of tank floors, grinding, welding, grit blasting, repainting internals Maintenance/Workshop - Cleaning chemicals, carbon monoxide 27. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Health Hazards of Some Petroleum Operations Warehouse operations - CO, forklifts, ergonomics (manual handling) movement of drums, loading trucks Waste product recovery, drum cleaning - Hydrocarbons, Noise, ergonomics (manual handling) Fuel Testing Laboratory - Hydrocarbons, Noise, ergonomics (manual handling), alkyl lead, chemicals, Engine laboratory (knock engine operators), lab technicians/chemists 28. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Health Hazards of Some Petroleum Operations Boiler house - Noise, Asbestos insulation, SMF insulation, Water treatment chemicals Cooling towers - Water treatment chemicals, Legionella Waste water treatment - Water treatment chemicals, hydrocarbons Drum fill operations - Hydrocarbons, Noise, ergonomics (manual handling) – Various types of filling Tank truck fill operations & driving - Hydrocarbons, Noise, ergonomics (manual handling), driver fatigue – Various types of loading Rail car fill operations - Hydrocarbons, Noise, ergonomics (manual handling) – Various types of loading Ship loading operations - Hydrocarbons, Noise, ergonomics (manual handling) - Various types of loading 29. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

End of Section 12 Distribution 30. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry