Occupational Hygiene in the Oil Gas Industry Day

Occupational Hygiene in the Oil & Gas Industry Day 1 – Section 8 Production Processes Oil Refineries 1. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Overview of Refining Processes – Fuel & Lubes Separation of crude oil into various fractions. • Gas – LPG (Propane, Butane) • Gasolines, Naphthas – Petrol, Avgas, Solvents • Kerosenes – Home kerosene, Jet Fuel, Light Heating Oils, Solvents • • • 2. Diesels – Automotive diesel fuel (ADO) Fuels oils – Bunker fuel Bitumens – Road making, other products Lube Oil Feedstock – production of Lube oils Petrochemical Feedstock – plastics production © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Refineries • • Refinery - land based, fixed installation Close to coast or river systems for shipping Connect to markets by pipelines Loading facilities to receive crude oil and feed stocks • Load-out facilities to distribute products • Crude supplied by ship, pipeline or rail car. • Capacity 100, 000 -300, 000 Bbls/day Smallest <50, 000 Bbls/day (<8 million Litres/day to Largest 1, 000 Bbls/day (180 million Litres/day) 3. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Typical Layout of Fuels Refinery 4. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Typical Layout of Fuels Refinery Process Units 5. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

PROCESS FLOW – FUELS REFINERY DISTILLATION • Atmospheric Crude (oil) Distillation unit – primary distillation of crude oil into fractions based on boiling range • - gas, naphtha, kerosenes, middle distillates (gas oils) and residual oils (‘bottoms’) • Vacuum Distillation – the secondary distillation of residual oils from atmospheric distillation to make feedstock for the Catalytic Cracker and feed stocks for bitumen plants or lube oil refining 6. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Distillation Fractions Carbon Number Boiling Range Name Deg. C Deg. F C 1 -C 4 <0 <30 C 4 -C 12 0 -200 30 -392 Naphtha C 12 -C 15 200 -300 392 -572 Kerosene, Jet Fuel C 15 -C 25 300 -400 572 -750 Gas Oil, Heating Oil, Diesel >400 >750 >C 25 Gas Bottoms, Residuum, Vacuum Distillation Feedstock 7. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

PROCESS FLOW – FUELS REFINERY CONVERSION PROCESSES • Catalytic Cracking unit (FCC), (TCC) - residual oils (bottoms) ‘crack’ heavy molecules into lighter fractions gas, naphtha, middle distillates (gas oils) and heavy oils. • Catalytic Reformers - low octane naphtha, change molecules in a hydrogen rich atmosphere to make high octane gasoline blend stocks • Alkylation Unit - light hydrocarbon gases (propylene, butylene with iso butane) combined to produce high octane (liquid) gasoline blend stocks, using Sulphuric or hydrofluoric, or phosphoric acid 8. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

FCC Unit showing the Large Reactor and Fractionating Towers 9. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Small Fuels Refinery 10. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

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PROCESS FLOW – LUBE REFINERY • Vacuum Distillation - to process atmospheric tower residues and remove the light components (gas oils). • Extraction Process (Furfural) - to remove poly aromatic hydrocarbons (PAH or PNA) • Methyl Ethyl Ketone dewaxing - to remove wax • Hydrofinishing Unit - to remove unsaturated hydrocarbons leaving a finished lubricating base oil of various grades. 13. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Lube Oil Refinery Process Flow 14. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

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Understand the Process, Products and the Hazards Process Name Action & Purpose Atmos. distillation Vacuum distillation 17. Product(s) Potential Health Hazards Separation – Desalted Thermal, crude oil Separate fractions Gas, naphtha, gas oil, distillate, residual Hydrocarbons. (Paraffinic, Olefinic, Naphthenic, Aromatic, PAH, Carbon (Coke) H 2 S, Mercaptans. Heat, Noise, Insulation materials Separation – Thermal, Separate without cracking Gas oil, lube Hydrocarbons, (Paraffinic, stock, Olefinic, Naphthenic, residual Aromatic, PAH, Carbon (Coke). Heat, Noise, Insulation materials © 2013 Petroch Services Pty Ltd Feedstock Atmos. tower residual BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Fuel and Lube Processes Refinery processes – broad categories • Fractionation Processes (Distillation) • Conversion Processes—decomposition • Conversion Processes—unification • Conversion Processes—alteration or rearrangement • Treatment Processes 18. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

Petroleum Refining (Fuel & Lube) Processes and Their Potential Health Hazards • Hydrocarbons. (Paraffinic, Olefinic, Naphthenic, Aromatic, Benzene, PAH, Carbon (Coke), Aromatic oils, PAH (boiling point >385 deg C) • Hydrogen, Carbon Monoxide, Carbon Dioxide, H 2 S, Mercaptans, Sulphur oxides, Gases • Catalyst dust, Metal Carbonyls, Metal sulphides • Caustics, Amines, Acids (Sulphuric or Hydrofluoric, or Phosphoric) Acid sludge • Heat, Noise, Insulation materials. 19. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues For Gas Processing Plants a) b) c) d) e) f) g) h) i) 20. Hazardous Substances Thermal Environment Noise Asbestos and Other Fibres Ergonomic Radiation Maintenance & Turnaround Hazards Other Hazards Environmental hazards © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (a) Hazardous Substances • Process streams and contaminants – crude oil, natural gas, (condensate), Mercury, Hydrogen sulphide and sulphur compounds • Purchased chemicals and products – catalysts, treatment chemicals (amines, caustic) - this requires a chemical inventory and MSDS information • Generated substances e. g. welding fume, catalyst dust • Generated waste and waste disposal • Odour control - envirronmental 21. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (b) Thermal Environment • General environment & location • Refineries usually located on land in populated arreas relatively close access to shipping and/or pipelines. This can be in cold or hot climates. 22. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (c) Noise • Noise from process units, utilities and maintenance activities • High noise sources are heaters, compressors and generators (typically >105 d. BA) however with modern designs and improved engineering the refineries may be able to achieve noise levels < 85 d. BA • Community noise becomes an issue 23. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (d) Asbestos and Other Fibres Removal of asbestos insulation 24. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (e) Ergonomic • Ergonomic hazards associated with any facility • Opening/closing valves – poor posture 25. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (f) Radiation • Ionizing – Radiation – level measurement, radiography • Non-Ionizing Radiation- Visible – Lighting • UV radiation (sun, welding) • NORM (Naturally Occurring Radioactive Material) usually not a significant problem in refineries as nearly all the NORM has been retained in upstream gas plants near the crude oil source 26. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (g) Maintenance & Turnarounds • Planned and unplanned shutdowns • Potential release of product • Inspection of process equipment both external and internal – confined space entry • Turnarounds – Increased workforce – trained & untrained – Untrained and unskilled workforce need training on O&G hazards 27. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (h) Other Hazards • Location hazards – on land, insects, disease (Cholera, Malaria, HIV) • Legionella (from cooling towers) • Civil Unrest - stability of government • Security of site. • Generally refineries are located in populated areas, therefore the hazards associated with remote and isolated operations do not apply. However other subjects come into consideration – public safety, site security, community impact - environmental 28. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

OH Issues (i) Environmental Hazards • Environmental hazards – earthquakes, hurricanes, flood, and fire 29. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry

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End of Section 8 Refineries 31. © 2013 Petroch Services Pty Ltd BP Version J 11002– Occupational Hygiene in the Oil & Gas Industry