1. 1. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Occupational Hygiene in the Oil & Gas Industry Day 1 – Section 8 Production Processes Oil Refineries

2. 2. © 2013 Petroch Services Pty Ltd BP Version J11002– 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 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

3. 3. © 2013 Petroch Services Pty Ltd BP Version J11002– 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 1,000,000 Bbls/day (180 million Litres/day)

4. 4. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Typical Layout of Fuels Refinery

5. 5. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Typical Layout of Fuels Refinery Process Units

6. 6. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

7. 7. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Distillation Fractions Carbon Number Boiling RangeName Deg. CDeg. F C1-C4<0<30Gas C4-C120-20030-392Naphtha C12-C15200-300392-572Kerosene, Jet Fuel C15-C25300-400572-750Gas Oil, Heating Oil, Diesel >C25>400>750Bottoms, Residuum, Vacuum Distillation Feedstock

8. 8. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

9. 9. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry FCC Unit showing the Large Reactor and Fractionating Towers

10. 10. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Small Fuels Refinery

11. 11. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry

12. 12. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry

13. 13. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry 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.

14. 14. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Lube Oil Refinery Process Flow

15. 15. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry

16. 16. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry

17. 17. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Process Name Action & Purpose FeedstockProduct(s)Potential Health Hazards Atmos. distillation Separation – Thermal, Separate fractions Desalted crude oil Gas, naphtha, gas oil, distillate, residual Hydrocarbons. (Paraffinic, Olefinic, Naphthenic, Aromatic, PAH, Carbon (Coke) H 2 S, Mercaptans. Heat, Noise, Insulation materials Vacuum distillation Separation – Thermal, Separate without cracking Atmos. tower residual Gas oil, lube stock, residual Hydrocarbons, (Paraffinic, Olefinic, Naphthenic, Aromatic, PAH, Carbon (Coke). Heat, Noise, Insulation materials Understand the Process, Products and the Hazards

18. 18. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

19. 19. © 2013 Petroch Services Pty Ltd BP Version J11002– 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.

20. 20. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues For Gas Processing Plants a) Hazardous Substances b) Thermal Environment c) Noise d) Asbestos and Other Fibres e) Ergonomic f) Radiation g) Maintenance & Turnaround Hazards h)Other Hazards i) Environmental hazards

21. 21. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

22. 22. © 2013 Petroch Services Pty Ltd BP Version J11002– 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.

23. 23. © 2013 Petroch Services Pty Ltd BP Version J11002– 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 dBA) however with modern designs and improved engineering the refineries may be able to achieve noise levels < 85 dBA Community noise becomes an issue

24. 24. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (d) Asbestos and Other Fibres Removal of asbestos insulation

25. 25. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (e) Ergonomic Ergonomic hazards associated with any facility Opening/closing valves – poor posture

26. 26. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

27. 27. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

28. 28. © 2013 Petroch Services Pty Ltd BP Version J11002– 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

29. 29. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (i) Environmental Hazards Environmental hazards – earthquakes, hurricanes, flood, and fire

30. 30. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry

31. 31. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry End of Section 8 Refineries