Montreal Refinery Horizon Project: Delayed Coking Unit

Presentation for Occupational Hygiene Association March 26, 2008 Colleen Stevenson MHSc, CIH, ROH

AGENDA

1. Purpose of Presentation 2. What is the Horizon Project?

• What is a Delayed Coking Unit?

3. EH&S Deliverables on the Project 4. Examples of Interesting Issues

Purpose of this Presentation

To share my EH&S experiences on a large scale project.

Why?

– – – To share learnings and network with others who may be doing something similar To demonstrate how EH&S professionals can be involved in the design of a facility to mitigate EH&S risks prior to operation To validate that the IH education/experience provides a background that positions us well for any disciplines within EH&S field

The Horizon Project- an upgrade to Montreal Refinery

• • Involves the construction of a delayed coking unit (DCU) or a “coker” Involves the revamp of process units and offsites & utilities – – – – When its all said and done: – 271 Pieces of Equipment – 96 Km of Pipe – – 9000 Tonnes sof Steel 29,400 Cubic Metres of Concrete 800 Km of Cable and Wire ~$1,000,000,000 Dollars 6,400,000 Man-hours People • Petro-Canada, Bantrel (Engineering Procurement, Construction Management firm), contractors, subcontractors

Montreal Refinery-Coker Simulation Picture

The Challenges

1.

2.

3.

4.

5.

6.

Language Safety Culture in Quebec Cost Constraints Tight construction schedule Largest Downstream project Working with an EPCM on such a project

What the Heck is a Coker?

• The benefit of a delayed coking unit is that it allows the refinery to use a lower cost crude; • It makes more valuable products like gasoline and distillates vs lower margin products like asphalt and heavy fuel oil; • reduces our imports of gasoline/distillates

Simple Coker Block Flow Diagram Coke Drum Coke Drum Vacuum Tower Bottoms/Asphalt Extraneous Feeds Off gas Light naphtha Heavy naphtha Kero Distillate Gas Oil Charge Heater Coke

My Involvement/EH&S Deliverables Refinery Site

1.

Involvement with Certificate of authorization process and stakeholder engagement 2.

Involvement with design for the whole project – – Ensure design meets regulatory compliance and internal practices Meet deliverables for project management system 3. Involvement with on site safety/prevention program and construction – Creating the H/S Program including details around CSST Principle Contractor issues – – – – HSE resources on site to support the project Setting expectations with Sr. Management of Contractors to understand their H/S programs Creation of Metrics Stewardship

TME (Port)

– Storage area for coke at the Port of Montreal – Involvement with self assessment – Monitoring Canterm and C of A process

Marsulex (Sulphur Plant)

– plant next door that takes our H2S laden streams and converts it to sulphur (its the sulphur plant for Shell and PC) – Review t of expansion options and impact on emissions – Walk through and preliminary review of safety program

Assessments To Support Permits or Stakeholder Engagement

• Dispersion modeling for combustion emissions using by law 90 equation for permit • Additional dispersion modeling and deposition modeling using Aermod for PM 10 and 2.5um

• Baseline noise survey and then modeling estimate of new coker impact (occupational and community risk) • Community Risk/Impact Assessment • Soil Assessment for classification and occupational hazard risk • Economic Impact Assessment

Environmental Emission Impact Summary of air emissions (M T/ Y)

Carbon monoxide (CO) Sulphur dioxide (SO2) Nitrogen oxide (NOx) Volatile organic compound (VOC) Particulates Benzene

CO 2 Equivalent (KMT / Y)

CO 2 Equivalent

Refinery Post Coker

2000 2005 2010 Differences 2010 vs 2005 656 5,079 538 3,469 616 3316

14.5% -4.4%

1,705 1,021 1,260 865 1322 541

4.9% -37.5%

402 26 315 18 312 5

-1.1% -72 %

1,281 1,231 1124

-8.7%

Vapour recovery project for ship loading will reduce benzene emissions

Interesting Issues

1.

PM 10 and PM 2.5 emission modelling 2.

3.

• Noise- City by-law 50 dBA; Quebec MDDEP, 40 dBA or ambient (43 dBA) Ongoing modelling to determine predictive compliance – Tank Dykes Current gas oil and Sour Water W tank dyke capacity constraints – New SW tank will be added as part of project 4.

Coker foundation work next to live butane spheres

Coke Handling and Particulate Emissions

Coke Drum Wet Coke Pile Wate r spra ys Drop to Storage Pile 30 ft.

Coke Storage Piles (2) Drop to Loading Bin Wate r spra ys Drop to Receiving Hopper Wate r spra ys C on ve yo r Truck Loading Process Flow Sketch For Coke handling Petrocanada Delayed Coker December 22, 2006 By: J. Hill There are emission factors related to all coke handling sources.

Credit for controlling emissions is taken.

Final emission releases are calculated and then placed in a dispersion model to determine impact to the community

PM 2.5 particulate emissions in community

Draft Air Quality Regulation stipulates 24 hr average of 30 ug/M3 Results from new coker unit and existing plant indicate 1.8 ug/M3 However background of City at closest air monitoring stations is 32 ug/M3

Sour Water and Gas Oil Tanks

Concerns included: 1) Dyke capacity 2) H2S concentrations in the event of catastrophic release

Coker Foundation Work Close to Butane Spheres

• Significant schedule delays if coker foundation work is not started this year • Live butane spheres • Current berm around spheres needs to be removed and recontoured • Then rock removal 3-4’ • Then build barrier wall • Then start foundation work • It would appear that this is a significant risk but how much?

• We engaged Ertugral Alp-risk consultant

Summary

• The education and experience in IH has left me well positioned to understand and manage effectively, the complexities of this large scale project

Back up Slides

Project Management Deliverables

C1.2

C1.2.1

Site Information

Site Characteristics - Available vs Required C1.2.2A Dismantling & Demolition C1.2.3

C1.2.4

Lead / Disciplines Selection & Scope Comprehension Site Location C1.2.5

C1.2.6

Geotechnical Surveys Environmental Impact Assessment C1.2.7

Permits and Licenses (PDM 3.29) C1.2.8

C1.2.9

Utility sources w/supply conditions Fire protection & safety considerations

E2

E2.1

E2.2

HS&E PLAN

HSE & S Process and Objectives HSE Management system E2.3

Obligations: Owners, Employers, Workers, etc.

E2.4

Prime Contractor / Multiple Obligations E2.5

Leadership Roles and RACI E2.6

Training and Education E2.7

Awareness & Recognition Program E2.8

E2.9

Inspection & Audits Occupational Health Program E2.10

Environmental Management Program E2.11

Emergency Plan E2.12

E2.13

Accident / Incident Investigation & Reporting Security E2.14

Safety Communications E2.15

Policies, Procedures, Standards, Practices