Transcript Slide 1

Occupational Hygiene in the
Oil & Gas Industry
Day 3 – Section 12
Distribution to the supply network
Terminals, Lube Oil Blend Plants,
Depots
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Distribution Terminal
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Bottom loading – fill lines and vapour line
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Vapour Recovery Unit - VRU
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BP Version J11002– 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.)
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Drum filling using a stub
High potential exposure via
inhalation and skin contact.
Note: no vapour extraction
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Vapour extraction systems
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Drum fill (200L) line
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Packaged Goods
• Small containers 20L, 5L, 1L, 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
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BP Version J11002– 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.
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BP Version J11002– 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.
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BP Version J11002– 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
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BP Version J11002– 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 200L drums for
large industrial uses, 20L for
small industrial users, 5 L for
domestic users and retail market
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BP Version J11002– 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
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–
–
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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
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BP Version J11002– 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.
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BP Version J11002– 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.
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BP Version J11002– 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
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Coastal Bulk
Plant (CBP)
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Depots
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Depot fill stand
Top Spear Loading Gasoline & Diesel
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BP Version J11002– 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
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Bad products, working conditions, and
supervision
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Poor work conditions
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Poor work conditions – bad design
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BP Version J11002– 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]
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BP Version J11002– 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
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BP Version J11002– 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
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BP Version J11002– 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
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BP Version J11002– 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
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
End of Section 12
Distribution
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry