Oil amp Gas Industry Day 3 Section 12 Distribution to the supply network Terminals Lube Oil Blend Plants Depots Distribution Terminal Bottom loading fill lines and vapour line ID: 437221
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Slide1
Occupational Hygiene in the
Oil & Gas Industry
Day
3
– Section
12
Distribution
to the supply network
Terminals, Lube Oil Blend Plants,
DepotsSlide2
Distribution TerminalSlide3
Bottom loading – fill lines and vapour lineSlide4
Vapour Recovery Unit -
VRUSlide5
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.) Slide6
Drum filling using a stub
High potential exposure via inhalation and skin contact. Note: no vapour extractionSlide7
Vapour extraction systemsSlide8
Drum fill (200L) lineSlide9
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 silencerSlide10
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.Slide11
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.Slide12
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
compoundsSlide13
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
marketSlide14
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 kettlesSlide15
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. Slide16
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. Slide17
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 compressorsSlide18
Coastal Bulk
Plant (CBP)Slide19
DepotsSlide20
Depot fill stand
Top Spear Loading Gasoline & DieselSlide21
Other Potential Hazards
Moisture forming ice on LPG line due to cooling of line from expanding LPG LiquidSlide22
Bad products, working conditions, and supervisionSlide23
Poor work
conditionsSlide24
Poor work conditions – bad designSlide25
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
Thermal Environment -
general environment & location
[Grease plants use heated pressurised kettles] Slide26
Occupational Hygiene Issues
Noise
-
fire pumps, filling lines, pumps, vehicles, maintenance activities. Utilities boilers, compressors, and generators.
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
hazardsSlide27
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
monoxideSlide28
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/chemistsSlide29
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 loadingSlide30
End of
Section 12
Distribution