1. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas...

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


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


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/daySmallest <50,000 Bbls/day (<8 million Litres/day to

Largest 1,000,000 Bbls/day (180 million Litres/day)


Storage Tank Farm

Crude Oil Tank Farm

Process units

Effluent ponds

Storage Tank Farm

Crude Oil Tank Farm

Process units

Effluent ponds

Typical Layout of Fuels Refinery


Sulphur Recovery Unit

Fluidized Catalytic Cracker (FCC)

Alkylation Unit

Plat ReformerNaphtha Fractionation & Plat Reformer, Benzene Reduction Unit

Thermofor Catalytic Cracker (TCC)

Crude Distillation Unit

Saturated Gas PlantBitumen plant


LPG Storage

Co

ol in

g T

ow

ers

Gas spheres

Catalytic Hydro-desulphurisation Unit (CHD)

MaintenanceWorkshops

Laboratory

Fuels Refinery Layout – Process Units



Alkylation Unit






LPG Storage

Co

ol in

g T

ow

ers

Gas spheres



Laboratory



Alkylation Unit






LPG Storage

Co

ol in

g T

ow

ers

Gas spheres



Laboratory

Fuels Refinery Layout – Process Units

Typical Layout of Fuels Refinery Process Units


PROCESS FLOW – FUELS REFINERYDISTILLATION

• 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


Distillation FractionsCarbon

Number

Boiling Range Name

Deg. C Deg. F

C1-C4 <0 <30 Gas

C4-C12 0-200 30-392 Naphtha

C12-C15 200-300 392-572 Kerosene, Jet Fuel

C15-C25 300-400 572-750 Gas Oil, Heating Oil, Diesel

>C25 >400 >750 Bottoms, Residuum, Vacuum

Distillation Feedstock


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


FCC Unit showing the Large Reactor and Fractionating Towers


Small Fuels Refinery


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.


Lube Oil Refinery Process Flow

Vacuum Distillation

FurfuralExtraction

MEKDewaxing

Hydro-Finishing

Catalytic dewaxing

PropaneDeasphalting

(PDA) Bitumen blendstocksVac TowerResidue

PDA Oil

Heavy Neutral

Medium Neutral

Light Neutral

Slack Wax

DWO

Light Neutral Base Oil

Medium Neutral Base Oil

Heavy Neutral Base Oil

Bright Stock


AtmosphericTowerResidue

Vacuum GasOil

Furfural Extracts

PDA Tar

Vacuum Distillation

FurfuralExtraction

MEKDewaxing

Hydro-Finishing

Catalytic dewaxing

PropaneDeasphalting

(PDA) Bitumen blendstocksVac TowerResidue

PDA Oil

Heavy Neutral

Medium Neutral

Light Neutral

Slack Wax

DWO

Light Neutral Base Oil

Medium Neutral Base Oil

Heavy Neutral Base Oil

Bright Stock


AtmosphericTowerResidue

Vacuum GasOil

Furfural Extracts

PDA Tar


Vacuum Distillation Furfural Extraction MEK Dewaxing

Vac Tower

Hydro-finishingLube Oil Refinery Layout


Vac Tower

Hydro-finishing


Vac Tower

Hydro-finishingLube Oil Refinery Layout


Process Name

Action &Purpose

Feedstock Product(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) H2S, 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


Fuel and Lube Processes

Refinery processes – broad categories• Fractionation Processes (Distillation)• Conversion Processes—decomposition• Conversion Processes—unification• Conversion Processes—alteration or

rearrangement• Treatment Processes


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, H2S, Mercaptans, Sulphur oxides, Gases

• Catalyst dust, Metal Carbonyls, Metal sulphides• Caustics, Amines, Acids (Sulphuric or Hydrofluoric,

or Phosphoric) Acid sludge• Heat, Noise, Insulation materials.


OH Issues For Gas Processing Plantsa) 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


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


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.


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


OH Issues (d) Asbestos and Other Fibres

Removal of asbestos insulation


OH Issues (e) Ergonomic

• Ergonomic hazards associated with any facility• Opening/closing valves – poor posture


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


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


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


OH Issues (i) Environmental Hazards

• Environmental hazards – earthquakes, hurricanes, flood, and fire


End of Section 8

Refineries

1. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas...

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