Montreal Refinery Horizon Project: Delayed Coking UnitPresentation for Occupational Hygiene Association March 26, 2008

Colleen Stevenson MHSc, CIH, ROH

AGENDA 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 PresentationPurpose 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 RefineryThe 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 PictureMontreal Refinery-Coker Simulation Picture

The ChallengesThe Challenges

1. Language

2. Safety Culture in Quebec

3. Cost Constraints

4. Tight construction schedule

5. Largest Downstream project

6. Working with an EPCM on such a project

What the Heck is a Coker?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 DiagramSimple Coker Block Flow Diagram

Off gas

Light naphtha

Heavy naphtha

Distillate

Gas Oil

Vacuum Tower Bottoms/Asphalt

Coke

Coke Drum

Coke Drum

Fra

ctio

nat

or

Charge Heater

Kero

Extraneous Feeds

My Involvement/EH&S DeliverablesMy Involvement/EH&S Deliverables

Refinery Site 1. Involvement with Certificate of authorization process and stakeholder engagement2. 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 EngagementAssessments 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 ImpactEnvironmental Emission Impact

Summary of air emissions (M T/ Y)

Refinery Post Coker

2000 2005 2010Differences

2010 vs 2005

Carbon monoxide (CO) 656 538 616 14.5%

Sulphur dioxide (SO2) 5,079 3,469 3316 -4.4%

Nitrogen oxide (NOx) 1,705 1,260 1322 4.9%

Volatile organic compound (VOC) 1,021 865 541 -37.5%

Particulates 402 315 312 -1.1%

Benzene 26 18 5 -72 %

CO2 Equivalent (KMT / Y)        

CO2 Equivalent 1,281 1,231 1124 -8.7%Vapour recovery project for ship loading will reduce benzene

emissions

Interesting IssuesInteresting Issues

1. PM 10 and PM 2.5 emission modelling

2. Noise- City by-law 50 dBA; Quebec MDDEP, 40 dBA or ambient (43 dBA)

• Ongoing modelling to determine predictive compliance

3. 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 EmissionsCoke Handling and Particulate Emissions

Coke Drum

Truck Loading

Drop to Storage Pile

Drop to Receiving Hopper

Drop to Loading Bin

Wet Coke Pile

CokeStorage Piles (2)

Process Flow SketchFor Coke handling

Petrocanada Delayed CokerDecember 22, 2006

By: J. Hill

30 ft.

Water

sprays

Water

sprays

Water

sprays

Conve

yor

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 communityPM 2.5 particulate emissions in community

Draft Air Quality Regulation stipulates 24 hr average of 30 ug/M3Results from new coker unit and existing plant indicate 1.8 ug/M3However background of City at closest air monitoring stations is 32 ug/M3

Sour Water and Gas Oil TanksSour Water and Gas Oil Tanks

Concerns included:1) Dyke capacity2) H2S concentrations in the event of catastrophic release

Coker Foundation Work Close to Butane SpheresCoker 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

SummarySummary

• 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 SlidesBack up Slides

Project Management DeliverablesProject Management Deliverables

E2 HS&E PLANE2.1 HSE & S Process and ObjectivesE2.2 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 Inspection & AuditsE2.9 Occupational Health Program

E2.10 Environmental Management Program

E2.11 Emergency Plan

E2.12 Accident / Incident Investigation & ReportingE2.13 Security

E2.14 Safety Communications

E2.15 Policies, Procedures, Standards, Practices

C1.2 Site InformationC1.2.1 Site Characteristics - Available vs Required

C1.2.2A Dismantling & Demolition

C1.2.3 Lead / Disciplines Selection & Scope ComprehensionC1.2.4 Site Location

C1.2.5 Geotechnical Surveys C1.2.6 Environmental Impact Assessment

C1.2.7 Permits and Licenses (PDM 3.29)

C1.2.8 Utility sources w/supply conditionsC1.2.9 Fire protection & safety considerations