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Oil refinery safety

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Published by SALUS

Toolbox Talk: Oil Refinery Safety: Hazard Awareness and Control

Date: [DATE] Duration: [DURATION] minutes Presenter: [PRESENTER NAME] Location: [LOCATION]

Objective

The objective of this toolbox talk is to increase awareness of the hazards present in oil refineries and to provide practical guidance on implementing control measures to minimize risks and ensure a safe working environment.

Introduction

Oil refineries are complex industrial facilities with numerous inherent hazards. It is crucial for all personnel to understand these risks and follow established safety procedures to prevent accidents and injuries. This toolbox talk will cover common hazards, control measures, and safe work practices specific to oil refineries.

Presenter Note: Engage the audience by asking if anyone has personal experience related to the topic.

Key Points

  • Hazard Identification: Recognizing potential hazards is the first step in preventing accidents. [1]
  • Control Measures: Implementing effective control measures reduces the likelihood of incidents. [1]
  • Safe Work Procedures: Following established procedures ensures tasks are performed safely. [1]
  • Personal Protective Equipment (PPE): Using appropriate PPE minimizes exposure to hazards. [1]
  • Emergency Procedures: Knowing how to respond in an emergency can save lives. [1]

Hazard Identification

Oil refineries contain a variety of hazards that can lead to serious incidents. [1]

  • Flammable Materials: Refineries handle large quantities of flammable liquids and gases, increasing the risk of fires and explosions. [2]
  • Chemical Exposure: Workers may be exposed to hazardous chemicals through inhalation, skin contact, or ingestion, leading to health problems. [3]
  • Confined Spaces: Entering confined spaces without proper precautions can result in asphyxiation or exposure to toxic substances. [4]

Presenter Note: Encourage participants to share any additional hazards they've encountered.

Control Measures

To mitigate the identified hazards, the following control measures should be implemented:

  • Engineering Controls: Use process enclosures, local exhaust ventilation, or other engineering controls to keep worker exposure to airborne contaminants below any recommended or statutory limits [5]. Use explosion-proof ventilation equipment [5].
  • Administrative Controls: Develop and enforce safe work procedures, conduct regular safety training, and implement a permit-to-work system for hazardous tasks. [1]
  • Personal Protective Equipment (PPE): Provide and require the use of appropriate PPE, such as respirators, gloves, eye protection, and flame-resistant clothing. [1]
  • Hygiene Measures: Workers should wash hands and face thoroughly after handling chemical products, before eating, smoking, and using the lavatory and at the end of the working period [5]. Appropriate techniques should be used to remove potentially contaminated clothing [5].

Safe Work Procedures

  1. Follow Permit-to-Work Procedures: Ensure a permit is obtained and followed for all hazardous tasks. [1]
  2. Conduct Hazard Assessments: Before starting any task, assess the potential hazards and implement appropriate controls. [1]
  3. Use Lockout/Tagout Procedures: De-energize and isolate equipment before performing maintenance or repairs. [1]
  4. Monitor Atmospheric Conditions: Regularly monitor the air for flammable gases, oxygen levels, and toxic substances, especially in confined spaces. [1]
  5. Maintain Equipment: Regularly inspect and maintain equipment to prevent failures and leaks. [1]

Presenter Note: If possible, demonstrate the safe work procedure or use visual aids.

Personal Protective Equipment (PPE) Requirements

  • Eye Protection: Wear safety glasses with side shields or goggles to protect against chemical splashes and flying debris. [1]
  • Hand Protection: Use chemical-resistant gloves to prevent skin contact with hazardous substances. [3]
  • Respiratory Protection: Wear a respirator when working in areas with potential exposure to harmful gases or vapors. [3]

[Emphasize the importance of proper PPE use and maintenance]

Real-World Example or Case Study

[Provide a detailed description of a relevant real-world scenario or case study]

[Discuss what went wrong or right, and the lessons learned]

Presenter Note: Ask participants if they can relate this example to their own experiences.

Group Discussion

Discuss the following questions:

  1. What are the most common hazards you encounter in your daily work?
  2. How can we improve hazard identification and risk assessment processes?
  3. What additional training or resources would be helpful in enhancing safety?

Presenter Note: Encourage active participation and facilitate the discussion.

Emergency Procedures

[Outline the steps to take in case of an emergency related to the topic]

  1. Evacuate: In case of a fire, explosion, or chemical release, evacuate the area immediately. [1]
  2. Alert: Activate the emergency alarm and notify the control room. [1]
  3. First Aid: Provide first aid to injured personnel, if trained to do so. [6]
  4. Reporting: Report all incidents and near-misses to your supervisor. [1]

Questions and Answers

[Encourage participants to ask questions]

[Provide answers to common questions related to the topic]

  • Q: What should I do if I smell a gas leak?

A: Immediately report the leak to your supervisor and evacuate the area.

  • Q: How often should I inspect my PPE?

A: Inspect your PPE before each use and report any damage or defects.

  • Q: What is the proper procedure for entering a confined space?

A: A confined space entry permit is required, and the atmosphere must be tested before entry.

Summary

[Recap the main points covered in the toolbox talk]

  • Hazard awareness is crucial for preventing accidents.
  • Control measures must be implemented to minimize risks.
  • Safe work procedures must be followed at all times.
  • Proper PPE must be used and maintained.
  • Emergency procedures must be understood and followed.

Action Items

[List specific actions participants should take following this toolbox talk]

  1. Review and understand the site-specific safety procedures.
  2. Participate actively in safety training programs.
  3. Report all hazards, near-misses, and incidents to your supervisor.

Remember: Safety is everyone's responsibility. [1]

Report all hazards, near-misses, and incidents to your supervisor immediately.

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6 source record(s)

Sources used for this answer

[1] MAPEI - Type 1

Page 2

Open source document

Source excerpt

## 4. FIRST AID MEASURES (cont.) Wash immediately with water. In case of Ingestion: Do not induce vomiting, get medical attention showing the SDS and the hazard label. In case of Inhalation: Remove casualty to fresh air and keep warm and at rest. Most important symptoms/effects, acute and delayed Not available Indication of any immediate medical attention and special treatment needed Treatment: Not available (see paragraph 4.1) ## 5. FIRE-FIGHTING MEASURES Extinguishing media Suitable extinguishing media: Water. Carbon dioxide (CO2). Unsuitable extinguishing media: None in particular. Specific hazards arising from the chemical Do not inhale explosion and combustion gases. Burning produces heavy smoke. Hazardous combustion products: Not available Explosive properties: Not Relevant Oxidizing properties: Not Relevant Special protective equipment and precautions for fire-fighters Use suitable breathing apparatus. Collect contaminated fire extinguishing water separately. This must not be discharged into drains. Move undamaged containers from immediate hazard area if it can be done safely. ## 6. ACCIDENTAL RELEASE MEASURES Personal precautions, protective equipment and emergency procedures Wear personal protection equipment. Remove persons to safety. Do not allow to enter into soil/subsoil. Do not allow to enter into surface water or drains. Limit leakages with earth or sand. Methods and material for containment and cleaning up - Suitable material for taking up: absorbing material, organic, sand - Retain contaminated washing water and dispose it. ## 7. HANDLING AND STORAGE Precautions for safe handling Avoid contact with skin and eyes, inhalation of vapours and mists. Do not eat or drink while working. See also section 8 for recommended protective equipment. Conditions for safe storage, including any incompatibilities Keep away from food, drink and feed. Incompatible materials: None in particular. Instructions as regards storage premises: Adequately ven…

[2] MAPEI - Ker 909

Page 3

Open source document

Source excerpt

# Safety Data Sheet KER 909 (cont.) ## 6. ACCIDENTAL RELEASE MEASURES (cont.) Provide adequate ventilation. Use appropriate respiratory protection. Do not allow to enter into soil/subsoil. Do not allow to enter into surface water or drains. Limit leakages with earth or sand. ## Methods and material for containment and cleaning up Suitable material for taking up: absorbing material, organic, sand Retain contaminated washing water and dispose it. ## 7. HANDLING AND STORAGE ## Precautions for safe handling Avoid contact with skin and eyes, inhalation of vapours and mists. Exercise the greatest care when handling or opening the container. Use localized ventilation system. Don't use empty container before they have been cleaned. Before making transfer operations, assure that there aren't any incompatible material residuals in the containers. Contaminated clothing should be changed before entering eating areas. Do not eat or drink while working. See also section 8 for recommended protective equipment. ## Conditions for safe storage, including any incompatibilities Keep away from food, drink and feed. Incompatible materials: None in particular. Instructions as regards storage premises: Adequately ventilated premises. Storage temperature: Not available 8. EXPOSURE CONTROLS/PERSONAL PROTECTION Control parameters Community Occupational Exposure Limits (OEL) <table><tr><th rowspan="4">petroleum hydrocarbons; Stoddard Solvent CAS: 8052-41-3</th><th>OEL Type</th><th>Country</th><th>Occupational Exposure Limit</th></tr><tr><td>OSHA</td><td></td><td>Long Term: 2900 mg/m3 - 500 ppm</td></tr><tr><td>ACGIH</td><td></td><td>Long Term: 100 ppm CNS impairment;eye, kidney and skin damage;nausea;</td></tr><tr><td>ACGIH</td><td></td><td>Long Term: 100 ppm CNS impairment;eye, kidney and skin damage;nausea</td></tr><tr><td>free crystalline silica (Ø &gt;10 µ) CAS: [redacted postal code]-60-7</td><td>ACGIH</td><td></td><td>Long Term: 0.025 mg/m3 A2 - Suspected Human Carcinogen;lun…

[3] Henry 212 All-Purpose Sealant

Page 4

Open source document

Source excerpt

# HE212 - CRYSTAL-CLEAR ROOF PATCH Revision Date 08-Dec-2015 - Personal precautions, protective equipment and emergency procedures - Personal precautions - Other Information - Environmental precautions Environmental precautions ELIMINATE all ignition sources (no smoking, flares, sparks or flames in immediate area). All equipment used when handling the product must be grounded. Do not touch or walk through spilled material. Stop leak if you can do it without risk. - Water spray may reduce vapor; but may not prevent ignition in closed spaces. Prevent entry into waterways, sewers, basements or confined areas. Methods and material for containment and cleaning up Methods for containment - Methods for cleaning up ## Precautions for safe handling Advice on safe handling A vapor suppressing foam may be used to reduce vapors. Absorb or cover with dry earth, sand or other non-combustible material and transfer to containers. Use clean non-sparking tools to collect absorbed material. Dike far ahead of liquid spill for later disposal. ## 7. HANDLING AND STORAGE Ensure adequate ventilation, especially in confined areas. Keep away from heat, sparks, flame and other sources of ignition (i.e., pilot lights, electric motors and static electricity). Take precautionary measures against static discharges. Use spark-proof tools and explosion-proof equipment. All equipment used when handling the product must be grounded. Use with local exhaust ventilation. Use personal protective equipment as required. Do not breathe dust/fume/gas/mist/vapors/spray. ## Conditions for safe storage, including any incompatibilities Storage Conditions - Incompatible materials Keep tightly closed in a dry and cool place. Keep in properly labeled containers. Keep away from heat, sparks, flame and other sources of ignition (i.e., pilot lights, electric motors and static electricity). Keep containers tightly closed in a cool, well-ventilated place. Strong oxidizing agents. Strong acids. Str…

[4] Henry 505 FlashMaster Flashing Cement

Page 4

Open source document

Source excerpt

# HE505 - FLASHMASTER Revision Date 22-Nov-2015 Environmental precautions Environmental precautions Page 4/9 ## Methods and material for containment and cleaning up Methods for containment Prevent further leakage or spillage if safe to do so. Prevent product from entering drains. Do not flush into surface water or sanitary sewer system. Prevent further leakage or spillage if safe to do so. Methods for cleaning up ## 7. HANDLING AND STORAGE Dam up. Soak up with inert absorbent material (e.g. sand, silica gel, acid binder, universal binder, sawdust). Pick up and transfer to properly labeled containers. ## Precautions for safe handling Advice on safe handling Ensure adequate ventilation, especially in confined areas. Keep away from heat, sparks, flame and other sources of ignition (i.e., pilot lights, electric motors and static electricity). Take precautionary measures against static discharges. Use spark-proof tools and explosion-proof equipment. All equipment used when handling the product must be grounded. ## Conditions for safe storage, including any incompatibilities Storage Conditions Keep tightly closed in a dry and cool place. Keep in properly labeled containers. Keep away from heat, sparks, flame and other sources of ignition (i.e., pilot lights, electric motors and static electricity). Incompatible materials Strong oxidizing agents. Strong acids. Strong bases. ## 8. EXPOSURE CONTROLS/PERSONAL PROTECTION ## Control parameters Exposure Guidelines <table><tr><th>Chemical Name</th><th>ACGIH TLV</th><th>OSHA PEL</th><th>NIOSH IDLH</th></tr><tr><td>Asphalt 8052-42-4</td><td>TWA: 0.5 mg/m3 benzene soluble aerosol fume, inhalable fraction</td><td>-</td><td>Ceiling: 5 mg/m3 fume 15 min</td></tr><tr><td>Solvent naphtha, petroleum, medium aliphatic [redacted postal code]-88-7</td><td>-</td><td>TWA: 500 ppm TWA: 2900 mg/m3</td><td>-</td></tr><tr><td>Cellulose 9004-34-6</td><td>TWA: 10 mg/m3</td><td>TWA: 15 mg/m3 total dust TWA: 5 mg/m3 respirable f…

[5] Safety Data Sheet - Mineral Spirits

Page 6

Open source document

Source excerpt

# Section 8. Exposure controls/personal protection [kerosene] Absorbed through skin. TWAEV: 200 mg/m3 8 hours. ## Occupational exposure limits (Mexico) <table><tr><th></th><th>CAS #</th><th>Exposure limits</th></tr><tr><td>Light Aliphatic Hydrocarbon</td><td>[redacted postal code]-47-8</td><td>ACGIH TLV (United States, 1/2024). [Kerosene] Absorbed through skin. TWA: 200 mg/m3, (as total hydrocarbon vapor) 8 hours.</td></tr></table> Biological exposure indices (United States) No exposure indices known. Biological exposure indices (Canada) No exposure indices known. Biological exposure indices (Mexico) No exposure indices known. <table><tr><th>Appropriate engineering : controls</th><th>Use only with adequate ventilation. Use process enclosures, local exhaust ventilation or other engineering controls to keep worker exposure to airborne contaminants below any recommended or statutory limits. The engineering controls also need to keep gas, vapor or dust concentrations below any lower explosive limits. Use explosion-proof ventilation equipment.</th></tr><tr><td>Environmental exposure : controls</td><td>Emissions from ventilation or work process equipment should be checked to ensure they comply with the requirements of environmental protection legislation. In some cases, fume scrubbers, filters or engineering modifications to the process equipment will be necessary to reduce emissions to acceptable levels.</td></tr><tr><td>Individual protection measures</td><td></td></tr><tr><td>Hygiene measures :</td><td>Wash hands, forearms and face thoroughly after handling chemical products, before eating, smoking and using the lavatory and at the end of the working period. Appropriate techniques should be used to remove potentially contaminated clothing. Wash contaminated clothing before reusing. Ensure that eyewash stations and safety showers are close to the workstation location.</td></tr><tr><td>Eye/face protection :</td><td>Safety eyewear complying with an approved standa…

[6] Safety Data Sheet - Mineral Spirits

Page 5

Open source document

Source excerpt

# Section 7. Handling and storage Precautions for safe handling Protective measures <table><tr><th>Protective measures</th><th>Put on appropriate personal protective equipment (see Section 8). Do not swallow. Avoid contact with eyes, skin and clothing. Avoid breathing vapor or mist. Use only with adequate ventilation. Wear appropriate respirator when ventilation is inadequate. Do not enter storage areas and confined spaces unless adequately ventilated. Keep in the original container or an approved alternative made from a compatible material, kept tightly closed when not in use. Store and use away from heat, sparks, open flame or any other ignition source. Use explosion-proof electrical (ventilating, lighting and material handling) equipment. Use only non-sparking tools. Take precautionary measures against electrostatic discharges. Empty containers retain product residue and can be hazardous. Do not reuse container.</th></tr><tr><td>Advice on general occupational hygiene</td><td>Eating, drinking and smoking should be prohibited in areas where this material is handled, stored and processed. Workers should wash hands and face before eating, drinking and smoking. Remove contaminated clothing and protective equipment before entering eating areas. See also Section 8 for additional information on hygiene measures.</td></tr><tr><td>Conditions for safe storage, including any incompatibilities</td><td>Store in accordance with local regulations. Store in a segregated and approved area. Store in original container protected from direct sunlight in a dry, cool and well-ventilated area, away from incompatible materials (see Section 10) and food and drink. Store locked up. Eliminate all ignition sources. Separate from oxidizing materials. Keep container tightly closed and sealed until ready for use. Containers that have been opened must be carefully resealed and kept upright to prevent leakage. Do not store in unlabeled containers. Use appropriate containment to avoid environmen…

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