PETROLEUM

REFINERY
PROBLEMS AND SOLUTIONS

PROBLEMS
ENCOUNTER
Arc Flash
Confined Space Entry
Fire and Explosion
H2S Exposure
Oxygen Deficient Atmosphere

ARC FLASH
Eletrical accident/ electrical hazard
Most electrical accidents are not the result of direct electric
shocks, but instead result from a particularly hazardous type
of shorting fault, called an arc fault or flash, that can occur
throughout oil and gas facilities. Arc flash is the sudden
release of electrical energy through the air when insulation
or air separation causes a high voltage gap between
conductors, leading to a breakdown in safe conduction of
electricity.

ARC FLASH

ARC FLASH
Arc flashes can result from a variety of causes:
A worker being in close proximity to a high amp source with
a conductive object can cause the electricity to flash over
Human error, including dropped tools, accidental contact
with electrical systems, and improper work procedures
Equipment failure due to use of substandard parts,
improper installation, or even normal wear and tear
Breaks or gaps in insulation
Dust, corrosion, or other impurities on the surface of the
conductor

ARC FLASH

ARC FLASH

ARC FLASH

ARC FLASH

ARC FLASH
Safety Precautions
To ensure safety and compliance measures are being taken
throughout a workplace, it is critical that both upper
management and employees know how to identify arc flash
hazards in their facilities, utilise safe work practises, and
understand labels and other awareness aids. It is critical that
everyone stays up to date on standards and reinforces safe
behaviour.

ARC FLASH
This requires training and education for workers to identify
the risks, as well as an arc flash mitigation plan in place both
for existing equipment and new projects, with initiatives
such as:
Creating and enforcing a complete arc flash strategy
Conducting ongoing employee training
Providing the proper arc flash personal protective
equipment for the level of risk
Identifying and evaluating arc flash potential throughout a
location
Calculating incident energy exposure and arc flash
boundaries
Utilising warning labels to specify arc flash hazard levels

ARC FLASH
The most effective way to eliminate the risk of electrical
shock or arc flash is to simply de-energise the equipment
some important safety recommendations on how to establish
an electrically safe work condition before working on a
circuit:
Identify all power sources
Interrupt the load and disconnect power
Visually verify the disconnect has opened the circuit
Lock out and tag the circuit
Perform voltage testing
Ground all power conductors

ARC FLASH
In truth, there is no way to completely eliminate arc flash
accidents, but the risk can be further mitigated by providing those
working on electrical equipment with suitable personal protective
equipment, as covered above and below.
Personal Protective Equipment
This includes safety glasses, voltage rated gloves, flame resistant
neck protection, arc-rated face shields, flash suits with hoods, and
hearing protection.
Also, workers are outfitted with arc rated work suits, insulated
rubber gloves (preferably with leather protectors), and insulated
leather footwear. All materials must be metal-free to avoid the
possibility of arc flash, whereby a fault creates electrical contact
with the worker.

ARC FLASH
Personal protective equipment for arc flash includes the
following:
1. Gloves. These are a crucial piece of PPE for electrical
workers, combining high dielectric and physical strength with
flexibility and durability. Depending on the hazard level of work,
there are several kinds of gloves to choose from, such as heavy
duty leather gloves, rubber insulating gloves, or a combination
of both.
2. Clothing. Employees must wear protective clothing that is
deemed appropriate based on the energy and risk associated
with the task being performed. Other PPE may be required for
specific tasks with various weight fabrics, which can be
provided as a shirt and trousers, as coveralls, or as a
combination of both for increased protection.

ARC FLASH
3. Headgear. Employees must wear nonconductive head protection
wherever there is a danger of head injury from electric shock or
burns due to contact with live parts, or from objects flying as a
result of an electrical explosion. Headgear also includes
nonconductive protective equipment for the face, neck, and chin.
When necessary, face shields should have an arc rating suitable for
the arc flash exposure, and eye protection, such as safety glasses
or goggles, which should be worn under face shields or hoods.
4. Foot protection. There are two types of shoes that provide some
protection from electrical shock, both of which have insulated
soles: dielectric and electrical hazard rated. Dielectric overshoes
are used where there is a risk of electric shock from high voltages
in both dry and damp conditions. Electrical hazard footwear is
usually used in low voltage and dry conditions. Insulated soles
should not be used as the primary electrical protection, however.

ARC FLASH
5. Insulated tools and equipment. Employees must use
insulated tools and handling equipment when working
around energised electrical equipment or exposed live parts
where there is potential for contact. Insulated tools should
be protected from damage to the insulating material, such as
being composed of impact resistant and flame retardant
material.

CONFINED
SPACES

DEFINITION
A confined space is described to be an enclosed space
with restricted access which may be due to design, construction,
location, atmosphere and materials making it harder for the
worker entering it.

PROBLEMS
In oil refinery sites, complex collection of tanks,
reactors, vessels, and ducts combined with a wide variety of
hazardous chemicals and emissions are often in enclosed
areas.

HAZARDS AND RISKS

Oxygen Deficiency

Less than 19.5% oxygen

Poor ventilation due to confinement
Oxygen displaced by purging
Oxygen Enrichment
More than 23% oxygen
Increases flammability
Leads to light headedness and unconsciousness

Toxic Vapors
Due to gradual release of toxic substance
From chemical reactions
Gas residue agitation
Flammable Materials
Caused by vapors and liquids with potential for fire
Happens with the right quantity of combustible material heat and
oxygen

SOLUTIONS
Personal Protective equipments should be given to each
personnel
Availability of exhaust and natural ventilation
Personnel should be knowledgeable about the hazards of the
job
Cleaning of tanks should be adequate
Personnel must do their own responsibilities to minimize
chances of accidents

FIRE AND EXPLOSION

HAZARDS
Fire and explosion hazards generated by process operations
include the accidental release of syngas (containing carbon
monoxide and hydrogen), oxygen, methanol, and refinery
gases. Refinery gas releases may cause jet fires, if ignited
in the release section, or give rise to a vapor cloud explosion
(VCE), fireball or flash fire, depending on the quantity of
flammable material involved and the degree of confinement
of the cloud.

FIRE AND
EXPLOSION
HAZARDS

FIRE AND EXPLOSION

HAZARDS
Methane, hydrogen, carbon monoxide, and hydrogen sulfide
may ignite even in the absence of ignition sources, if their
temperature is higher than their auto ignition temperatures of
580C, 500C, 609C, and 260C, respectively.

FIRE AND EXPLOSION

HAZARDS
Flammable liquid spills present in petroleum refining
facilities may cause pool fires. Explosive hazards may also
be associated with accumulation of vapors in storage tanks
(e.g. sulfuric acid and bitumen).

FIRE AND EXPLOSION

HAZARDS

FIRE AND EXPLOSION

HAZARDS

FIRE AND EXPLOSION

HAZARDS
Solution:
Recommended measures to prevent and control fire and
explosion risks from process operations include the
following:
Designing, constructing, and operating petroleum refineries
according to international standards10 for the prevention
and control of fire and explosion hazards, including
provisions for segregation of process, storage, utility, and
safe areas. Safety distances can be derived from specific
safety analyses for the facility, and through application of
internationally recognized fire safety standards;11

FIRE AND EXPLOSION

HAZARDS
Providing early release detection, such as pressure
monitoring of gas and liquid conveyance systems, in
addition to smoke and heat detection for fires;
Evaluation of potential for vapor accumulation in storage
tanks and implementation of prevention and control
techniques (e.g. nitrogen blanketing for sulfuric acid and
bitumen storage);
Avoiding potential sources of ignition (e.g. by configuring the
layout of piping to avoid spills over high temperature piping,
equipment, and / or rotating machines);

FIRE AND EXPLOSION

HAZARDS
Providing passive fire protection measures within the
modeled fire zone that are capable of withstanding the fire
temperature for a time sufficient to allow the operator to
implement the appropriate fire mitigation strategy;
Limiting the areas that may be potentially affected by
accidental releases by: o Defining fire zones and equipping
them with a drainage system to collect and convey
accidental releases of flammable liquids to a safe
containment area, including secondary containment of
storage tanks

FIRE AND EXPLOSION

HAZARDS
Installing fire / blast partition walls in areas where
appropriate separation distances cannot be achieved;
Designing the oily sewage system to avoid propagation of
fire.

FIRE AND EXPLOSION

HAZARDS
Here are five ways to improve fire protection:
1. Assess initial fire safety workplace preparedness
While companies believe they are ready for fires or other
incidents, a thorough inspection and safety audit may reveal
unknown vulnerabilities at worksites. Evaluate any particular
areas and workers at higher risk for flash fires or explosions.
For example, workers performing hot work, such as welding,
may be exposed to combustible or flammable materials.
Look for areas where fire protection equipment is either old
or malfunctioning and replace them with ones that are in
good, working condition. These can include sprinkler
systems as well as fire extinguishers.

FIRE AND EXPLOSION

HAZARDS
2. Keep equipment for emergency response onsite
For welders and other workers at risk for similar hazards,
supply their work stations and areas nearby with equipment
such as fixed and portable fire extinguishers. Fire
extinguishers need to be readily available for workers to use in
an emergency and isolate the fire before it spreads to other
parts of the worksite.
3. Install alert systems employees to fire risk
In the event of a fire, workers need to be warned immediately
so they can evacuate the building or work area safely.
Implement emergency alarm and mass notification systems
that will alert employees to the danger. Companies also have
the option of using a mass notification system that messages
employees on their mobile devices warning of emergencies.

FIRE AND EXPLOSION

HAZARDS
4. Measure dangerous gases with detection equipment
With the risk of fires and explosions, there may be hazardous
gases in the air that could endanger worker health and
safety. Monitor the presence of these gases and vapors
using combustible and toxic gas detection systems to avoid
activities that may increase the chance of fire. OSHA
recommends discontinuing work if the detectors find that a
flammable or combustible gas
surpasses 10 percent of the lower explosive level. Educate
workers on what is considered an acceptable level of these
gases to allow them to be proactive in knowing when to stop
work when it becomes unsafe.

FIRE AND EXPLOSION

HAZARDS
5. Train workers to use equipment for fire protection
To reinforce your plan, be sure to train workers to operate
fire protection equipment, including fire extinguishers. Give
them instructional materials for these tools as well as
provide a demonstration if necessary. Additionally, plan a fire
drill to remind employees about safety procedures and
educate them on how to properly evacuate the workplace.
Posting evacuation directions and ways to exit the building
near work stations may also help with protecting workers
from fire-related injuries and fatalities.

H2S
EXPOSURE

H2S EXPOSURE
H2S is a potential problem in the transport and storage of
crude oil. Many of the other classic confined-space entry
problems can occur here, including oxygen deficiency
resulting from previous inerting procedures, rusting, and
oxidation of organic coatings. Carbon monoxide can be
present in the inerting gas. In addition to H2S, depending on
the characteristics of the product previously stored in the
tanks, other chemicals that may be encountered include
metal carbonyls, arsenic, and tetraethyl lead.

H2S EXPOSURE
Hydrogen sulfide is an extremely toxic and irritating gas.
Early recognition and detection is crucial to protect
employees from deadly exposures. Employees working in
areas that contain or have the potential to contain hydrogen
sulphide should learn to recognize the signs and symptoms
of hydrogen sulfide exposure, how to monitor for hydrogen
sulfide, and know how to take measures to protect
themselves. Instrumentation is available to continuously
monitor the atmosphere in confined spaces for hydrogen
sulfide and other gases as well as oxygen deficiencies.

H2S EXPOSURE
At higher concentrations hydrogen sulfide may cause loss of
consciousness and death. Hydrogen sulfide has a strong
odor of rotten eggs at low concentrations and a sweetish
odor at higher locations. Odor should not be used as a
warning of exposure since at concentrations of (20-30 parts
per million) hydrogen sulfide may deaden the sense of smell
by paralyzing the respiratory center of the brain and olfactory
nerve.

H2S EXPOSURE

H2S EXPOSURE

H2S EXPOSURE
Solution
OSHA REGULATIONS
20 ppm (ceiling )
50 ppm (peak 10 minute exposure allowed only once if no
other measurable exposure occurs)

H2S EXPOSURE
DETECTION OF HYDROGEN SULFIDE
detector tubes indicate amount of gas by color change of
chemically coated granules in a glass tube
Electronic monitors

H2S EXPOSURE
Detector tubes
safely allow users
to perform field
screening and
tests for the
presence of
hazardous and
toxic gases, and
chemical vapors at
a very low costper-sample

H2S EXPOSURE
EXPOSURE PREVENTION
Conduct air monitoring before entering any confined space
that may contain hazardous atmospheres
Entering a confined space may require special confined
space training
Special procedures must be followed
An entry permit may be required
Rescue procedures must be in place

H2S EXPOSURE
AIR MONITORING
Must be conducted prior to entry, and periodically (continuous
monitoring is recommended)
Monitor confined space from the outside or use extension probe or
lower monitor into space
Monitor must be calibrated for accuracy
Conditions may change suddenly
Monitor alarms may be set or preset
Have back-up or stand-by equipment
Be sure batteries are charged
Electrochemical sensors will require periodic replacement
Detector tubes have a 1-3 year shelf life
Sensors will last 1-2 years

H2S EXPOSURE
RESPIRATORY PROTECTION
In air concentrations of 300 ppm or less
Use an air-supplied respirator with full face piece, helmet or
hood
Or use a self contained breathing apparatus with full face
piece
In concentrations over 300 ppm use a SCBA full face in
positive pressure mode

H2S EXPOSURE

H2S EXPOSURE

H2S EXPOSURE
MEDICAL EMERGENCY
If someone is exposed to a large amount of hydrogen sulfide
move the person to fresh air at once
If breathing has stopped perform artificial respiration
Get medical attention as soon as possible
EMERGENCY RESCUE
Should a co-worker ever be overcome by hydrogen sulfide
gas, do not attempt a rescue until you are properly protected
yourself
Remember at concentrations above 1000 ppm, collapse,
coma, and death due to respiratory failure can occur within
seconds after only a few breaths

OXYGEN
DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE
Oxygen-Deficient Atmosphere (The potential release and
accumulation of nitrogen gas into work areas may result in
the creation of asphyxiating conditions due to the
displacement of oxygen. )
Asphyxia or asphyxiation is a condition of severely deficient
supply of oxygen to the body that arises from abnormal
breathing. An example of asphyxia is choking.

OXYGEN-DEFICIENT
ATMOSPHERE
Workers can become asphyxiated by exposure to
atmospheres deficient of oxygen that can lead to serious
injury or loss of life. Oxygen is the only component of the air
we breathe capable of supporting life. Air is composed of
approximately 21% oxygen, 78% nitrogen and other trace
components. Asphyxiation is the greatest hazard associated
with nitrogen and other inert gases, such as argon and
helium

OXYGEN-DEFICIENT
ATMOSPHERE
Breathing as little as one or two breaths of air containing too
little oxygen can have serious and immediate effects,
including unconsciousness. Because there are no warning
signs of reduced oxygen concentrations, these environments
are extremely dangerous.

OXYGEN-DEFICIENT
ATMOSPHERE
Effects of exposure to low oxygen concentrations can
include giddiness, mental confusion, loss of judgment, loss
of coordination, weakness, nausea, fainting, loss of
consciousness and death.

OXYGEN-DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE

OXYGEN-DEFICIENT
ATMOSPHERE
Solution:
Prevention and control measures to reduce risks of
asphyxiant gas release include:
Design and placement of nitrogen venting systems
according to industry standards;
Installation of an automatic Emergency Shutdown System
that can detect and warn of the uncontrolled release of
nitrogen (including the presence of oxygen deficient
atmospheres in working areas6), initiate forced ventilation,
and minimize the duration of releases;
Implementation of confined space entry procedures

OXYGEN-DEFICIENT
ATMOSPHERE
Precautions
Workers handling gases should review the Material Safety
Data Sheet (MSDS) for information on gas properties and
safe handling. For example, the MSDS shows the specific
gravity or relative vapor density of the gas. Gases with a
relative vapor density less than one, such as helium, are
lighter than air and can collect near the ceiling.
Conversely, cold vapors and gases with a relative vapor
density greater than one, like argon, are heavier than air and
will tend to settle at or near the floor, or in low spots or
depressions, such as culverts, ditches and manholes. These
areas may contain little or no oxygen, while surrounding
areas have normal air composition.

OXYGEN-DEFICIENT
ATMOSPHERE
Workers handling gas cylinders or other containers must
read the label to identify the product. The container color or
outlet connections are not reliable methods for product
identification.
A formal risk assessment is required to identify all hazards
and evaluate the controls needed to ensure the safety of
workers

OXYGEN-DEFICIENT
ATMOSPHERE
When working in confined spaces, all the requirements of
confined space regulations must be strictly followed.
Effective emergency procedures for entry and rescue can
avoid serious injuries or fatalities.
Workplace safety regulations commonly regulate work in
atmospheres containing less than 19% to 19.5% oxygen.
When it is necessary to work in an oxygen-deficient
atmosphere, supplied air must be provided. Air can be
supplied with either an air-supplied respirator or selfcontained breathing apparatus (SCBA).

OXYGEN-DEFICIENT
ATMOSPHERE
Emergency response
Workers involved in emergency activities must not allow
emotions to override safe work procedures and training.
Only trained, qualified personnel equipped with supplied air
and necessary safety equipment should attempt a rescue in
accordance with safe rescue procedures. You cannot hold
your breath and safely enter areas with low oxygen levels.
Tragically, without supplied air equipment, attempts to save
someone in an oxygen-deficient atmosphere most often
result in additional victims.

OXYGEN-DEFICIENT
ATMOSPHERE
First aid
Persons exposed to oxygen-deficient atmospheres should be
quickly moved to fresh air. If the victim is not breathing,
artificial respiration should be administered immediately. If
the victim is breathing, give supplemental oxygen.