Fundamentals of petroleum refining will explore the critical role refining plays in unleashing the potential of a barrel of crude oil and turning it into the specially formulated products that we rely on every day. These products include gasoline, agricultural chemicals, heating oil, plastics, and even prescription medicines. The training will also cover basic refining streams and unit configurations. Also covered will be hazards inherent to high hazard facilities and common emergency response processes. A section of the training will explain refining culture as it may differ from other industry sectors. An introduction to common refining terminology will be covered.

A major objective of this course is to address:

• Fundamentals of the petroleum refining industry

• Crude oil and its properties

• Classes of refinery processes and refinery configurations

• Properties of the refinery-produced streams

• Refinery hazards and emergency response procedures

Suggested text and training material for instructors:

Fundamentals of Petroleum Refining, Authors: Mohamed A. Fahim, Taher A. Alsahhaf, Amal Sayed Elkilani

This course addresses the basic safety principles associated with working in high hazard facilities. The program provides an awareness level orientation of the following elements:

Overview/awareness of personal requirements for refineries

Transportation Worker Identification Credential

Drug Test

Respirator Fit Test

WAC 296-67-029 Contractors

WAC 296-67-025 Training

Refinery Site Specific Training

Hazard communication

Chapter 296-901 WAC

Emergency preparation and response

Chapter 296-824 WAC, Emergency response;

WAC 296-24-567, Employee emergency plans and fire prevention plans.

Exit routes and employee alarm systems

WAC 296-800-310

Fire brigades

Chapter 296-811 WAC

Understanding how refinery fire brigades work, including rescue operations, confined space entry protocols, fire suppression techniques, use of testing instruments, etc. May include facility-specific information.

Fire prevention and protection

WAC 296-24-567 (general industry);

WAC 296-155-250 (construction industry);

Basic overview on fire prevention, ignition sources, gas monitoring before hot work, etc. May include facility-specific information.

Toxicology

Asbestos awareness training

WAC 296-155-176, Lead in construction

Chapter 296-849 WAC, Benzene

Chapter 296-840 WAC, Respirable chrystalline silica

Best Practice Hydrogen Sulfide (H2S)

Best Practice Hydrofluoric Acid

Best Practice Asphyxiants

SDS's, CSB videos, department of labor & industries training kits, etc., recommended as training resources.

Personal protective equipment (PPE) for refinery work

WAC 296-800-160 (general industry);

WAC 296-155-200 (construction industry);

Flame Resistant Clothing

Hard Hat

Eye Protection

Appropriate Footwear

Hearing Protection

Fall Protection

Personal Cleanliness

Protective Clothing

Contaminated Clothing

Respiratory protection

Chapter 296-842 WAC

Hearing conservation

Chapter 296-817 WAC

Energy control (lockout/tagout)

Chapter 296-803 WAC (general industry);

WAC 296-155-429 (construction industry).

Confined space

Chapter 296-809 WAC (general industry);

WAC 296-155-203 (construction industry).

Heat related illness

WAC 296-62-095

Refinery safe work practices

Best practice - General safety in a refinery

Process safety management for

refineries

Chapter 296-67 WAC

Participants will learn the specific work performed by various trades working in the refinery. Working safely alongside other crafts and recognizing the similar and dissimilar risks associated with each craft is the focus of this course. Participants will also learn about interdependency and relationships between the crafts, stacked work, dissimilar trades working near each other, dissimilar risks associated with trade types (i.e., electrical energy, product energy, radiation, potential falling objects, etc.) job sequencing, and barricading.

Craft specific safety training must cover individual craft hazards in a minimum of three categories:

Hard trades: Boilermaker, pipefitting, welders, electricians, etc.

Soft trades: Painting, scaffold building, insulation, carpentry, etc.

Support crafts: Cranes, inspection, hydroblasting, vac trucks, safety attendant, etc.

Multiple trades are involved in hot work operations. Trades working in other operations on the location at the same time could be impacted from the hazards associated with hot work.

WAC 296-24-695 Fire prevention and protection (general industry);

WAC 296-155-250 fire prevention and protection (construction industry);

Understanding what hot work is and how to perform craft work safely; awareness of ignition sources such as welding, and performing dissimilar work around such areas;

Hot work permits are specific to each facility and facility-specific information may be included in training.

The work of multiple trades may require working at heights and supporting working at heights. Trades working in areas where overhead work is occurring at the same time could be impacted from hazards such as falling objects.

Chapter 296-874 WAC, Scaffolds;

Chapter 296-880 WAC, Unified safety standards for fall protection;

Recognizing where overhead work is occurring; understanding any hazards associated with craft work in such areas.

WAC 296-24-957 (general industry);

WAC 296-155-426 (construction industry);

Understanding electric shock and electrocution;

Recognizing potential hazards around work involving electricity;

Maintaining clearances around panels;

Using proper protective devices;

Eliminating access to exposed energized parts;

How electricians work relates to other work performed in the refinery.

Chapter 296-155 WAC:

Part D Fire protection and prevention;

Part F-1, rigging other than with the use of a crane (winch/tugger, chainfall, etc.);

Part G Tools - Hand and power;

Part H Welding and cutting;

Part L, rigging and signaling with cranes;

How pipefitters work relates to other work performed in the refinery.

Chapter 296-155 WAC:

Part L, rigging and signaling with cranes;

Part F-1, rigging other than with the use of a crane (winch/tugger, chainfall, etc.);

Chapter 296-863 WAC, Forklifts and other powered industrial trucks;

How equipment operating engineers work relates to other work performed in the refinery.

Chapter 296-155 WAC

How finishing trades work relates to other work performed in the refinery.

Chapter 296-155 WAC

How cement masons work relates to other work performed in the refinery.

Chapter 296-155 WAC

How construction laborers work relates to other work performed in the refinery.

Chapter 296-874 WAC, Scaffold;

Chapter 296-880 WAC, Unified safety standards for fall protection;

How carpenter scaffold erectors work relates to other work performed in the refinery.

Chapter 296-155 WAC

How ironworkers, boilermakers, and steelworkers work relates to other work performed in the refinery.

Chapter 296-155 WAC;

Chapter 296-65 WAC, Asbestos removal and encapsulation;

How asbestos workers work relates to other work performed in the refinery.