Job Safety Analysis Worksheet

Title Of Operation: Crude Oil Refining SOP/SWP No. 5

Position/Title: Refinery Operations Manager Building: Petron Bataan Refinery Plant

Department: Production Department – Production Of Crude Oil Distillation Division

SAFETY PRECAUTIONS
PROCEDURES TO BE FOLLOWED
BASIC STEPS POTENTIAL HAZARDS (if the procedure does not fully control risks)
(DO’s)
(DON’Ts)

• Despite the fact that these are closed • Control and monitor the temperature,
processes, heaters and exchangers in pressure, and reflux within operating
the atmospheric and vacuum parameters to prevent thermal cracking
distillation units could be a source of within the distillation towers.
ignition. • Relief systems should be checked on a • Temperature, pressure, and other operating
• potential for a fire exists should a leak regular basis for overpressure and parameters should not be left unmonitored.
or release occur. operations monitored to prevent crude • Remove or isolate any material or
Distillation
• An excursion in pressure, temperature, from entering the reformer charge. equipment that may clog the relief systems.
or liquid levels may occur if automatic • Inject sufficient wash water to prevent • Never enter a designated workplace without
control devices fail. the formation of ammonium chloride proper protective equipment.
• Loss of Control to temperature, which might cause serious corrosion
pressure, and reflux within operating • Use appropriate personal protective
parameters might fail to prevent equipment to prevent chemical
exposure and other hazards such as
 thermal cracking within the distillation heat and noise, as well as during
towers. sampling, inspection, maintenance, and
• The sections of this process are turnaround activities.
susceptible to corrosion.
• Where sour crudes are processed,
severe corrosion can occur in furnace
tubing and in both atmospheric and
vacuum towers
• Hydrogen chloride may be present in
the preheat exchanger, tower top zones,
and overheads.
• Wastewater may contain water-soluble
sulfides in high concentrations and
other water-soluble compounds such as
ammonia, chlorides, phenol,
mercaptans, etc.
• Even though it is a closed process, the
primary potential for fire is from leaks • Monitor and regulate the temperature
or releases of liquids, gases, or vapors • Conduct water or steam injection to
reaching an ignition source such as a prevent the formation of coke in
heater. delayed coker furnace tubes.
• The potential for fire is present in • Water must be completely drained • The processing temperature should not be
coking operations due to vapor or from the coker, so as not to cause an left unmonitored.
product leaks. explosion upon recharging with hot
Thermal Cracking • Never enter a designated workplace without
• Should coking temperatures get out of coke.
proper protective equipment.
control, an exothermic reaction could • Use appropriate personal protective
occur within the coker. equipment to prevent chemical
• In thermal cracking when sour crudes exposure and other hazards such as
are processed, corrosion can occur. heat and noise, as well as during
• Continuous thermal changes can lead sampling, inspection, maintenance, and
to bulging and cracking of coke drum turnaround activities
shells.
 • exposure to hazardous gases such as
hydrogen sulfide and carbon
monoxide, and trace polynuclear
aromatics (PNAs) associated with
coking operations.
• When coke is moved as a slurry,
oxygen depletion may occur within
confined spaces such as storage silos,
since wet carbon will adsorb oxygen.
• exposure to burns when handling hot
coke or in the event of a steam-line
leak, or from steam, hot water, hot
coke, or hot slurry that may be expelled
when opening cokers.
• Operating procedures should be
• This is a closed system; however, the followed to ensure control of hot spots
potential for fire exists should a leak or during start-up.
release of reformate gas or hydrogen • Safe catalyst handling is very
occur. important. • Do not drop the catalysts.
• Ammonium chloride may form in • Care must be taken not to break or • Place the catalyst in a location where it will
pretreater exchangers and cause crush the catalyst when loading the not be touched or moved.
Reforming
corrosion and fouling. beds • Never enter a designated workplace without
• exposure to hydrogen sulfide and • Use appropriate personal protective proper protective equipment.
benzene should a leak or release occur. equipment to prevent chemical
• Little emissions of carbon monoxide exposure and other hazards such as
and hydrogen sulfide may occur during heat and noise, as well as during
the regeneration of the catalyst. sampling, inspection, maintenance, and
turnaround activities.
• potential exists for fire from a leak or • Under normal operating conditions,
release of feedstock or product. exposures are expected to be minimal, • Never enter a designated workplace without
Treating • Treating processes such as sweetening but stay cautious. proper protective equipment.
use air or oxygen. • Use appropriate personal protective
equipment to prevent chemical
 • If excess oxygen enters these exposure and other hazards such as
processes, it is possible for a fire to heat and noise, as well as during
occur in the settler due to the sampling, inspection, maintenance, and
generation of static electricity, which turnaround activities.
acts as the ignition source.
• exposure to hydrogen sulfide, caustic
(sodium hydroxide), spent caustic,
spent catalyst (Merox), catalyst dust,
and sweetening agents (sodium
carbonate and sodium bicarbonate).
• Ignition sources in the area need to be
• potential exists for fire from the event controlled or prevented in the event of
• Avoid placing combustible materials or
of a leak or release. a leak or release.
anything else that could catch fire near the
• exposures to chemicals and other • Use appropriate personal protective area.
Blending hazards such as noise and heat; when equipment to prevent chemical
• Never enter a designated workplace without
handling additives; and during the exposure and other hazards such as
proper protective equipment.
inspection, maintenance, and heat and noise, as well as during
turnaround activities. sampling, inspection, maintenance, and
turnaround activities.

Prepared By: Buacemeno, Cecile S. Date: July 22, 2022

Approved By: Engr. Melvin C. Areola Date: July 22, 2022

H&S Rep/Committee Reviewed Date: July 24, 2022

Next Review Date < 5 years: