Fundamentals of Petroleum Refining | 4.0 Hours General Overview | Specific content |
Crude oil and its refining into downstream products | Basic high level information about refineries | How crude oil is processed; relevant hazards as described on the safety data sheet for crude oil; fractions and their related hazards (temperatures, pressures, etc.); introduction to key refining processes; classes of refinery processes and refinery configurations; properties of the refinery-produced streams; and the interrelationship between processing units. |
Refining Industry Safety Concepts | 8.0 Hours WAC Reference | Overview |
Exit routes and employee alarm systems | WAC 296-800-310 | Details of emergency action plan concepts. |
Process safety management for refineries | Chapter 296-67 WAC | Overview of the requirements for process safety management, including: Workplace assessments; stop work authority; job hazard analysis; contractor roles and responsibilities in a refinery facility; and other sections of the rule. |
Emergency response | Chapter 296-824 WAC, Emergency response; WAC 296-24-567 Employee emergency plans and fire prevention plans | General overview of emergency operations in a refinery. May include facility-specific information. |
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 touching on fire prevention, ignition sources, testing before hot work, etc. May include facility-specific information. |
Hazard communication | Chapter 296-901 WAC | Review of chemicals found in refineries and their locations, including general "streams"; personal protective equipment and practices; signs and symptoms of exposure; long-term health effects; and a comprehensive review of relevant safety data sheets. |
Personal protective equipment (PPE) for refinery work | WAC 296-800-160 (general industry); WAC 296-155-200 (construction industry) | Fire resistant clothing; head protection; eye protection; foot protection; hearing protection; and contaminated clothing. |
Respiratory protection | Chapter 296-842 WAC | The use of respirators in certain refinery locations. May include facility-specific information. |
Hearing conservation | Chapter 296-817 WAC | Understanding the areas in a refinery facility where hearing protection is required. May include facility-specific information. |
Lockout/tagout | Chapter 296-803 WAC (general industry); WAC 296-155-429 (construction industry) | Energy control protocols in a refinery. May include facility-specific information. |
Confined spaces | Chapter 296-809 WAC (general industry) in addition to WAC 296-155-203 (construction industry) | Types of confined spaces in a refinery; entry protocols; atmospheric testing; other related hazards. May include facility-specific information and permit forms. |
Heat related illness | WAC 296-62-095 | Maintain awareness of outdoor heat in the hot areas of a refinery, which may contribute to heat-related illness. |
Refinery safe work practices | General safety in a refinery | Identify walking/working surface hazards; areas of nonentry; understanding general hazards of vessels and other equipment. May include facility-specific information. |
Craft-Specific Safety Training Including, but not limited to: | 8.0 Hours WAC References | The purpose of this section is to have a discussion about specific interdependencies and relationships of trades, including stacked work; dissimilar trades in direct proximity with each other; dissimilar risks associated with various trades (i.e., radiation, potential falling objects, etc.); job sequencing; and barricading. |
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. |
Working at heights | 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. |
Electrical | WAC 296-24-957 (general industry); WAC 296-155-426 (construction industry) | Recognizing potential hazards about electrical work in a refinery and how to perform such work around other contract operations. |
Pipefitting | 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 | Basic knowledge of pipe safety: Including eliminating risk of contamination in process lines through fit, purge, weld techniques and pre and post weld buffing and machining. Basic knowledge of testing lines e.g.: Nondestructive pipe testing techniques; safety regarding fuel and pressure pipes including design, construction, location, leak detection and environmental considerations; pressure vessel fabrication certification; welding qualifications; knowledge and application of relevant standards; pipe corrosion; pipe cracks; pipe modifications, e.g., removing; cutting into or destroying existing pipe lines and piping, installing new pipes, maintaining old pipes, etc. |
Equipment operating engineers | 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.) | Crane principles, rigging, signaling; forklift principles, etc. |
Finishing trades | Chapter 296-155 WAC: Part F, general requirements for storage (Brick/block, handling cement/lime); Part G Tools—Hand and power; Part O Concrete, concrete forms, shoring, and masonry construction | Lead renovator, repair and painting program (RRP) Toxic Substance Control Act (TSCA) Section 402/chapter 365-230 WAC. |
Cement masons | Chapter 296-155 WAC: Part F, general requirements for storage (Brick/block, handling cement/lime); Part G Tools—Hand and power; Part O Concrete, concrete forms, shoring, and masonry construction | How cement masons work relates to other work performed in the refinery. |
Ironworkers, boilermakers, and steelworkers | 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; Part P Steel erection | How boilermakers', ironworkers', and steelworkers' work relates to other work performed in the refinery, including: Measuring, fabricating, cutting, welding and shaping steel parts such as girders, columns and frames; using equipment including shears, welding tools and torches; hoisting steel parts to their appropriate location; ensuring proper alignment and positioning and bolting them into place; assembly and use of equipment, including setting up cable and chain systems for hoisting or moving steel parts; disassembling it after completion of the task; following blueprint and instructions from supervisors to perform all tasks involved in assembly of steel structures; communicate with supervisors and coworkers to ensure smooth teamwork; notifying supervisors immediately of safety or structural concerns; taking apart structures or equipment in accordance with directions and standard operating procedures; repair steel components in older structures; directing crane operators as they move and position steel components; drilling holes and aligning parts with framework in preparation for riveting; use of tools including levels, laser tools and plumb bobs to ensure precise alignment.)) |
Fundamentals of Petroleum Refining (4-hours) | |
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 | |
Refining Industry Safety Concepts/Refinery Safety Overview (8-hours) 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: | Applicable WAC or Best Practices recommended as training resources |
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 |
Craft-Specific Safety Training (8-hours) | Applicable WAC or Best Practices recommended as training resources |
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. | |
Hot work 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. |
Working at heights 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. |
Electrical | 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. |
Pipefitting | 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. |
Crane and material handling | 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. |
Finishing trades - Painters and drywall | Chapter 296-155 WAC How finishing trades work relates to other work performed in the refinery. |
Cement masons | Chapter 296-155 WAC How cement masons work relates to other work performed in the refinery. |
Construction laborers | Chapter 296-155 WAC How construction laborers work relates to other work performed in the refinery. |
Carpenters scaffold erectors | 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. |
Ironworkers, boilermakers, steelworkers | Chapter 296-155 WAC How ironworkers, boilermakers, and steelworkers work relates to other work performed in the refinery. |
Asbestos workers | Chapter 296-155 WAC; Chapter 296-65 WAC, Asbestos removal and encapsulation; How asbestos workers work relates to other work performed in the refinery. |