Natural Resources Oil, Gas & Chemicals Services Level 1 Training Handbook
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Disclaimer This manual is designed and written to provide information about the subject matter involved. SGS makes no warranty, express or implied that it
Copyright This manual has been written for the exclusive use of the employees of SGS Natural Resource Oil, Gas, & Chemicals Services. Certain procedures contained in the manual may require or assume expertise or experience. Caution is therefore advised and SGS assumes no responsibility for any use by unauthorised or untrained persons. This manual has been compiled from publicly available material, appropriate industry standards, government publications and proprietary SGS data and documentation. The SGS generated portions of this manual have been produced as copyright material and SGS reserves all rights under all applicable copyright laws both national and international. No SGS generated portion of this manual may be reproduced, in any form, without the express written permission of SGS SA. Use of any portion of this manual is subject to the conditions of the disclaimers.
is fit for any purpose; or to the absolute sufficiency of the material presented. SGS assumes no responsibility for any inaccuracies in reproduction or errors in
interpretation of any authority. SGS reserves the right to modify or amend this manual, without prior notification, but SGS assumes no responsibility to update or issue corrections.
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Contents
Introduction Our History Our Purpose
7 8 8 8 8 9 9 9
1.2.4 Is There Any Other Useful Information About This Material? 1.3 Personal Protective Equipment 1.3.1 Respiratory Protection 1.3.1.1 Half Mask Respirators
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1.6 Static Electricity
21 22
1.7 Conclusion
13 13 13
Sampling
23 24 24 26 26 26 26 27 27 27 27 28 28
Our Value to Society
What Is Independent Inspection? Petroleum Measurement Standards The Job of Independent Inspection
2.1 Introduction 2.2 Equipment
1.3.1.2 Full Face-piece Respirators
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2.3 Types of Samples 2.3.1 All Levels Sample 2.3.2 Running Sample 2.3.3 Spot Samples
1.3.1.3 Self Contained Breathing Apparatus (SCBA) 15 1.3.2 Head, Face, Hand and Foot Protection 16 1.3.2.1 Hard Hats 16 1.3.2.2 Face Shields 17 1.3.2.3 Gloves 17 1.3.2.4 Shoes 17 1.3.2.5 Uniform 17 1.4 Hazardous Materials Handling 18 1.4.1 Benzene 18 1.4.2 Hydrogen Sulfide 19 1.5 Confined Space Entry 21
A Word on Compliance
Safety
11 12 12 12
2.3.4 Composite Spot Samples
1.1 Introduction
2.3.5 Tap Samples
1.2 Safety Data Sheet
2.3.6 Manual Pipeline Sampling 2.3.7 Vapor Pressure Samples
1.2.1 What Is the Material and What Do I Need Immediately in an Emergency? 1.2.2 What Should I Do if a Hazardous Situation Occurs? 1.2.3 How Can I Prevent Hazardous Situations from Occurring?
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2.3.8 Sample Handling 2.4 Commodity Specific Guidelines
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Temperature Determination
42 43 43 43 44 44 44 44 45 45 45 45 46 47 48 48 48 49
Contents 2.4 Commodity Specific Guidelines 2.4.1 Crude Oil
3.2.2 Volume Terminology 3.2.3 Types of Gauges 3.2.4 Gauging Equipment 3.2.5 Gauging Procedure 3.2.5.1 Innage Gauging 3.2.5.2 Outage Gauging 3.2.6 Gauging for Free Water 3.2.7 Floating Roof Tanks
32 33 35 35 36 36 36 37 38
28 28 28 28 28 28 28 29 29 29 29
4.1 Introduction
4.2 Types of Thermometer
2.4.2 Fuel Oil 2.4.3 Gasoline
4.3 Liquid in Glass Thermometer
2.4.4 Tap Samples
4.3.1 Accuracy Requirements 4.3.2 Accuracy Verification
2.4.5 Water-white Chemicals and Products
4.3.3 Immersion Times
2.5 Sample Labeling 2.6 Sealing Samples
4.4 Portable Electronics Thermometers
3.2.7.1 Critical Zone
4.4.1 Accuracy Requirements 4.4.2 Accuracy Verification 4.4.3 Immersion Times 4.5 Temperature Readings
3.3 Marine Vessel Tank Measurement
2.7 Sample Transportation 2.7.1 Transportation Boxes
38 39
3.3.1 Terminology
2.8 Calculation of Upper, Middle & Lower Spot Sample Ullages
3.3.2 Gauging Procedures – Full & Partially Full Tanks
40 40 40 41
4.6 Conclusion
2.9 Conclusion
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3.3.2.1 Trim Corrections 3.3.2.2 List Corrections
Verification Pipeline Fullness
Static Tank Gauging
31 32 32 32
3.3.3 Gauging Procedures-Free Water 3.3.3.1 Trim Correcting Free Water
5.1 Introduction
3.1 Introduction
41 3.3.4 Gauging Procedures – OBQ / ROB 41 3.4 Conclusion 41
5.2 Where Do Voids Come From? 5.3 API MPMS Chapter 17.6
3.2 Shore Tank Gauging
3.2.1 Tank Contents
5.3.1 Internal Circulation
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Wall Wash Test Procedure
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Contents 5.3.2 Line Displacement 5.3.3 High-Point Bleed-valve 5.3.4 Pigging Method 5.3.5 Line Press or Line Pack
49 49 49 49 50 50 50
8.6 To Calculate Gross Observed Volume (GOV) Shore Tanks 8.6.1 Total Observed Volume (TOV)
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7.1 Introduction
57 57 57 57 57 58 58 59 60 61 61 62 62 63 63 63 63 63
8.6.2 Free Water (FW)
7.2 Standard 7.3 Methods
8.6.3. Correction for the Effect of Temperature on the Steel Shell of the Tank (CSTH) 8.6.3.1 Calculate the Temperature of the Tank Shell (TSH) 8.6.3.2 To Determine the Correction 8.6.4 Floating Roof Adjustment (FRA) 8.7 To Calculate Gross Observed Volume (GOV) – Marine Vessel’s Tanks 8.7.1 Total Observed Volume (TOV)
5.4 Agreed Tolerance 5.5 General Procedures
7.4 Safety Requirements
64 64
7.4.1 Equipment
5.6 Conclusion
7.5 General Procedures 7.5.1 Funnel Method
64 65 66 66 66 66
Differences Between Product and Chemical Inspections
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7.5.2 Filter Paper / Blotter Method
6.1 Introduction
53 53 53 53 53 54 54 54 55 55 55
Calculation Procedures
6.2 Quality
6.3 Field Tests
8.1 Introduction
8.7.2 Trim Correction 8.7.3 List Correction
6.4 Tank Inspection
8.2 Explanation of Symbols
6.5 Sampling
8.3 Decimal Places and Rounding
8.7.4 Combining Trim and List Corrections 8.7.5 Free Water Volume (FW)
6.6 Cargo Pipelines
8.4 Observed Data 8.4.1 Shore Tanks
67 67
6.7 Safety
6.7.1 Safety Data Sheets 6.7.2 Confined Space Entry 6.8 Sample Transportation
8.4.2 Marine Vessel's Tanks
8.8 To Calculate Gross Standard Volume (GSV), Shore Tanks and Marine Vessel’s Tanks
8.5 Calculated Data 8.5.1 Shore Tanks
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6.9 Conclusion
8.5.2 Marine Vessel's Tanks
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Contents 8.8.1 Volume Correction Factor (VCF) 8.9 To Calculate Net Standard Volume (NSV) 8.9.1 Sediment and Water (S&W) 8.9.1.1 To Calculate the Correction for Sediment and Water (CSW) 8.9.1.2 To Calculate the Volume of Sediment and Water 8.10 To Calculate Apparent Mass or Weight in Air 8.10.1 Weight Conversion Factor (WCF)
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69 70 70
8.11 Calculation Sequence
Glossary
71 79
Conversion Tables
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Introduction
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Today, our focus is on innovative ways to deliver business benefits. This enables us to help our customers improve quality, safety, efficiency, productivity and speed to market while reducing risk and building trust in sustainable operations.
Our Value to Society Through our integrated leadership approach, we strive to become an increasingly sustainable company, maximizing the positive impact we have. We add more than just financial value to society. All our stakeholders (employees and suppliers, investors, customers, governments and industries, consumers, and communities and society) are the ultimate beneficiaries. In order to measure our success, we are developing an innovative impact valuation model to quantify our value to society. Established in 1878, SGS transformed grain trading in Europe by offering innovative agricultural inspection services. From those early beginnings, we steadily grew in size and scope as our agricultural inspection services spread around the world. During the mid-20th century, we began to diversify and started offering inspection, testing and verification services across a variety of sectors, including industrial, minerals, oil, gas, and chemicals. In 1981, SGS was listed on the Swiss Stock Exchange and forged an unrivaled reputation as the industry leader in finding solutions to the complex challenges faced every day by organizations.
Our History We are SGS – the world’s leading testing, inspection and certification company. We are recognized as the global benchmark for quality and integrity. Our 96,000 employees operate a network of 2,600 offices and laboratories, working together to enable a better, safer and more interconnected world.
What Is Independent Inspection?
Simply defined, independent inspection is, "The independent verification of quantity and /or quality of a commercially traded product." This independent inspection helps to ensure contract compliance and improve the speed and efficiency of transactions; safety and reliability of plant and equipment; and respect for delivery and production schedules This basic awareness course is going to focus on inspection of petroleum and petrochemical products. When these materials are traded, the point where the goods change hands is referred to as “custody transfer”. You should take note of this term as you will hear it many times. Inspections carried out using the three fundamental principals of independence, impartiality and quality can only be achieved by use of trained, competent and conscientious inspectors and technicians whose primary interest is the integrity of the cargo from point of shipment to the point of delivery.
Our Purpose Our purpose is to enable a better, safer and more
interconnected world. How do we do this?
We enable a better world by helping businesses everywhere to work efficiently, to deliver with quality, and to trade with integrity and trust. We enable a safer world by ensuring that your car is safe to drive, that the environment you work in is secure and clean, and that the food you eat is safe. We enable a more interconnected world by, for example, helping new technology to reach consumers quickly and affordably, by ensuring the security of IT systems and data, and by using AI and the Internet of Things to help develop smart cities.
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The activities of independent inspection services have always been determined by the needs of the industries that use their services. It is important for procedures and accuracy levels to remain consistent throughout the entire cargo movement; bearing in mind that load and discharge facilities are frequently in different countries. This need has resulted in the petroleum industry having produced measurement standards for determining quantity and quality of bulk petroleum shipments.
Maintaining an ethical level of confidentiality between cargo trading partners. Independent inspectors must be qualified to perform fieldwork safely and according to standards, apply correct calculations, interact professionally with others and produce accurate, complete and legible documents detailing the events of the job performed. This basic awareness course is designed to provide a firm foundation for building the necessary level of experience to meet the demands and challenges of this profession. Integrity is at the core of our business; it is the common thread through all of our activities. The SGS Code of Integrity defines the main principles of professional integrity for the SGS Group and is an expression of the values that are shared throughout our organization, our businesses and our affiliates. These rules apply to all employees of the SGS Group. Our joint venture partners, agents, intermediaries, consultants and subcontractors are also required to comply with them. It is the responsibility of all of us, at all levels of our organisation, to comply with, and live by our Code. A Word on Compliance as
The Job of Independent Inspection The scope of work provided by independent inspection companies is determined by contractual agreement which typically takes the form of a nomination order. This scope of work usually includes some or all of the following: Measuring, sampling and making required observations to verify that cargo transfer is carried out according to agreed standards. Working closely with refineries, terminals and other parties engaged in the custody transfer. Performing calculations and completing reports according to standards and company requirements. Protesting any actions or omissions of the terminal or vessel that might lead to a discrepancy. Promptly reporting findings to the parties who have requested services. As licensed by the US Customs to provide quantity and quality information for excise purposes on Customs' related movements. Examining all available information to determine if there are apparent discrepancies; and, if there are, taking a leading role in the systematic analysis of data to determine the likely cause of any variances.
Petroleum Measurement Standards
Strict adherence to the agreed upon measurement standards, as specified in the sales contract, is the principal way in which we demonstrate our independence, impartiality and quality. In the petroleum and petrochemical industry, the technical procedures that guide all measurement activities have been written into standards by a consensus of experts with years of measurement, sampling, tank calibration and data management experience. In the US, the American Petroleum Institute (API) sponsors the writing of the Manual of Petroleum Measurement Standards . Most members of API standards writing working groups are from refining companies, pipeline companies, independent inspection companies and equipment suppliers.
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Reports on suspected violations of the Code can be submitted, or advice obtained by calling the Integrity Helpline or by filing a written report online or sending it by fax or mail to the Chief Compliance Officer. See Integrity at SGS | SGS for further details about contacting the hotline. Parties other than SGS employees may utilise the contact information contained on our website as they deem appropriate.
No deviation can or will be tolerated and no employee will suffer any adverse consequence for having complied or for having reported suspected violations. Our Code of Integrity and Professional Conduct has been approved by our Board of Directors and the Operations Council. Its rules are fairly simple. However, if you have any difficulty in a particular situation, you should apply the following common- sense principles: Do not do anything which you know or believe to be illegal or unethical. Do not use any Company property for your own benefit. Do not engage into any transaction which does not have a genuine, legitimate business purpose. Ask yourself whether any contemplated transaction or business practice would withstand the scrutiny of the public eye if exposed. Do not do anything which could require you to be untruthful. Seek advice when in doubt.
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1. Safety
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1.2.1 What Is the Material and What Do I Need Immediately in an Emergency? Section 1: Chemical product and company identification Links the SDS to the material and identifies the supplier of the SDS. Section 2: Hazards identification Provides information on the potential adverse human health effects and symptoms that might result from reasonably foreseeable use and misuse of the material. Section 3: Composition, information on ingredients Lists the OSHA (Occupational Safety & Health Attributes) hazardous components 1.2.2 What Should I Do if a Hazardous Situation Occurs? Section 4: First aid measures Provides instructions to be taken if accidental exposure requires immediate treatment and can also provide information for attending physicians.
Section 5: Firefighting measures Provides basic firefighting guidance, including appropriate extinguishing media. Describes other fire and explosive properties useful for avoiding and fighting fires involving the material such as flash point or explosive limits Section 6: Accidental release measures Describes actions to be taken to minimize the adverse effects of an accidental spill, leak or release of the material. 1.2.3 How Can I Prevent Hazardous Situations from Occurring? Section 7: Handling and storage Describes actions to be taken to minimize the adverse effects of an accidental spill, leak or release of the material. Section 8: Exposure controls, personal protection Provides information on practices, or equipment, or both, that are useful in minimizing worker exposure. Provides guidance on personal protective equipment (PPE).
1.1 Introduction The safety information provided in this section is not intended to replace the regular safety training that you would normally receive, neither is it intended to replace any of the information found in the OI Management System (OIMS). It is, however, the intent of this section to provide you with an overview of the key safety elements that you must always be cognizant of when performing inspections. Safety has been intentionally placed at the beginning of this training guide because it is the most important part of any inspection; and it is the logical place to start. 1.2 Safety Data Sheet You should receive a safety data sheet (SDS) with your job instructions. If you do not, request one from your supervisor. An SDS is the key element in our Hazard Communication Program and will typically contain the following information:
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1.3.1 Respiratory Protection There are two basic classes of respiratory protection. These are the filter type and the supplied air type. Within these two basic groups there are many variations. We will be discussing two kinds of filter respirator (half mask and full-face piece) in addition to the self-contained breathing apparatus which is a supplied air unit. 1.3.1.1 Half Mask Respirators A half mask respirator has a face piece that covers the wearer's nose, mouth and chin and is fitted with one or two air purifying canisters that use a filter, sorbent or combination of both to remove airborne contaminants from otherwise breathable air. These units have the advantage of being small, light, simple to use and quick to put on. They are also very limited in scope and range and must not be used in atmospheres immediately dangerous to life or health (IDLH). The following requirements must be observed when using half mask respirators: Use only when the contaminant and maximum concentration is known. There must be SUFFICIENT OXYGEN to support life (20.9%). .
This information may be required in other aspects of your work, such as in the preparation of a hazardous materials sample for shipment or transportation. Once you determine the level of intervention required by your job assignment, the SDS is to be reviewed before you do anything else.
Section 9: Physical and chemical properties Provides additional data that can be used to help characterize the material and design safe work practices. Section 10: Stability and reactivity Describes the conditions to be avoided or other materials that may cause a reaction that would change the intrinsic stability of the material. 1.2.4 Is There Any Other Useful Information About This Material? The following information in sections (11-16) may not always apply in all countries but is usually provided.
1.3 Personal Protective Equipment
All petroleum products are hazardous and toxic. They can be handled safely if a level of care appropriate to their potential harm is exercised. The purpose of personal protective equipment is to prevent a hazardous material from coming into contact with the body.
Section 11: Toxicological information Section 12: Ecological information Section 13: Disposal considerations Section 14: Transport information Section 15: Regulatory information Section 16: Other information
The principal means of contact are: Direct contact to the skin or eyes. Inhalation of vapors or mists. Absorption through the skin.
The SDS is not simply another piece of paperwork that forms part of the overall job documentation. The SDS will tell you the level of respiratory protection you will need and what additional types of personal protective equipment could be needed.
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The maximum concentration of air contaminant must not exceed 10 times the "time weighted average" (TWA) of the "Permitted Exposure Limit" (PEL) or 1000 ppm, whichever is LOWER . Ensure that you have the correct type of canister. There are seventeen different types of canisters for various types of commonly encountered air contaminants along with numerous others for special situations. Ensure that this type of respirator is suitable for use with the anticipated contaminant. There are many contaminants that a half mask or full facepiece respirator will not provide protection against. These include H 2 S, Methanol, Sandblasting, Toluene, Mixed Xylene. The above is not a complete list. Always check the manufacturer's list of prohibited use contaminants. Every respirator user shall receive fitting and use instructions. Respirators shall not be worn when conditions prevent a good face seal. This includes beards and sideburns.
Respirators must be inspected and cleaned at least weekly. Disinfectant wipes are the most common cleaning agent although warm water and a mild detergent is also acceptable. Care must be taken to ensure that the canisters themselves are not affected by the cleaning agent. Cartridges have a LIMITED WORKING LIFE and must be replaced when any odor, taste or irritation is noted; or, if breathing becomes difficult. If the contaminants nasal detection range is greater than the "Permitted Exposure Level" (PEL) such as with acrylonitrile, then cartridges must be replaced at least every 24 hours. This also applies if you are uncertain about the warning properties of the contaminant. A rise in canister temperature indicates that gas or vapor is being removed from inhaled air. An uncomfortably high temperature indicates a high concentration of vapor or gas and requires an immediate return to fresh air. Whenever a canister is put into service, the date must be written in the space provided on the indicator band. With the exception of cleaning, these requirements are applicable to both disposable and non-disposable respirators.
Medical surveillance of respirator wearers must be established. The wearer must be physically capable of wearing a respirator. This typically includes a fit test every year and a pulmonary function test every three years. 1.3.1.2 Full Face-Piece Respirators The full-face piece respirator is designed to make a gas tight fit over the eyes, nose, mouth and under the chin. The advantage of full-face piece respirators over the half mask respirator is that they can be used on certain materials whose vapors are corrosive in nature, such as caustic soda, phenol and sulfuric acid. Additionally, they can provide protection against higher concentrations of contaminant than a half mask respirator can. However, they have all the basic limitations of half mask respirators. This segment is to be read in conjunction with the previous segment on half mask respirators. All the limitations applicable to half mask respirators also apply to full face-piece respirators; however, the air contaminant concentration limit must not exceed 50 times the "time weighted average" (TWA) of the "permitted exposure limit" (PEL) or 1000 ppm, whichever is LOWER.
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Different Types of Head Masks
Breathing Apparatus Holder
1.3.1.3 Self Contained Breathing Apparatus (SCBA) Self Contained Breathing Apparatus (SCBA) respirators are units that allow the wearer to carry his / her own supply of breathable air which is independent of the surrounding atmosphere; providing protection against oxygen deficiency and toxic atmospheres. The chief limitations of these units are: They do not afford protection against contaminants that can be absorbed through or are extremely irritating to the skin; such as ammonia, hydrochloric acid, hydrogen cyanide, etc., or unknown toxic waste. They are heavy and bulky and cumbersome to use in confined spaces. They have a short service life; as little as 15 minutes under some circumstances. Specifications: Self contained breathing apparatus respirators vary in scope and design of operation. The following outlines the specifications that are required or desirable in those units that we have in service:
Panorama Nova Respirator
Panorama Nova RA
Whistle
Panorama Nova P
Kareta Nova
Resistance warning device
Positive Pressure Demand Valve. The demand valve reduces the pressure of the air from that of the tank at 155 kg / cm2 (2216 psig) to that of a breathable pressure. A positive pressure demand valve ensures that the pressure in the face mask is always above the external atmospheric pressure and therefore any leakage due to a poorly fitting face mask will be outward. The use of "Negative Pressure Demand Valves" (whereby air is drawn into the facepiece by the negative pressure created when the wearer inhales) is PROHIBITED.
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Open Circuit SCBA is designed so that the exhaled air containing higher concentrations of carbon dioxide and a lowered concentration of oxygen is exhaled directly to the outside atmosphere. SCBA respirators should not be used unless you have received full instructions for their use and have been given a face piece fitting test. They shall not be worn when conditions prevent a good face seal. This also includes beards, sideburns and eyeglasses (contact lenses are also prohibited). It is also very important to carefully read the operating and maintenance instructions that come with each unit. It is not the intention of this document to reproduce these instructions here, as they vary from unit to unit; however, there are two points common to both that are worthy of reiteration: Most of the units in our service are approved as 30-minute devices. HOWEVER , the actual duration will vary due to many factors including the degree of physical activity, the physical condition of the user, the amount of experience that the user has with the equipment, etc. The actual duration could be as low as 15 minutes. On all units a warning WHISTLE will sound when 20-25% of the useful service life of the air tank remains. You must evacuate the area you are working and go to the nearest fresh air base as soon as this alarm goes off.
It is the responsibility of each branch or division manager to ensure that SCBA respirators are cleaned and inspected at least monthly. Follow the manufacturer's cleaning and periodic maintenance schedules paying particular attention to specific replacement dates for critical parts, such as tilt valves and seals. These units must only be repaired by an approved service technician and must never be modified except by the manufacturer. Air-line supplied respirators are basically a SCBA unit that is supplied by an air hose as opposed to a portable bottle. These are very useful for extended operations but should only be used with a 5-minute (minimum) emergency bottle in the event air hose is cut or restricted. 1.3.2. Head, Face, Hand and Foot Protection 1.3.2.1 Hard Hats All field personnel are to be issued a safety hat (hard hat) which must be worn at all times when in terminals or refineries, on vessels, in warehouses, etc. That is, any time you are working, except when in your vehicle or an office building. To help protect the eyes from the impact of flying objects and liquid splash, all field personnel are to be issued single lens goggles with flush sides and indented temple areas.
Goggles are to be worn when gauging or sampling any material or at any other time when there is a likelihood of liquids or objects getting into the eyes. If goggles are worn over sight correcting glasses then the glasses are to have impact resistant, splinter proof lenses. Contact lenses MUST NOT be worn when working in the field, regardless of whether goggles are worn. The vapors from petroleum and petroleum products can dangerously affect the wearing of contact lenses. Removal of goggles: if you are sprayed with a petroleum product you must get under a shower as soon as possible; and, it may be necessary to remove the goggles to be able to see the way to the shower. If you cannot see sufficiently to locate a shower with the goggles on, the following precautions must be taken to keep any of the splashed material out of the eyes: Bend over until looking directly at the ground. Pull goggles down and away from the face by stretching the headband and then slipping them over the top of the head. Place the hand across the forehead and then straighten up and proceed to the nearest shower.
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1.3.2.2 Face Shields For use in areas where product / chemical splashes pose a greater than average hazard or when handling very corrosive material such as strong acids or bases where protection beyond that of goggles is required. Face shields are NOT to be worn independently of safety goggles. Their purpose is to provide additional protection to the face and are not designed as a substitute for goggles. 1.3.2.3 Gloves Hand protection is extremely important as the parts are irreplaceable. Additionally, many petroleum products are ingested into the body through the skin and the hands are the primary contact point for any material.
Molded Handwear
Nitrile gloves are rated for medium to heavy duty use and provide above average abrasion and puncture resistance for use with chlorinated, aromatic and petroleum-based solvents, most alcohols, salts detergents and acids. Not recommended for use with methyl ethyl ketone (MEK); otherwise, a good choice for standard issue. Disposable gloves are not recommended for most field applications as their construction does not usually provide sufficient tear and puncture resistance. 1.3.2.4 Shoes All employees are required to wear safety shoes when working in a "field environment". They may be in the style of shoes or boots, provided that they meet local or national requirements 1.3.2.5 Uniform All employees are issued an SGS Uniform. This may in the form of coveralls or shirt and pants. Depending upon your location, they may also be constructed of a flame-retardant material such as NOMEX. You are required to wear your uniform whenever you are working.
121/2” length rough finish
121/2” length embossed finish
151/2” length embossed finish
161/2” length rough finish
Gloves come in all types, shapes and sizes, with as many different applications. When choosing a type of glove, you should be guided by the following: Cotton or woolen gloves must not be used except as inner liners for cold weather or as part of a thermal liner for handling hot materials such as asphalt: and must be fully covered by the outer glove. extending at least halfway between the wrist and elbow. Gloves with elastic wristbands are specifically prohibited. Only gloves made of nonabsorbent materials such as latex, rubber, vinyl plastic, neoprene, butyl rubber, nitrile, viton, etc., are to be used. Leather gloves are not to be used. Gloves should be of the gauntlet type
Coated Work Gloves
Fully coated gauntlet
Fully coated safety gloves (band top)
Fully coated kurlwrist
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Skin Exposure If spilled on clothing or skin, remove contaminated clothing, wash effected area with soap and water. Breathing Remove victim to a fresh air area immediately; if breathing has stopped administer artificial respiration (CPR); call for immediate medical assistance. Swallowing Call for immediate emergency medical assistance, do not induce vomiting. Respirators are required when work control practices are such that airborne concentrations exceed permitted exposure levels. The minimum required respiratory equipment is: 10 ppm or less. Half mask respirator with organic vapor cartridge. 50 ppm or less. Full face respirator with organic vapor cartridge. Over 50 ppm. Self contained breathing apparatus with full face piece in positive pressure mode.
Short Term Exposure Limit (STEL): 5 ppm for any 15-minute period.
1.4 Hazardous Materials Handling 1.4.1 Benzene
Benzene is a toxic substance of which exposure to high concentrations produces almost immediate acute or chronic effects to the nervous system. Benzene is usually ingested by the inhalation of vapors, which are then readily absorbed into the blood. It can also be absorbed through skin by direct contact and greater levels of absorption occur through broken skin such as cuts, scrapes, etc. Acute Exposure is short term exposure to high concentrations that will typically result in any combination of the following: Shortness of breath, irritability, euphoria or intoxication. Irritation of the eyes, nose and respiratory tract. Headache, dizziness and nausea. Severe acute exposure can lead to convulsions and loss of consciousness. Chronic Exposure is repeated and prolonged exposure which even at relatively low concentrations can lead to serious blood disorders, including leukemia. Eye and Face Exposure Exposed area should be washed immediately with large amounts of clean fresh water.
Although the greatest risk of exposure to benzene will be during the handling of a benzene cargo itself, benzene is also known to be present in other petrochemicals, many crude oils and petroleum products such as gasoline and other light hydrocarbons. The characteristics of benzene are: A clear, colorless, noncorrosive liquid with a strong, pleasant, sweet odor. Highly flammable, having a flash point of -11 ° C (12 ° F). All fire and explosion precautions must be observed. Readily gives off vapors that are three times heavier than air; therefore, be very cautious of areas such as sumps, excavations and natural windbreaks, in addition to confined spaces where vapors can accumulate. Permissible Exposure Limit (PEL): A time weighted average (TWA) exposure limit of 1 part of benzene vapor per million parts of air, 1 ppm for an 8-hour workday or 0.67 ppm for a 12- hour workday.
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Typical exposure levels have been established ( note - these may differ based upon geographical location): Permissible Exposure Level (PEL) 5 ppm Short Term Exposure Level (STEL) for 15 minutes 10 ppm Only self-contained breathing apparatus respirators are approved for protection against hydrogen sulfide. Exposure Exposure to low concentrations cause irritation of the skin, eyes and air passages. H 2 S is absorbed by the blood, combines with the hemoglobin and produces asphyxia. High concentrations cause sudden paralysis of the respiratory system resulting in coma and rapid death. Treatment speed is critical. Victims must be removed to fresh air immediately. If breathing has stopped, give artificial respiration at once as they will NOT resume breathing on their own. Call for immediate medical assistance. H2S is heavier than air. This factor adds to the potential danger of the toxic and explosive effects of H2S. Be especially cautious of low-lying areas and natural wind breaks.
1.4.2 Hydrogen Sulfide Hydrogen Sulfide (H 2 S) is probably the most dangerous gas commonly encountered in the petroleum industry. Although rarely handled as a commercial commodity, it is found in almost all crude oils and even refined products, especially fuel oils. Both petroleum refineries and natural gas processing plants must treat H 2 S, which is an unwanted pollutant, and a potential source of exposure. The term "sour" is usually applied to crude oils and gas feedstocks that have high concentrations of H 2 S. The sense of smell is not reliable for detecting the level of concentration of hydrogen sulfide. At 100 ppm the sense of smell is deadened within minutes. H 2 S is a colorless gas which has a sweetish taste and an unpleasant odor of "rotten eggs". There are three major hazards associated with hydrogen sulfide; toxicity, flammability and corrosion. However, the most consistently dangerous of these three hazards is toxicity. H 2 S is very poisonous, being 5 times as toxic as carbon monoxide and almost as toxic as hydrogen cyanide. While H 2 S can be detected nasally at concentrations as low as 0.2 ppm, even relatively low concentrations rapidly paralyze the olfactory nerves and lead one to a false sense of security.
Gauging and Sampling Always check in with the terminal / refinery shift supervisor prior to entering active work areas. Facilities that handle benzene are required to determine and designate areas where high concentrations of benzene vapor are likely. Be on the lookout for posted "Benzene Designated Areas". Never enter such an area without respiratory protective equipment. Whenever possible, you should not work over openings in tanks that are actively receiving benzene. If this should happen, you MUST wear a self-contained breathing apparatus unit. A full- face piece respirator with organic vapor cartridges is mandatory when performing manual gauging and / or sampling of benzene or, if there is a splash or spill hazard. Viton or nitrile gloves must be worn when contact with skin is possible. Neoprene boots and chemical suit must also be worn if a splash or spill is possible. A safety data sheet (SDS) is an excellent source of safety information and is also an essential part of our "hazard communication program" (hazcom). Personal hygiene is very important when handling benzene or any other chemical. Always keep food and drink away from chemicals and their vapors; and wash your hands thoroughly before eating or drinking.
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You must keep in mind that whenever a piece of your equipment touches any other equipment or structure that is electrically conductive and grounded, then the potential for sparking from a static electrical discharge exists. The discharge or sparking of the accumulated charge is the primary manifestation of static electricity. Ground your equipment and yourself, before opening the gauge hatch. You will have little control, or knowledge, of the vapor / air mix inside the tanks you are working. ALWAYS assume that a commodity is flammable and that a tank atmosphere is between its' upper and lower explosive limits. ALWAYS assume that a commodity is flammable and that a tank atmosphere is between its' upper and lower explosive limits.
Do not lower equipment into tanks where abnormal sounds such as dripping water or steam leaks are suspected. These types of situations, especially steam, can create a heavily ionized atmosphere which will increase the risk of electrostatic build up immensely. Report this type of condition to a responsible vessel or terminal representative. Using a tank's handrail or casually touching tank fixtures aids in bleeding a static body charge. Any electrical or electronic device must be grounded prior to and at all times during its entry into a tank. The ground connection must be firmly attached to an integral part of the tank structure, preferably away from the gauge hatch. Product handling, pumping, mixing, blending, etc., is a major producer of electrostatic generation. It is therefore very important that a period of relaxation be allowed after a product activity, prior to gauging, sampling etc., to allow for charge dissipation. Active tanks should not be gauged or sampled, unless the vapor space is known to be inert.
Some materials, however, have been found to be more susceptible to static generation than others; for example: Ropes and cords used with sampling devices and thermometers must be of 100% natural fiber such as cotton. SYNTHETIC FIBER CORD OR ROPE MUST NOT BE USED. Hazardous electrostatic charges can accumulate only on bodies that are relatively well insulated from each other; and the ground. Otherwise, charges leak away and recombine with their counterparts as fast as they are formed. There are many things that YOU can do to prevent the buildup of an electrostatic charge. Only use gauging tapes that are approved for use in the petroleum industry. Tapes designed for use in other industries may have a protective coating, such as teflon, which acts as an insulator, thereby preventing the dissipation of the charge. Always keep the gauging tape or sampling cord in continuous contact with the rim of the gauge hatch unless some part of it is immersed in the liquid.
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When testing for the presence of H 2 S in a confined space, you MUST test the BOTTOM of the tank or space. When gauging or sampling, always stand upwind of the gauge hatch, even if test results indicate low H 2 S readings. Be especially careful on very calm days. When working sour crude or other known or suspected H 2 S contaminated material, you must establish the level of H 2 S contamination of each tank prior to commencement of any other type of work. You are required to wear a SCBA respirator while performing this test function. Refineries are not the only industrial sources of H 2 S. It can be found on drilling rigs, pulp mills, leather tanning factories, iron and steel mills, viscose rayon plants, sewage treatment facilities and any agricultural facility where rot, mildew and decay of organic matter might occur. Some crude oils are known to have very high levels of H 2 S. However, all crude oils and fuel oils have the potential of having very high levels. Readings as high as 64,000 ppm have been recorded. These are extremely dangerous levels which could be fatal almost instantaneously. Additionally, the head space of a crude oil cargo is frequently a mixture of inert gas and H 2 S. These two in combination are even more dangerous.
The hazards associated with confined spaces fall into the following groupings: Oxygen Deficiency. Flammable or Explosive Mixtures. Toxic Atmosphere. The purpose of this section is to describe what a confined space is and to advise you that this level of training does not include the requirements of confined space entry and that you are not authorized to enter confined spaces until such time as you receive the required training. 1.6 Static Electricity This section addresses the hazards associated with static electricity, along with various measures that should be taken to prevent or reduce the associated risks. There is not a lot that can be done to prevent the generation of static electricity. The inspector has little control over the speed at which a product is pumped through a pipeline and winding up tapes or lowering thermometers into tanks is an unavoidable part of the daily routine.
1.5 Confined Space Entry Confined spaces pose a special and particular hazard to those employees that are required to work in them. A confined space is designated as having one or more of the following characteristics: Limited openings for entry and exit. Unfavorable natural ventilation, which could contain or produce dangerous air contaminants or pollutants.
Manholes
Sewers
Tunnels
Ships’ holds
Wells
Tanks
Subcellars
Not intended for continuous employee occupancy.
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H 2 S H 2 S vapors deaden a person's sense of smell. A self-contained breathing apparatus is the only permissible respiratory protection. Confined Space Entry You are not permitted to enter confined spaces without the specified training. Static Electricity Always ground your thermoprobe or any other electronic device before opening the gauge hatch.
1.7 Conclusion Filter Respirators Do not provide oxygen.
Can never be used above 1000 ppm. You must have received a fit test and a pulmonary function test before you are allowed to wear a respirator. SCBA Use of negative pressure demand valves is prohibited. Personal Protection A hard hat, gloves, safety shoes, goggles and uniform are the minimum in personal protective equipment required for all jobs. Benzene Exposure above 1 ppm requires respiratory protection. Liquid benzene is readily absorbed through the skin.
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2. Sampling
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Sampling methods are designed to capture a sample of the material in a tank; or flowing through a pipeline that is representative of the whole. There are many conditions which may cause a sample to be nonrepresentative; such as stratification resulting from temperature, density or other differences in product composition. If these differences are extreme, it may be impossible to obtain a representative sample by manual methods.
Caps, Restricted Flow Caps, Split Corks, or Stoppers Sampling equipment must be properly maintained to obtain good samples. Sampling equipment must first be clean. Some analytical tests measure impurities to ppm (parts per million) and even ppb (parts per billion). Therefore, a very small amount of residue in a sample container can result in an erroneous test result. This is the principal drawback of the beaker sampler. It is difficult to ensure that all residue from the previous sample is removed. In addition, sample cords must not contain residue from incompatible material.
2.1 Introduction The Sampling is one of the most important job functions performed. The concept of sampling is to take a small portion of a product that is representative of a much larger portion. Usually, the amount of sample taken is only a tiny fraction of a percentage of the entire cargo. Therefore, the importance of exercising due care and diligence when taking samples cannot be over emphasized. Laboratories typically have millions of dollars invested in equipment, some of which can measure down to parts per billion. However, all this investment in equipment is only as good as the sample that is taken. All the laboratory equipment in the world cannot compensate for a nonrepresentative sample. Samples of crude oil and petroleum products are taken to determine physical properties (such as API and S&W, chemical components, such as sulfur and benzene), and compliance with quality specifications such as those required in sales contracts. Samples may also be taken to ensure that the commodity is not contaminated during transfer. Sampling technique is important because oil and chemical products may not be homogeneous and may contain impurities.
2.2 Equipment A variety of equipment is used to perform
manual sampling, some of which are shown in the figure on the following page. These include: Natural Fiber Cord or Chain Amber, Clear Glass, Plastic Bottles or Metal Cans (Sometimes Lined) Sample Thief’s, Beakers, Sampling Cans, Bacon Bombs or Zone Samplers Lead Weight or Bottle Catcher (Cage)
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1 Quart Weighted Bottle
1 Quart Weighted Beaker
Certain sample containers should not be used with some products. A product requiring extreme care is jet fuel. ASTM has written one entire standard (ASTM D 4306) to describe the proper sampling containers to be used, depending upon the tests to be performed. In general, epoxy lined steel cans are preferred for all testing except metals. The can must be rinsed three times with the product being sampled before use. High density polyethylene containers are preferred for trace metal and lubricity analysis. Aluminum containers must not be used. Also, equipment containing brass or copper must not come into contact with the sample or the cargo. Gasoline and naphtha samples are not taken in clear glass bottles or unlined cans. Cool the sample containers before filling, by immersing them in the product. This also rinses the bottle with the product to help insure contaminants are removed.
Clove hitch
Cork detail
Eyelet
Cork Washer
Cork Arrangements
11/4” pound lead weight
11/4” copper wire handle
Copper wire lugs
3”
1 Quart Weighted Bottle Catcher (can be fabricated to fit any size bottle)
Sheet lead
31/4”
Beaker
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It can be problematical to take all level samples reliably as it is difficult to remove the stopper at the bottom of the tank. This may cause the sampler to insert the cork too loosely, so that it falls out of the bottle before reaching the bottom, an event that may remain undetected and ruin the sample. Another problem can occur if the sampler fails to begin raising the bottle as soon as the stopper is out. The sample will then contain too much product from the lower part of the tank. For these reasons, an all-level sample is not recommended. 2.3.2 Running Sample A running sample is obtained by lowering an open (unstoppered) device to the bottom of the bottom of the outlet suction level, but always above any free water, and returning it to the top of the product at a uniform rate such that the sampling device is between 70% and 85% full when withdrawn from the product or discarded. Flow restrictors are used if the bottle cannot be moved through the liquid rapidly enough to achieve this result. 2.3.3 Spot Samples Spot samples are those samples taken from a specific location in a tank, (refer to the diagram on the following page), or from a pipeline.
Spot samples are taken by lowering a stoppered bottle to a designated point in the tank, removing the stopper with a sharp jerk, and allowing the bottle to fill completely before withdrawing it. After removing the bottle from the tank, product is poured from the bottle, so it is around full before closing. Spot samples can be taken from any point in the tank; however, API MPMS Chapter 8.1 defines certain specific points where spot samples are routinely taken. These include: TOP: Six inches below the upper surface of the liquid. UPPER: Middle of the upper third of the liquid. MIDDLE: Middle of the liquid. LOWER: Middle of the lower third of the liquid. BOTTOM: Bottom surface of the tank, sometimes called the Dead Bottom. 3", 6", etc: Sample taken a specified distance from the bottom of the tank, usually using a Bacon bomb with an extension rod.
2.3 Types of Samples s What samples should be taken? This is a key critical item. This information is usually provided to us in the inspection nomination and this information is passed onto you, the inspector, on your job instruction form. It is normal to take multiple samples on a product transfer. For example, typical sampling instructions would be to take upper, middle and lower samples from each shore tank; a spot sample from the shore pipeline at start up and a running sample out of each barge tank. 2.3.1 All Levels Sample An all-levels sample is taken by lowering the stoppered device to the bottom of the outlet suction level, but always above any free water, then opening the sampler and raising it at a uniform rate such as it is between 70% and 85% full when withdrawn form the product . For light products or deep tanks, a restricted opening may be necessary to avoid filling the bottle. No product should be poured from the bottle before closing. If the bottle is more than 85% full the sample should be discarded, and the sampling repeated.
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