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Appendix 6 Chinese Petroleum Corp. Kaohsiung Refinery

Appendix 6 Chinese Petroleum Corp. Kaohsiung Refinery. Paul Boyce, MD and Jennifer Cavallari, SM. Harvard School of Public Health. Chinese Petrochemical Corp Kaohsiung Refinery. Founded 1946 Refines crude oil into various petroleum products and petrochemical raw materials

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Appendix 6 Chinese Petroleum Corp. Kaohsiung Refinery

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  1. Appendix 6Chinese Petroleum Corp.Kaohsiung Refinery Paul Boyce, MD and Jennifer Cavallari, SM Harvard School of Public Health

  2. Chinese Petrochemical CorpKaohsiung Refinery • Founded 1946 • Refines crude oil into various petroleum products and petrochemical raw materials • Products: Fuel Gas, Diesels, LPG, Asphalt • Capacity: 270,000 Barrels/Stream Day Harvard School of Public Health

  3. Overview • Residue Desulfurization Unit (RDS) • Wastewater Treatment Facility • Maintenance/Contract Workers • Health Screening • Recommendations

  4. Company Overview • 2,000 Employees • Average age: 45 yrs • 35 units • 4 shifts • 200-300 Contract Workers Harvard School of Public Health

  5. Wastewater Treatment Harvard School of Public Health

  6. Residue Desulfurization Unit (RDS) H2S Sulfur Recovery Unit High Sulfur Crude Oil (4.15% Sulfur) + Hydrogen Low Sulfur Crude Oil (0.50% Sulfur) RDS Harvard School of Public Health

  7. RDS Operation Tasks • 6 Workers per shift (4 shifts total) • 1 Foreman • 1 Panelman • 4 Operators • Most processes automated • Majority of time inside positive control room • Operators monitor outside of plant twice per hour • Sampling occurs once per shift • Contract workers for yearly maintenance & repair Harvard School of Public Health

  8. Occupational Hazards - RDS Unit • Explosion and Fires • Chemical Exposures • Respiratory • Dermal • Maintenance-Related Activities Harvard School of Public Health

  9. Explosion and Fire (1) • Prevention • Open flames & cell phone use prohibited • Smoking in designated areas • Safety release valves and 2o emergency release valves • Pressure monitoring systems • Wireless mobile phone system Harvard School of Public Health

  10. Explosion and Fire (2) • Control • Positive pressure control room • Halogen fire extinguishing system • Fire detection and sprinkler system • On-site fire response • Emergency power system • Explosion proof design • Safety drills Harvard School of Public Health

  11. Chemical Exposures (1) • Chemicals include hydrogen sulfide, VOCs, amines, sulfuric acid products and steam • Exposures • Sampling (open and closed system) • Leaks from joints (fugitive emissions) • Valve opening and closing • Accidents • Maintenance activities Harvard School of Public Health

  12. Chemical Exposures (2) • Prevention • Closed sampling system implemented • Monthly monitoring of emissions from joints • Use of respirators during sampling • Gloves Harvard School of Public Health

  13. Wastewater Treatment Plant No.2 • Removal of oil • Concentration and filtration • Treatment via closed sequencing batch reactor • Effluent released to sea Harvard School of Public Health

  14. Wastewater Treatment Plant No.2 Operation Tasks • 28 employees • 4 shifts • Outside monitoring by operators • Periodic sampling Harvard School of Public Health

  15. Occupational Hazards • Chemical Exposures • Biological and water treatment reagents • Hearing Loss • Areas over 85 dBA • Hearing protection provided Harvard School of Public Health

  16. Maintenance • Confined space entry • Formal procedures • Contractual workers • Usually less training and experience • Hit by and fall injuries most common Harvard School of Public Health

  17. Health and Safety Training • Taiwan OSHA based training specific to area hazards • 5 day pre-employment training • 6 month internship • Yearly updates

  18. Health and Safety Programs • Respirator Protection • Fit-testing and training • Hearing Protection • Noise monitoring • Training and protective equipment • Confined Space Entry • Permit requirements • Safety procedures • Training

  19. Health Screening • Dedicated clinic for employee and their families • Annual health exam • Routine monitoring • Pulmonary function testing • Audiometry testing • CBC, liver function and cholesterol • Referrals to KMU Occupational Clinic Harvard School of Public Health

  20. CPC Occupational Incidents over the Past Five Years

  21. Recommendations (1) • Explosion/Fire Safety • Shoes should be worn in control room at all times incase of emergency egress • Chemical Exposures • Continued implementation of closed sampling devices • Safety showers if not already incorporated • Automated monitoring of fugitive gas • Enforcement of respirator & protective equipment usage • Continued personal exposure monitoring • Re-evaluation of exposure standards (ACGIH Guidelines) Harvard School of Public Health

  22. Recommendations (2) • Health Screening • Continued longitudinal follow-up of workers including psychological & neurological screening • Periodic disease surveillance & analysis for industry related disorders • Promote collaboration with universities & governmental agencies • Contract Workers • Evaluation and enhancement of contractor safety program

  23. Acknowledgements • President Wang • Chairman Chen • KMU – Harvard Alliance • Prof. Ming Wu • Prof. David C. Christiani • KMU Master’s Students • CPC – Kaohsiung Refinery

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