Site Visit Report

An analysis of two hazards at

Bossong Engineering, Welshpool, WA

and

BP Refinery, Bulwar Island,

Queensland

and the environmental Impact of both sites

Report for Associate Professor Nicoleta Maynard

Written By

Name - Myo Ko Ko

Student ID - 16568455

Tutor - Una Carabba

(Engineering Foundations: Principles and Communications)

(1479 words)

Executive Summary

The objective of the report was to identify a safety hazard at each of the two Engineering sites namely Bossong and BP. It also aims to produce the nature of the relationship between each site and its respective environment, both in terms of the location impact on the site and the environmental impact on the site.

In doing so, it brought attention to the need to revise the level of negligence or complacency in the workplace which turns potential hazards into actual incidents.

In the case of BP, the hazard is possible explosion.

In the case of Bossong, the extreme temperature of heavy machinery in the workplace.

As a result of primary investigation and secondary research, the findings are that the possibility of explosion was due to mismanagement and handling of dangerous chemicals for BP. The accidental touching of extremely hot and cold equipments during the processing time was also a major concern for Bossong.

The report makes the following recommendations;

Provide regular training for staff

Regular inspections of faulty chemicals and equipments

Provide instruction manuals on each machine

Extra Protective Clothing

The audience of this report is Associate Professor Nicoleta Maynard.

Table of Contents 1.0 Introduction ....................................................................................................................................... 1

1.1 Purpose and Audience .................................................................................................................. 1

1.2 Brief Backgrounds of the Sites ...................................................................................................... 1

1.3 Scope and Limitations ................................................................................................................... 1

2.0 Environmental Effects on Plants ....................................................................................................... 2

2.0.1 The plants Impact on the Surrounding Environment ................................................................. 2

2.0.2 The Location of the Plants and Their Impact on Plants' Safety .................................................. 3

2.1 Hazardous Conditions on each site ................................................................................................... 4

2.1.1 Possible Explosion in BP Refinery .............................................................................................. 4

2.2.2 Temperature of Machinery in Bossong Engineering Site ........................................................... 5

3.0 Conclusion ......................................................................................................................................... 6

4.0 Recommendations ............................................................................................................................ 7

5.0 Referencing ....................................................................................................................................... 8

6.0 Appendix............................................................................................................................................ 9

6.0.1 Appendix 1:Final Reflection........................................................................................................ 9

6.0.2 Appendix 2 ................................................................................................................................ 11

Table of Figures Figure 1 BP Refinery, Bulwar Island, Queensland and its surroundings (map.google.com) ................... 2 Figure 2 Bossong Engineering and its surroundings(map.google.com) .................................................. 3 Figure 3 BP Refinery in Texas City Explosion(www.csb.gov) ................................................................... 4

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1.0 Introduction

1.1 Purpose and Audience

The purpose of this report is to discuss the impact of the plant on the safety of surrounding environment and the location of the plant impact on the safety of the plant itself. Also one hazardous condition created by each plant is needed to be identified and commented. Two sites used for this report are Bossong Engineering, Welshpool, Western Australia and BP refinery, Bulwar Island, Queensland. The audience for this report is associate professor Nicoleta Maynard.

1.2 Brief Backgrounds of the Sites

The BP refinery located in the Bulwar Island, Queensland is bounded by Brisbane River and Boggy Creek which is currently producing 101,000 barrels of oil per day. It was constructed by Amaco in 1965 but was bought by BP in 1984 and has developed gradually into current state which mainly produce fuels for transportation. About 340 workers are employed in this site. The range of fuels product from this refinery mainly include petrol, diesel, aviation fuels and LPG(liquid petroleum gas).

Bossong Engineering was found in Western Australia in 1988 by Steven and Janice Bossong in servicing oil and gas and mining equipments and machinery. It has both Australian and international market and has developed significantly to meet the future industries demand. It is recognised as market leaders in non-magnetic repairs, robotic wielding and machining services, etc based on quality, precision and flexibility.

1.3 Scope and Limitations

The report will include the pollution of air and water caused by BP refinery, the industrial accidents, noise and waste storage by Bossong Engineering site, the expected environmental issues and the impact of location affected to both sites and the potential explosion hazard in BP refinery and the intense temperature created by functioning machines and equipments in Bossong Engineering site. The report is limited by the word count(1500 words), the photos not being able to taken during the actual site visit, the limited research and only one hazard is restricted to described for each site.

2.0 Environmental Effects on Plants

2.0.1 The plants Impact on the S

Figure 1 BP Refinery, Bulwar Island, Queensland and its surroundings

According to figure 1, it is discovered of the river and on the mouth of theclose proximity. The fuel refining process release a number of toxic chemical gases into the air. (World Bank Group, 1998, 377)refinery. It will mainly have negative impact onareas and the harbour. Apart from air pollution, there are also The refineries use a large amount of water for cooling systems and the wastewaters are also generated. (Beychock, 1967, 126)river and the sea so that it will affect

2.0 Environmental Effects on Plants

2.0.1 The plants Impact on the Surrounding Environment

BP Refinery, Bulwar Island, Queensland and its surroundings (map.google.com)

According to figure 1, it is discovered that the is located beside the airport and on the bank and on the mouth of the open sea. The port and the residential area

The fuel refining process release a number of toxic chemical gases into the Bank Group, 1998, 377). Also a notable odour is present due to

have negative impact on the atmosphere of the airport, residential Apart from air pollution, there are also concerns for water pollu

The refineries use a large amount of water for cooling systems and the wastewaters are also (Beychock, 1967, 126). The waste from this site will mainly be disposed into the

river and the sea so that it will affect both the purity of water and the marine life.

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(map.google.com)

is located beside the airport and on the bank open sea. The port and the residential areas are also in

The fuel refining process release a number of toxic chemical gases into the Also a notable odour is present due to the nearby

the atmosphere of the airport, residential concerns for water pollution.

The refineries use a large amount of water for cooling systems and the wastewaters are also The waste from this site will mainly be disposed into the

and the marine life.

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Figure 2 Bossong Engineering and its surroundings(map.google.com)

According to the figure 2, it is clearly seen that the Bossong Engineering plant is located in the industrial area close to the residential area and a railway line. The risks of industrial accidents such as fire and explosion can also effect the nearby factories and local housings. Besides the noise health effects due to industrial noises can affect the residential areas. The waste products are also stored in one large container and they are really expensive to dispose so that the waste are disposed gradually from that container in several ways(Personal Communication, site manager). Industrial accidents, noises and the undisposed waste can mainly affect the surrounding environment.

2.0.2 The Location of the Plants and Their Impact on Plants' Safety

As BP refinery is located at the bank of the river and near the sea, the coastal erosion is possible. The Brisbane Times(June 29, 2009) reported that some of the most valuable beachfront properties in Queensland are in danger of severe erosion across the coastline. Therefore, as the site located within the same state, there is a chance that the similar situation will happen in the future. In 2011, a series of floods hit the state of Queensland including its capital city, Brisbane due to the heavy rain and several rivers in the state broke their banks with 35 people dead and 200,000 people affected(Australian Red Cross 2012). Due to the record of this devastating disaster, a history can repeat itself and the safety of the BP refinery are in concern.

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The Bossong Engineering site is constructed on a flat terrain with sandy soils which does not absorb water well(Personal observation). It has well-designed drain system to prevent flooding from heavy rain. It is also surrounded by other industrial buildings. Perth experience the Mediterranean climate consists of hot, dry summers and mild, we winters. During some days in summer, the temperature can be raised up to more than 40 degree Celsius and in winter, it can be nearly zero degree Celsius(Australian Bureau of Meteorology). This will affect the temperature in the workplace of the site, too. Workplace temperature that are too high or too low can contribute to fatigue, heat-illness and cold related medical conditions.

2.1 Hazardous Conditions on each site

The hazard identified for the BP Refinery is the possible explosion and for Bossong Engineering site, the temperature of machinery.

2.1.1 Possible Explosion in BP Refinery

Figure 3 BP Refinery in Texas City Explosion(www.csb.gov)

On March 23, 2005, a series of explosion occurred at BP Texas City. Explosion in the oil refineries are possible during the operating times and even during the periodic shut down of a refinery process unit or plant to perform maintenance where explosive contents are required to remove in and out of position(US Chemical Safety Board Final Report, 2007). Although oil refinery sites are constructed differently from one another, their main components and functions are the same. According to the Arnold & Itkin LLP, industrial injury attorneys, the main common causes of plant explosions are

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Boilers that are not properly cared for Malfunctioning and dangerous equipment Improper maintenance of machinery The use of impure or dirty chemicals Failing to properly train all employees

Although all the site employees in this BP refinery are well trained in terms of quality and occupational health and safety as well as the regular checking of the equipments in the sites, one single minor fault mentioned above can result in an explosion.

2.2.2 Temperature of Machinery in Bossong Engineering Site

A wide range of machines including drills, cranes, filters, wielding tools and robotic arms are constantly running throughout the site during the working hours(personal communication, site manager). All these equipments are in a wide range of temperature while being operated. According to Code of Practice (Safeguarding machinery or plant) released from department of commerce, WA, there are a range of hot and cold hazards including

incidents where people constantly need to work near a very hot or cold machine extreme heat or extreme cold, which may affect machinery operations; and injuries that may occur if there is contact

Therefore it is obvious that employees who work within the range of such types of machines are in possible danger.

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3.0 Conclusion

In conclusion, BP refinery mainly contaminate air and also water due to being located near the river and the sea. Bossong Engineering site may negatively affect the surrounding environment with industrial accidents, noises and the storage of the waste products. The coastal erosion and the flooding can be the environmental issue for the BP refinery. Although Bossong was located in well-suited area with flat terrain, the temporary extreme climatic temperature may create issues on safety of the site. One hazardous condition for BP refinery is the explosion in part of the site due to human and equipment errors or the handling of chemicals. The temperature of operating machines in Bossong Engineering site can affect the safety of the plant in terms of handling those machines by the workers.

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4.0 Recommendations

Improvements are needed to be done in both sides to ensure that those specified hazards are being avoided. For BP refinery, all the employees are needed to give regular trainings of occupational health and safety. By doing so, the staff will always be aware of the danger of accidents and will be able to react immediately even if there is an emergency case. It also needs strict and regular inspections of the faulty chemicals and equipments so that they can be replaced or fixed before . In terms of Bossong Engineering, instruction manuals showing how to operate each equipment should be available near the machine will greatly help the staffs to process the task without any accident touch or handling. Also extra protective clothing including facemask, helmet, gloves and protective wearing will be able to add as another additional layer of protection.

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5.0 Referencing

Arnold & Itkin LLP. Common Causes of Plant Explosion. http://www.industrialinjuryattorney.com/Industrial-Accidents/Plant-Explosions/Causes-of-Explosions.aspx (accessed 10th September 2012)

Australian Bureau of Meteorology. Weather Observations for Perth Area. http://www.bom.gov.au/wa/observations/perth.shtml (accessed 9th September 2012)

Beychok, Milton R. 1967. Aqueous Wastes from Petroleum and Petrochemical Plants (1st Edition). John Wiley & Sons.

Brisbane Times. 2007. Coastal Erosion Battle Escalates. http://www.brisbanetimes.com.au/national/coastal-erosion-battle-escalates-20090629-d1fi.html (accessed 7th September 2012)

Department of Commerce. Code of practice(Safeguarding machinery and plant) http://www.commerce.wa.gov.au/worksafe/PDF/Codes_of_Practice/Safeguading%20of%20machinery/Risk_management.pdf (accessed 10th September 2012)

Red Cross Australia. 2012. Queensland Floods 2011. http://www.redcross.org.au/ourservices_acrossaustralia_disasteremergencyservices_Queensland-floods-2010.htm (accessed 8th September 2012)

US Chemical Safety Board. 2007. Investigation Report BP Texas Refinery. http://www.csb.gov/assets/document/CSBFinalReportBP.pdf (accessed 10th September 2012)

World Bank Group. 1998. Petroleum Refining. Pollution Prevention and Abatement Handbook. 377

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6.0 Appendix

6.0.1 Appendix 1:Final Reflection

At the start of the EFPC unit, I have learnt that there were a lot of task to do during the whole semester according to the unit outline. They include both individual and group work. During Stage one, we were advised to form a group so that I became part of the group with other four students I have never met before. Also they were not the same nationality as me so that the only way to communicate with them was in English which helped me to use English more often. We decided who would become contractors and designers and I became one of the designers. Then I needed to learn tasks to be done as a designer so that I had a responsibility to be part of a team. Our group was assigned for a bridge. As a designer me and other designer need to discuss about how we design a bridge. It was no doubt the hardest part for two of us but we finally managed to produce a good design. We also wrote specification together. Also weekly progress report has been a new experience for me. There was not only an individual tasks in it but also group organisation that were needed in order to achieve a good score. Although we only managed to get a mere score for our first week, our marks had been dramatically improved in our next reports.

For stage two, we need to meet with other contractors from other assigned group for tendering process. It was also a good experience of dealing with new people as a form of professionals. At that stage we, designers learnt that there were requirements in our tender evaluation criteria which contractors at that time took responsibility to do that. It was due to lack of communication with contractors during stage one. But in the end we were able to produce a good designers' tender review and able to choose the most preferred contracting company. They did not disappoint us by building a good bridge which matched our disposal plan in stage three. Every time we inspected our bridge, they produced favourable progress during the construction.

In stage four before the official testing, we were required to test our bridge initially to ensure it could hold certain rolling loads and passing vehicles as well as the amount of static load failure. We learnt that the initial testing was as important as the actual testing because we can predict how well our bridge would perform. On the testing day, our bridge had no trouble with rolling load and passing vehicle and also the static load failure was close with our prediction. Overall, we did a fairly good job with our design while consulting with the building contractors and also the initial testing. The next thing we need to do is the oral presentation about our report. We needed to consider which part we were going to talk about while preparing our presentation. We were able to rehearse before the actual presentation one week before in front of our classmates and tutors so that they gave us very good advices and it greatly helped us to make our presentation to be as good as

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possible. For me, I rarely had the presentation experience before and it was somewhat a totally new and exciting thing to learn.

During the course, we needed to write a site visit report base on one virtual site and one real site we were sent to explore before start writing the report. During the site visit, it was a good way to discover how the real industry was running. At the start, I did not know how to write such kind of report but with the help of the skill development session provided, I learnt how to write a formal report which I would need to write many of this type in the future. We needed to submit our first attempt in week 8 so that we could get a marking feedback from a tutor before the final submission.

In conclusion, EFPC was new, challenging and exciting experience for me. I have done a few tasks which I have never done before and it would greatly help me in my further studies. It also showed how important to work as a team to achieve in engineering industry.

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6.0.2 Appendix 2

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1.0 Introduction1.1 Purpose and Audience1.2 Brief Backgrounds of the Sites1.3 Scope and Limitations

2.0 Environmental Effects on Plants2.0.1 The plants Impact on the Surrounding Environment2.0.2 The Location of the Plants and Their Impact on Plants' Safety

2.1 Hazardous Conditions on each site2.1.1 Possible Explosion in BP Refinery2.2.2 Temperature of Machinery in Bossong Engineering Site

3.0 Conclusion4.0 Recommendations5.0 Referencing6.0 Appendix6.0.1 Appendix 1:Final Reflection6.0.2 Appendix 2