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Discover essential occupational safety documents for employees working in the challenging environment of an oil refinery. Learn about protective measures and safety procedures to ensure the health and safety of employees in the high-risk work environment of this industry.

Table of Contents

PART I: CURRENT STATUS OF SAFETY WORK IN OIL REFINERIES

I. General Situation

The Ministry of Labour, Invalids and Social Affairs informs sectors and localities of the occupational accident situation in the first 6 months of 2024 and outlines key solutions to proactively prevent incidents and accidents in the last 6 months of 2024. According to reports from 61 out of 63 centrally governed provinces and cities, in the first 6 months of 2024, there were a total of 3,201 occupational accidents nationwide (a decrease of 227 cases, equivalent to 7.09% compared to the same period in 2023), resulting in 3,065 victims (a decrease of 197 people, equivalent to 6.04% compared to the first 6 months of 2023), including both employees under labor contracts and those working without labor contracts. Specifically:

Number of fatal occupational accidents: 320 cases, a decrease of 25 cases (7.25%) compared to the first 6 months of 2023 (including 245 cases in areas with labor relations, a decrease of 28 cases or 10.3%; and 75 cases in areas without labor contracts, an increase of 3 cases or 4.2% compared to the first 6 months of 2023);
Number of deaths due to occupational accidents: 346 people, a decrease of 7 people or 1.98% compared to the same period in 2023 (including 268 in areas with labor relations, a decrease of 13 people or 4.63%; and 78 in areas without labor contracts, an increase of 6 people or 8.33%).
Number of people seriously injured: 810 people, an increase of 26 people or 3.32% compared to the first 6 months of 2023 (including 710 in areas with labor relations, a decrease of 5 people or 0.7%; and 100 in areas without labor contracts, an increase of 31 people or 44.92%).

Download the PDF file Occupational Accident Report – First 6 Months of 2024 issued by the Ministry of Labour, Invalids and Social Affairs.

The occupational accident situation in the first 6 months of 2024 in both sectors with and without labor relations saw a decrease in the number of deaths and fatal accidents compared to the same period in 2023.

II. Some Occupational Accidents in Oil Refineries

Oil refineries, with their hazardous working environment and complex production processes, often face the risk of serious occupational accidents. Below are some notable accidents that oil refineries have encountered:

Gas pipeline system explosion: In some cases, the use of gas pipeline systems can lead to serious accidents. Incidents can originate from technical failures during operation or from unforeseen events such as gas leaks, leading to explosions or fires.
Accidents with machinery and equipment: In a work environment where machinery and equipment are in continuous operation, accidents can occur due to collisions, loss of control, or technical failures. This can lead to severe injuries or even death for workers.
Fire and explosion hazards: Oil refineries are one of the work environments with the highest risk of fire and explosion. Causes include the combustion of volatile chemicals, ignition from heat sources, or incidents during the processing of oil and gas.
Chemical accidents: The use of hazardous chemicals in the oil production and processing can lead to serious accidents if safety and protection procedures are not properly followed.
Risks from high temperature and pressure: The oil refining process often requires high temperature and pressure conditions, and a minor incident can cause a chain of serious problems, including explosions or leaks of toxic chemicals.

These accidents not only affect the health and safety of workers but can also have negative impacts on the environment and surrounding community. Therefore, implementing safety measures and strictly adhering to safety regulations is extremely important in minimizing the risk of accidents in oil refineries.

PART II: OCCUPATIONAL SAFETY AND HEALTH WHEN WORKING IN AN OIL REFINERY

I. Occupational Safety and Health for Crude Oil Distillation Unit Operators

1. Job Characteristics of a Crude Oil Distillation Unit Operator

In operating a crude oil distillation unit, workers play a crucial role in adjusting parameters such as temperature, pressure, and flow rate to ensure the distillation process occurs efficiently and safely. This job requires special attention to the technical specifications of the machine and the production process.

Workers must regularly monitor and control these parameters to ensure that crude oil is distilled and separated into different components like gasoline, diesel, and lubricating oil accurately. Additionally, they need to react quickly when any incident occurs during machine operation, such as a technical failure or an unexpected fluctuation in the production process. This ensures that the distillation process runs continuously and stably, while also guaranteeing safety for both the employees and the plant.

2. Types of Occupational Accidents during Crude Oil Distillation Unit Operation

During the operation of a crude oil distillation unit, there are several types of occupational accidents that workers may encounter. These risks are often related to activities involving the adjustment of temperature, pressure, and flow rate of crude oil to separate it into different components such as gasoline, diesel, and lubricating oil.

A common type of accident is related to high pressure and temperature. Working near equipment operating at high pressure can pose a risk of heat exposure, burns, or even explosions. In addition, technical failures in the temperature and pressure control systems can also lead to safety issues if not addressed promptly.

Accidents related to oil flow can also occur, including leaks or spills due to malfunctioning pipes or valves. Oil leaks can create a hazardous work environment and lead to the risk of fire, explosion, or environmental pollution.

Finally, working with equipment and machinery in a high-temperature environment can also create a risk of occupational accidents, including collisions, loss of control, or getting caught in machine parts.

3. Causes of Occupational Accidents when Operating a Crude Oil Distillation Unit

There are many potential causes of occupational accidents when operating a crude oil distillation unit, especially during activities that involve adjusting the temperature, pressure, and flow rate of various crude oils to separate them into different components like gasoline, diesel, and lubricating oil.

One of the main causes is a lack of knowledge and experience among workers in operating and adjusting the equipment and systems. Workers need to be adequately trained on work procedures and know how to respond when an incident occurs.

Secondly, technical faults or breakdowns in equipment and systems can also cause accidents. Regular maintenance and inspection of machinery are extremely important to detect and rectify technical problems early before they cause an accident.

Furthermore, a lack of attention and non-compliance with safety procedures is another cause. Workers may not adhere to personal protective equipment regulations, fail to use protective gear, or not follow safety rules during their work.

4. Preventive Measures for Occupational Accidents when Operating a Crude Oil Distillation Unit

To ensure the safety of workers when operating a crude oil distillation unit, several important accident prevention measures need to be implemented.

First and foremost, conducting Occupational Safety Training is extremely important. Workers need to be fully trained on potential hazards and safety measures when working near equipment operating at high pressure and temperature. This training should also include instruction on the use of personal protective equipment and how to respond in case of an incident.

Secondly, performing regular inspections and maintenance for equipment and systems is crucial to prevent technical incidents and breakdowns. This may include checking temperature and pressure control systems, inspecting oil valves and pipelines, as well as maintaining machine parts.

In addition, establishing and adhering to safe work procedures is critically important. Workers need to be instructed to follow safe work procedures, including how to adjust temperature, pressure, and oil flow safely and accurately.

Finally, maintaining a clean and tidy work environment also plays a significant role in reducing the risk of accidents. Disposing of waste and creating a safe and orderly work environment helps to minimize the risk of occupational accidents.

5. Occupational Safety Regulations for Operating a Crude Oil Distillation Unit

Occupational safety regulations for operating a crude oil distillation unit play a vital role in ensuring the safety of workers in this hazardous work environment. These regulations include the following:

First, workers must be fully trained on the potential hazards of operating a crude oil distillation unit, including risks related to temperature, pressure, and hazardous chemicals. This training must focus on recognizing and responding correctly when an incident occurs.

Second, the use of personal protective equipment is mandatory. Workers must be fully equipped with and use items such as helmets, safety glasses, heat-resistant gloves, and flame-retardant jackets to protect themselves from potential hazards.

Third, adherence to safe work procedures is indispensable. Workers must strictly follow operating procedures and accurately and safely adjust temperature, pressure, and oil flow.

Finally, performing regular inspections and maintenance on equipment and systems is important to ensure that machinery operates safely and effectively. Workers must conduct periodic checks and report any technical issues to the maintenance and repair department.

6. Handling Emergency Occupational Accidents when Operating a Crude Oil Distillation Unit

In the event of an emergency occupational accident while operating a crude oil distillation unit, response measures must be implemented quickly and effectively to ensure the safety of workers and the work environment.

First, ensuring one’s own safety and that of others is the top priority. Workers must immediately report the accident and activate emergency response measures. If there is a risk of fire or explosion, they should use firefighting equipment and try to control the situation.

Second, calling or contacting the plant’s safety and security department is extremely important to get the necessary support in an emergency. This department can provide specific guidance on handling the accident and deploy rescue measures if needed.

Third, reporting and documenting the accident in detail is very important for analyzing the cause and learning from the experience. Workers must record all information related to the accident, including the rescue measures taken and any damage to people or property.

II. Occupational Safety and Health for Processing and Refining Unit Operators

1. Job Characteristics of a Processing and Refining Unit Operator

In the job of operating oil processing and refining machinery, workers are involved in crucial activities to remove impurities and refine the oil to achieve the desired final product quality. This stage requires special attention and specialized knowledge of production processes and specific equipment. Workers typically perform the following tasks:

First, they must control the equipment and systems that operate the machinery, including filters, refining equipment, and temperature and pressure control systems. Adjusting technical parameters such as pressure, temperature, and flow rate is extremely important to ensure the processing and refining process occurs efficiently and safely.

Next, workers take measures to remove impurities from the oil, including using methods such as filtration, precipitation, or separation. Equipment like filters, separators, and chemical treatment systems are often used in this process.

The job also includes checking the quality of the output oil product to ensure it meets quality standards and requirements. Workers often perform tests for chemical composition, clarity, and other indicators to assess product quality.

2. Types of Occupational Accidents during Processing and Refining Unit Operation

During the operation of oil processing and refining machinery, there are several types of occupational accidents that workers may encounter. These risks are often related to the use of special methods and equipment to remove impurities and refine the oil to achieve the desired final product quality.

One of the common risks is the risk of injury when working near operating equipment such as filters, refining equipment, and temperature and pressure control systems. Inattention or lack of experience can lead to collision accidents, getting trapped, or being injured by machine parts.

In addition, working with hazardous chemicals during the processing and refining process can also create a risk of accidents. Exposure to toxic chemicals can cause dermatitis, skin irritation, or even a risk of fire and explosion if safety regulations are not followed.

Accidents related to the use of special equipment such as filters, refining equipment, and control systems can also occur due to technical failures or malfunctions during operation.

3. Causes of Occupational Accidents when Operating Processing and Refining Machinery

There are many potential causes of occupational accidents when operating oil processing and refining machinery, especially in activities using special methods and equipment to remove impurities and refine oil to achieve the desired final product quality.

4. Preventive Measures for Occupational Accidents when Operating Processing and Refining Machinery

To ensure occupational safety when operating oil processing and refining machinery, implementing preventive measures is very important, especially when this stage involves the use of special methods and equipment to remove impurities and refine oil to achieve the desired final product quality.

An important measure is to conduct periodic workplace environmental monitoring. This includes measuring and recording indicators such as the concentration of chemicals in the air, working pressure, and ambient temperature. This monitoring helps to detect hazardous situations early and minimize the risk of occupational accidents.

Secondly, ensuring the use of personal protective equipment is very important. Workers need to be fully equipped with and use types of equipment such as safety glasses, masks, and protective clothing to protect themselves from potential hazards like exposure to toxic chemicals or the risk of fire and explosion.

In addition, following safe work procedures is essential. These procedures should include specific instructions on the use and maintenance of equipment, control of temperature and pressure, and safe disposal of waste.

5. Occupational Safety Regulations when Operating Processing and Refining Machinery

During the operation of oil processing and refining machinery, adhering to occupational safety regulations is extremely important, especially when this stage involves the use of special methods and equipment to remove impurities and refine oil to achieve the desired final product quality.

First, all workers involved in the machine operation process must be fully trained on safe work procedures and know how to use the equipment correctly. This includes guidance on adjusting pressure, temperature, and flow rate to ensure the process runs safely and effectively.

Second, the use of personal protective equipment is mandatory and cannot be overlooked. Workers must ensure they are using full protective gear such as safety glasses, masks, protective clothing, and gloves to protect themselves from potential hazards like exposure to toxic chemicals or the risk of fire and explosion.

6. Handling Emergency Occupational Accidents when Operating Processing and Refining Machinery

In the event of an emergency occupational accident while operating oil processing and refining machinery, handling the situation quickly and accurately is extremely important to ensure the safety of everyone in the work area.

First, workers must immediately report the accident and activate emergency response measures. If there is a risk of fire or explosion, they should use firefighting equipment and try to control the situation.

Next, calling or contacting the plant’s safety and security department is extremely important to get the necessary support in an emergency situation. This department can provide specific instructions on handling the accident and deploy rescue measures if necessary.

Third, reporting and documenting the accident in detail is very important for analyzing the cause and learning from the experience. Workers need to record all information related to the accident, including the rescue measures taken and any damage to people or property.

III. Occupational Safety and Health for Quality Control Staff

1. Job Characteristics of Quality Control

In quality control work, workers are often involved in ensuring that the produced oil products meet safety and quality standards. This stage requires special attention and specialized knowledge of quality control standards and procedures.

First, workers perform tests on the chemical composition of oil products to ensure they meet specific requirements for composition and blending. This may include testing the concentration of important chemicals such as sulfur, carbon, and hydrocarbons to ensure the product meets regulated standards.

Next, workers perform tests on the physical properties of oil products such as viscosity, color, and clarity. These tests help to assess uniformity and meet the quality requirements of the product.

Furthermore, workers also perform tests on the performance and features of oil products such as boiling point, flash point, and storage stability. This helps ensure that the product can operate effectively and safely in practical applications.

2. Types of Occupational Accidents during Quality Control

During the quality control process of oil products, there are several types of occupational accidents that workers may face. Workers are often involved in checking the quality of oil products to ensure they meet safety and quality standards. However, this can present several risks and causes for accidents.

One of the common types of accidents is chemical accidents. Workers can be exposed to toxic chemicals during the quality control process, causing serious health problems such as dermatitis, pneumonia, or even poisoning.

In addition, accidents related to the use of testing equipment can also occur. The use of complex machinery and equipment can lead to collision accidents, getting trapped, or being injured due to technical failures.

Furthermore, working in an unsafe work environment also creates a risk of accidents. Working conditions such as high pressure, extreme temperatures, or the presence of hazardous chemicals can lead to unexpected accidents.

3. Causes of Occupational Accidents during Quality Control

There are many potential causes of occupational accidents during the quality control process of oil products. Workers are often involved in checking the quality of oil products to ensure they meet safety and quality standards. However, several factors can contribute to the occurrence of unwanted accidents.

One of the main causes is a lack of knowledge and experience with work procedures and equipment use. Workers need to be fully trained on quality control procedures and know how to use the equipment safely and effectively.

Second, quality control equipment may not be regularly maintained and thoroughly inspected, leading to incidents or breakdowns during use. Regular maintenance and inspection of equipment are very important to ensure they operate safely and reliably.

4. Preventive Measures for Occupational Accidents during Quality Control

To prevent occupational accidents when checking the quality of oil products, several measures need to be implemented carefully and fully.

First, ensuring that all workers are fully trained on work procedures and occupational safety is very important. Workers need to clearly understand the safety rules and procedures, as well as know how to use quality control equipment safely and effectively.

Second, the use of personal protective equipment is indispensable. Workers need to be fully equipped with and use types of equipment such as safety glasses, masks, protective clothing, and gloves to protect themselves from potential hazards like exposure to toxic chemicals or the risk of collision.

In addition, maintaining a clean and tidy work environment also plays an important role in minimizing the risk of occupational accidents. Removing waste and maintaining facility hygiene are effective ways to ensure a safe and healthy work environment for everyone.

5. Occupational Safety Regulations during Quality Control

Occupational safety regulations when checking the quality of oil products play an important role in ensuring the safety of workers and the work environment. Workers are often involved in checking the quality of oil products to ensure they meet safety and quality standards.

First, comprehensive training and guidance on work procedures and occupational safety is the most important step. Workers need to be equipped with knowledge about safety rules and procedures, as well as know how to use quality control equipment safely and effectively.

Second, the use of personal protective equipment is mandatory and indispensable. Workers must ensure they are using full equipment such as safety glasses, masks, protective clothing, and gloves to protect themselves from potential hazards such as exposure to toxic chemicals or the risk of collision.

In addition, complying with the safety regulations and procedures set by the plant is a crucial step to ensure safety during the work process. Workers must implement the specified safety measures, follow instructions, and limit risks when checking the quality of oil products.

Complete tests at occupational safety centers to obtain an occupational safety certificate. This will ensure that workers understand safety knowledge and have valid certification for employment.

6. Handling Emergency Occupational Accidents during Quality Control

In the event of an emergency occupational accident while checking the quality of oil products, handling the situation quickly and effectively is very important to ensure the safety of everyone.

First, workers must immediately report the accident to their manager or the plant’s safety department. This helps to activate the emergency plan and get the necessary support from a team of experts.

Next, workers need to ensure their own safety and that of their colleagues by carrying out basic rescue measures such as moving the victim out of the danger zone, administering first aid, and using personal protective equipment.

Afterward, conducting an incident investigation is very important to determine the cause of the accident and propose preventive measures to avoid recurrence in the future. Collecting information and evidence related to the incident also supports the process of analysis and improvement of work procedures.

IV. Occupational Safety and Health for Equipment Maintenance and Repair Staff

1. Job Characteristics of Equipment Maintenance and Repair

Equipment maintenance and repair work in an oil refinery plays a crucial role in ensuring the robust and safe operation of the entire production system. Workers are not only involved in product quality control but also have the duty of maintaining and repairing equipment and machinery.

This job requires patience, technical skills, and specialized knowledge of equipment operation. Workers often have to perform tasks such as lubricating, cleaning, inspecting, and replacing damaged parts to ensure that the machinery operates effectively and safely.

In addition, planning periodic maintenance is also an important part of this job. Workers need to follow the proposed maintenance schedules to ensure that the equipment is maintained correctly and at the right time.

2. Types of Occupational Accidents during Equipment Maintenance and Repair

During the process of equipment maintenance and repair in an oil refinery, several types of occupational accidents can occur. Workers often participate in this work to ensure that equipment and machinery operate effectively and safely, but there are potential risks that need to be considered and minimized.

A common type of accident is an accident caused by faulty equipment or machinery during use or maintenance. Old, worn-out, or improperly maintained parts can cause unexpected incidents such as falling, exploding, or breaking, injuring workers.

In addition, accidents can occur due to negligence during the performance of maintenance and repair tasks. Not following safety procedures correctly, using equipment improperly, or lack of experience can also lead to unwanted accidents.

3. Causes of Occupational Accidents during Equipment Maintenance and Repair

There are many causes of occupational accidents during the process of equipment maintenance and repair in an oil refinery. Workers often participate in these activities to ensure that equipment operates effectively and safely, but some factors can cause unwanted accidents.

A common cause is a lack of experience and training. Workers who are not adequately trained on maintenance and repair procedures or lack experience in working with specific equipment can lead to negligence and accidents.

In addition, old, worn-out, or improperly maintained equipment can also cause accidents. Skipping periodic maintenance tasks or not performing them correctly can lead to unexpected breakdowns during use.

A lack of risk awareness is also a cause. Workers who do not recognize or fully understand the potential risks during maintenance and repair can lead to unsafe actions and accidents.

4. Preventive Measures for Occupational Accidents during Equipment Maintenance and Repair

To prevent occupational accidents when performing equipment maintenance and repair in an oil refinery, there are several important measures that workers need to follow.

First, workers need to be fully trained on safety procedures and techniques for working with specific equipment. This includes a clear understanding of potential risks, safety procedures, and the proper use of personal protective equipment.

Second, performing periodic maintenance and repair procedures correctly is very important. Workers need to adhere to the proposed maintenance schedules and ensure that these tasks are performed carefully and accurately.

In addition, inspecting and monitoring equipment during use is also an important preventive measure. Workers should pay attention to any unusual signs and report immediately to their manager or the safety department if any problems are detected.

Complete occupational safety training to be issued an occupational safety card by the safety training center to strengthen your work profile in accordance with regulations.

5. Occupational Safety Regulations during Equipment Maintenance and Repair

Occupational safety regulations when performing equipment maintenance and repair in an oil refinery are very important to ensure a safe and effective work environment for all employees. Workers, as well as managers, need to comply with the following regulations:

Second, performing maintenance and repair procedures correctly is very important. Workers need to adhere to the proposed maintenance schedules and ensure that these tasks are performed carefully and accurately.

In addition, inspecting and monitoring equipment during use is also an important part of occupational safety regulations. Workers should pay attention to any unusual signs and report immediately to their manager or the safety department if any problems are detected.

6. Handling Emergency Occupational Accidents during Equipment Maintenance and Repair

In the event of an emergency occupational accident while performing equipment maintenance and repair in an oil refinery, immediate and correct handling is very important to protect the health and safety of all employees. The following measures can be taken:

First, the worker needs to ensure their own safety and that of those around them by immediately reporting the accident and activating the highest level rescue plan.

Next, they need to control the accident situation by preventing the spread of the hazard and minimizing injury to the victim. This may include shutting off power, water, or providing first aid if needed.

Then, it is necessary to report the accident to the manager or the plant’s safety department so they can investigate the incident and apply preventive measures to avoid similar situations in the future.