Oisd GDN 232

Draft 3 OISD- GDN- 232 First Edition
For Restricted Circulation Only
Identification of Hazards and Control Measures in E&P Industry
OISD GDN 232

First Edition, September 2011
Prepared by
FUNCTIONAL COMMITTEE ON GUIDELINES FOR IDENTIFICATION OF HAZARDS AND CONTROL MEASURES IN E&P INDUSTRY
OIL INDUSTRY SAFETY DIRECTORATE 8th Floor, "OIDB Bhavan" Plot No. 2, Sector-73 Noida-201301
Note
OISD (Oil Industry Safety Directorate) publications are prepared for use in the Oil and Gas Industry under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.
Though every effort
has been made to assure the accuracy and reliability of the data contained in
the document, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use.
The document is intended to supplement rather than replace the prevailing statutory requirements.
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(ii)
Foreword
The Oil Industry in India is more than 100 years old. Because of various collaboration agreements, a variety of international codes, standards and practices have been in vogue. Standardisation in design philosophies and operation and maintenance practices at a national level was hardly in existence. This coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state- of- the-art in designing, operating and maintaining oil and gas installations. With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry, in formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safe operations. Accordingly, OISD constituted a number of functional committees of experts nominated from the industry to draw up standards and guidelines on various subjects. The present guidelines on Identifications of Hazards and Control Measures in E&P Industry have been prepared by the Functional Committee. The document is based on the accumulated knowledge and experience of industry members and the national / international codes and practices. This document will help in adopting a systematic approach for identification of hazards and control measures in E&P industry. The Guidelines allow the users to choose the relevant provisions and adapt them in light of their particular circumstances. Suggestions are invited from the users after it is put into practice to improve the document further. Suggestions for amendments to this document should be addressed to:
The Coordinator Functional Committee on Guidelines for Identification of Hazards and Control Measures in E&P Industry, Oil Industry Safety Directorate, 8 Floor, OIDB Bhavan, Plot No. 2, Sector-73,
th
Noida - 201301.
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(iii)
Functional Committee on
Guidelines for Identification of Hazards and Control Measures in E&P Industry

________________________________________________________________________ Name LEADER Shri P.S. Sehmi Oil & Natural Gas Corporation Limited Organisation
MEMBERS Shri A.K. Chakrabarty Shri D.K. Varshney Shri D.M. Pradhan Oil & Natural Gas Corporation Limited Oil & Natural Gas Corporation Limited Oil India Limited
Shri Pankaj Goswami
Oil India Limited
MEMBER CO-ORDINATOR
Shri H.C. Taneja
Oil Industry Safety Directorate
In addition to the above, several other experts from Industry contributed in the preparation, review and finalisation of the Guidelines.
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Contents
_____________________________________________________________ Section
1.0 2.0 3.0 4.0 5.0 6.0 6.1 6.2 6.3 6.4 6.5
Description
Introduction Scope Definitions Statutory Requirements Process of Hazard Identification and Risk Assessment Qualitative Risk Assessment Risk matrix framework Screening criteria for risk assessment Risk reduction measures Job safety analysis Functional requirements
Page No.
01 01 01 03 03 05 06 07 07 09 10
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7.0 7.1 7.2 7.3
Generic Checklists of Hazards and Risk Reduction Measures for E&P Industry Drilling and related operations Production, processing and related operations Well servicing and related operations
11 11 12 13
8.0 Annexures:
References
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Annexure-1: Checklist for drilling and related operations Annexure-2: Checklist for production, processing and related operations Annexure-3: Checklist for well servicing and related operations
16 32 48
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OISD-GDN- 232

1.0 Introduction Hazards associated with operations in E&P industry may lead to incidents due to human factors, equipment failure, procedures failure, planning failure, risk assessment failure and organizational management (control, cooperation, communication, competence, monitoring and review) failure. Risk management is a critical component of safety management system. This document has been prepared with an objective of providing guidance to the organizations to identify hazards and establish control measures. Organizations can use these guidelines to develop effective control measures for any potential hazard(s), which are location and scenario specific.
2.0
Scope This document lays down guidelines for identifying hazards and establishing control measures in E&P Industry: in drilling, production, well servicing and related operations; in both on land and offshore, in existing installations, with focus on qualitative risk assessment. This document should also be referred during design stage of new E&P installations.
3.0
Definitions Barrier Measure which reduces the probability of realizing a hazards potential for harm and its consequence. Barriers may be physical (materials, protective devices, shields, segregation, etc.) or non-physical (procedures, inspection, training, drills, etc.).
Control of hazards Limiting the extent and/or duration of a hazardous event to prevent escalation.
Hazard An inherent property of a substance, agent, source of energy or situation having the potential of causing undesirable consequences for human injury, damage to the environment, damage to property or a combination there of.
Hazards / risk register Document providing a brief, but complete, overview of the identified hazards and the measures necessary to manage them. Hazard analysis Identification of individual hazards of a system, determination of the mechanisms by which they could give rise to undesired events, and evaluation of the consequences of these events on health (including public health), environment and property.
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
Standards / Guidelines
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High consequence event
An incident with potential of causing high consequences for human injury, damage to the environment, damage to property or a combination there of.
Mitigation Limitation of the undesirable effects of a particular event
Performance standard A statement which can be expressed in qualitative or quantitative terms, of the performance required of a system, item of equipment, person or procedure, and which is used as the basis for managing the hazard through the life cycle of the installation
Risk Combination of the chance that a specified hazardous event will occur and the severity of the consequences of the event
Risk assessment Overall process of risk analysis and risk evaluation against risk acceptance criteria
Risk evaluation Judgement, on the basis of risk analysis, of whether a risk is tolerable
Risk management Coordinated set of activities and methods used to direct an organization and to control many risks that can affect organisations ability to achieve objectives. Coordinated set of activities and methods are also known as architecture and this architecture includes risk management principles, risk management framework, and risk management process.
Safety management system The part of an organisations general management system that includes the organisational structure, responsibilities, practices, procedures, processes, and resources for determining and implementing an accident prevention policy. The safety management system normally addresses a number of issues including, but not limited to: organisation and personnel; identification and evaluation of hazards and risks; operational control; management of change; planning for emergencies; monitoring performance; audit and review
Screening criteria Standard used to judge the tolerability of an identified hazard or effect
Shall The word shall is used to indicate that requirements / provisions are mandatory.
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Should The word should is used to indicate that requirements / provisions are recommended as per sound engineering / good management practice.
4.0
Statutory Requirements Relevant statutory requirements, as per the following, as amended from time to time, inter alia, are applicable for hazard identification, risk evaluation and establishing control measures in E&P industry: 4.1 4.2 The Oil Mines Regulation 1984 (OMR). The Petroleum and Natural Gas (Safety in Offshore Operations) Rules, 2008. For environment related regulatory requirements refer OISD-RP-201.
4.3
Additionally, all statutory requirements notified by the Central Government or States, from time to time, shall be complied with, as applicable.
5.0
Process of Hazard Identification and Risk Assessment
Understanding of the concept that hazard has the potential for something undesirable to happen rather than the actual event itself is important for approach to be adopted towards hazard identification and risk assessment. Identification of hazards is based on physical and chemical properties of the material (including fluids) being handled, processing conditions, environmental conditions, arrangements of equipment and operating and maintenance procedures. Risk is evaluated by estimating the likelihood of the hazardous event occurring and the severity of the consequences that might be expected from it. Steps involved are identification of initiating events, identification of possible accident sequences, estimation of probability of occurrence of these accident sequences and assessment of consequences. The effectiveness of a hazards and risk assessment depends on the skills, knowledge and efforts of the personnel undertaking the work. Multi disciplinary team including members from field operations having competence should carry out hazard identification, risk evaluation and establishing control measures. Competence includes skills in the risk assessment techniques and knowledge about the design, operation and maintenance of the facilities under consideration. At every installation appropriate risk management should be established and maintained. For guidance on hazard identification and risk assessment techniques refer section 6.1 of OISDGDN-227 (2007 edition) and Annexure B of ISO 17776. Elements of a risk management process as described in ISO 31000 include Establishing the context, Hazard identification, Risk analysis (analysis of potential initiating events, analysis of potential consequences), Risk evaluation (comparing with acceptance criteria), Risk treatment (includes control measures). In addition to these elements of the process, two key functions to be performed continuously throughout the risk management process are: Communication and consultation; and Monitoring and review.
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A framework for risk management, based on ISO 31000 and NORSOK Standard Z-013 is presented below.
Risk Management Process: ISO 31000:2009 / NORSOK Standard Z-013:2010
Establishing the Context

Risk Assessment Risk Assessment
Communication and Consultation
Hazard Identification
Analysis of potential initiating events
Analysis of potential Consequences
Risk Evaluation / Establishing Risk Picture
Risk Treatment
Objective of establishing the context for risk assessment process is to set scope and criteria for the risk assessment process, while ensuring that process is: Suitable with respect to its intended objectives and purpose. Appropriate for area of interest e.g. facility, system(s), operations etc. Suitable for the required and available level of details. Executed with desired scope and quality. Includes all activities carried out and all control measures implemented prior to or as a part of the initiating phase of risk assessment process. Provides sufficient and appropriate inputs for the decision support at the right time. During defining of scope the following should be considered: Risk to persons, environment and assets. The risk acceptance criteria and the objectives of risk assessment process. Frequency of loosing main safety functions and impairment of barrier functions and / or elements, systems. Scope should also include identification, assessment and/or establishment of: Defined situation of hazards and accidents Dimensioning accident loads Requirements for barrier functions, systems and/or elements
Monitoring, review and update
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Operational limitations Equipment, area, system classification. Human and organisational factors
Methods, models and tools to be used in the process should be suitable with respect to the decisions to be made, keeping in view objective(s) and scope for the assessment. Boundaries of system to be subjected to risk assessment should be defined and described covering following aspects: Technical system(s): structures, buildings, layout, process, storage, pipelines, wells, utility, safety, emergency preparedness etc. Period, phase(s) and activities. Organisation and the operational system. Responsibilities for planning and executing risk assessment process should be defined. Relevant concept is risk owner defined in ISO 31000, as person (or entity) with the accountability and authority to manage the risk. For guidance on hazard identification, analysis of potential initiating events, analysis of potential consequences, establishing the risk picture, risk evaluation, communication and consultation and monitoring and review of risk assessment process refer NORSOK standard Z-013:2010 on Risk and emergency preparedness assessment. For detailed checklist of hazards and effects refer Annex D (table D.1) of ISO 17776. Where risk potential is high (high on consequences), it would be desirable to carry out quantitative risk assessment, to decide upon the extent of control measures required. For guidance on quantitative risk assessment (QRA) during life cycle stages (concept selection phase, concept definition, optimisation and detailed engineering phases, operational phase) refer NORSOK standard Z-013:2010
6.0
Qualitative Risk Assessment Following a systematic approach for the identification of hazards and the assessment of associated risk is an essential prerequisite for an effective safety management system. The information provided by this systematic hazard identification and assessment of risk, is fundamental for decision making, on the need of introducing risk reduction measures. Hazard identification should be carried out by using hazard identification methods such as preliminary hazard analysis (PHA), what-if analysis, hazard checklist, hazard and operability study (HAZOP), failure modes and effects analysis (FMEA), cause-consequence analysis (CCA) and Human factors (interface between the human operators and the systems they operate) analysis. Likelihood is the possibility of something happening. Likelihood is based on probability and/or frequency. Probability is number of chances an event may occur to the total number of chances. It is expressed as a number in the range of 0 to 1. Frequency is a rate; how often an event occurs within a stated time period and is defined as the reciprocal of the average time between events, such as 1 per 1000 years. In qualitative risk assessment likelihood of incident is based on qualitative assessment. The judgement regarding the likelihood of the hazard actually causing harm is more difficult than deciding on the consequence of the hazard. Typical factors affecting the analysis of likelihood are:-
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The number of times the situation occurs Duration of exposure Quantity of materials involved Condition of equipment Competence of people involved Environmental conditions Distractions
The other important factors to take into account are the control measures already provided or to be provided. In analysing the likelihood of harm, the risk assessor(s) must take into account the possibility of in place control measures not being implemented due to human error, lack of maintenance, difficulty in compliance, complexity of instructions, etc. It is essential to discover how the task is actually carried out and base the assessment on this, rather than assessing the likelihood on how the task is supposed to be carried out. In qualitative risk assessment, the risk can be expressed as the direct product of the probability of occurrence and the severity in relative term such as low, medium, high.
6.1.
Risk matrix framework (from ISO 17776):
Consequence A
Increasing probability B C
Severity rating
Environment
0 1 2
Zero injury Slight injury Minor injury Major injury Single fatality
Zero damage Slight damage Minor damage Local damage Major damage
Zero effect Slight effect Minor effect Local effect Major effect
Reputation
People
Assets
Has occurred in E&P Industry
Has occurred in the operating company
Occurr ed several times a year in the operati ng compa ny
Occurr ed several times a year at the locatio n
Zero Impact Slight impact Limited impact Consider able impact Major national impact Major internatio nal impact
Manage for continued improvement (Low risk hazards)
Multipl e fataliti es
Extensiv e damage
Massiv e effect
Incorporat e risk reducing measures (Medium risk hazards) Fail to meet screening criteria (High risk hazards)
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6.2. Screening criteria for risk assessment
Screening criteria for risk assessment should be appropriate for the hazards identified and should reflect best practice as per national or international standards. Diligence should be exercised when screening out low probability / high consequence events. The person(s) carrying out the risk assessment should not become too obsessed with the figures. One of the objectives of the risk assessment is to identify the additional control measures; that need to be implemented and these figures are designed to assist with the prioritisation of such measures. The objective of this process is not to arrive at a certain number but to provide a systematic method of ensuring that consequence and likelihood ratings are analysed carefully. For qualitative assessments: it is possible to use a risk matrix to compare options and the value of risk-reducing measures. Also records of the analysis should be made for future reference and review.
6.3.
Risk reduction measures
Hazardous event occurs when the hazards potential to cause harm is realised. In order to prevent a hazard being realised, risk reducing measures or barriers are required. Barriers may be either physical, such as shields, isolation, separation, protective devices, etc. or nonphysical measures, such as procedures, alarm systems, training, drills, etc. Hierarchy of risk reducing measures prevention, detection, mitigation and emergency response should be followed. Control measures / barriers have to be divided in two categories preventive measures and protective measures. Preventive measures have objective of reducing probability of occurrence. Protective measures (also called residual risk control) have objective of mitigating the effects of hazard situations. Protective measures should be considered after possible preventive measures. Hierarchy of control: Elimination; Substitution; Engineering controls; Administration controls and PPE should be followed during identification of control measures. Elimination is removal of hazard by eliminating a requirement to carry out the task, use of particular equipment or use of a chemical. Substitution is replacement of the material; plant- equipment, process; or work practice with a less hazardous one. Engineering controls reduce the reliance on human factors. Engineering controls can be redesign of equipment, redesign of process or increase of automation. Engineering controls also include changes in layout separation distances, ventilation, guards, enclosures, firewalls etc. Administration controls are the procedural aspects of managing hazards, such as planned and preventive maintenance programmes, standard operating procedures (SOP), work permit system and competence of personnel. Personal protective equipment (PPE) is the last and least effective control method because it relies on human behaviour. Risk reducing measures in case of low risk hazards include: controls as per general workplace practices and procedures, based on job safety analysis (JSA). JSA is covered in detail in section 6.4. Risk reducing measures in case of medium risk hazards include: availability of barriers or controls for prevention and mitigation of hazards; controls as per workplace practices and procedures based on job safety analysis (JSA).
OISD-GDN- 232
Risk reducing measures for high risk hazards should include: a. For each cause of hazard, identify the barriers to prevent the release of hazard. b. For every hazard, identify the barriers to reduce the consequences and/or facilitate the recovery from the consequences. c. For each identified barrier: Identify the critical task / activities required to ensure barriers are in place, working effectively and their integrity is maintained. Identify the resources and competencies required for the barriers to be implemented and effective. Identify where barrier is referred in safety management system. Identify any factors that prevent such barriers from being defeated, removed from service or any reduction or elimination of their effectiveness. Identify any compensatory barriers and the associated activities, resources, competencies to address such barrier defeating factors.
Risk reduction measures should include: a. Preventive measures such as using inherently safer designs and ensuring asset integrity; SOPs; to prevent incidents or reduce the probability of occurrence of incidents and to control incidents (limit the extent and duration of a hazardous event). b. Mitigating measures to mitigate the effects or reduce the consequences. c. Measures to recover from incidents taking into account possible failures of the control. Preventive measures should be emphasised. In case of failure of barriers provided to prevent occurring of a hazardous event, mitigating measures to bring the situation to normal are required. Examples of mitigating measures are fire and gas detection systems, active and passive fire protection including fire water systems, evacuation systems, emergency procedures etc. All measures taken following a hazardous event are known as emergency response. For guidance on emergency preparedness and response, refer OISD-GDN-227. Selection of risk reduction measures should be based on sound engineering principles and common sense. Risk Matrix (based on ISO 17776, as explained above) is suggested below, which can be used for qualitative risk assessment.
Sl. No.
Work Activi ty
Associat ed Hazards
Control measures in place
Probability
Consequences
Environment
* Remarks should specify, in case of medium and high risk levels, whether these risk levels are because of inherent hazardous nature of the activity OR because of deficiencies in control measures. In case of latter, action(s) in hand to remove deficiencies should be recorded.
Reputation
Risk Level (Low / Mediu m/ High)
Remarks*
People
Assets
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The risk matrix should include all the emergency scenarios considered in the Emergency Response Plan of the installation. Risk matrix should be treated as a live document, to be updated periodically to reflect the action(s) taken related to deficient control measures besides incorporating new hazards (due to change in process parameters, plant modifications, change of personnel, learning from incidents etc.).
6.4.
Job safety analysis
Job safety analysis (JSA) is a systematic stepwise review of all risk factors prior to an activity or operation, with an objective of ensuring operational safety. JSA or job hazard analysis (JHA) is a qualitative method of assessing risks for a particular job. JSA helps in identifying the measures to be taken for eliminating or reducing identified hazards, and integrating accepted safety standards and practices into a particular task or job operation. The terms job or task are commonly used interchangeably for a specific work assignment. JSAs are not suitable for jobs defined too broadly, for example drilling a well; or too narrowly, for example, placing power tong on tool joint. Following category of jobs should be considered for JSA: a. Jobs where incidents occur frequently b. Where the potential consequences of accidents are severe (in case of infrequent incidents) c. Newly established jobs d. Modified jobs / changed job procedures e. Non routine infrequently performed jobs Job or activity is defined in terms of the work to be performed and JSA is carried out by breaking down the job or activity into a number of logical (correct sequence) steps to be taken; to accomplish the task. A step is the segment of the operation, necessary to move ahead the work process. It is expressed as what is done rather than how it is done. Care should be taken for not to miss specific steps and associated hazards. JSA should not attempt to uncover individual unsafe act(s). A number of questions are asked for each step, in order to identify hazards, potential consequences and risks associated with that particular step. The job, not the individual is being studied to make it safer by identifying hazards and required control measures. Potential hazard is identified by listing what can go wrong at each step. Use of a checklist can help in identifying all the potential hazards. Control measures (as per hierarchy of risk reducing measures); both precautions and contingency measures that should be taken are identified, for each hazard to reduce the risks. In listing of the control measures, general statements such as be careful, use PPE, and use caution etc. should be avoided. Specific statements describing what action(s) is to be taken and how it can be performed should be preferred. Documented work method statement identifying the job / work activity, environmental context, key processes involved, and the equipment used; are used as basis to facilitate job safety analysis. Operating procedures incorporate clear instructions and all controls; necessary to manage the hazards associated with the job steps (identified through the process of JSA). Controls may include but are not limited to tools and equipment to be used, supervision and assistance required, work permits, safety observers, emergency response measures and personal protective equipment. Generally JSA is carried out by observing actual performance of the job (for the jobs being performed frequently).
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Advantage of JSA is that it is carried out by involving persons, with varied experience, responsible for performing the particular job, which helps in promoting acceptance of the operating procedures. Additional advantage is that it increases job knowledge of participants and safety awareness is increased. JSA can be used as benchmark for safety inspections or observations and is also useful for carrying out comprehensive accident investigations. SOPs should be revised whenever there is change in equipment, raw materials, processes, procedure, the environment, personnel (new / inexperienced personnel) and after any incident linked with the particular JSA.
6.5.
Functional requirements
Functional requirements (also known as performance standards) are performance criteria which should be satisfied to meet the objective of the control measure. Due emphasis on establishing functional requirements and monitoring of control measures against the established functional requirements would ensure risk control. Functional requirements should be realistic (achievable) and verifiable. Periodic review of functional requirements should be carried out to ensure their continuous suitability. For identifying the critical equipment, systems and procedures, for which functional requirements (performance standards) are to be established, following factors should be considered: a. Should make a significant contribution for controlling risk. b. The measures selected should be directly relevant to the achievement of the system goals. c. The measures selected should be capable of verification.
Functional requirements for control measures should include: a. Parameters which are clearly identifiable. b. Operational criteria which are essential for control of risk. c. Directly verifiable criteria which do not require extensive computational effort. d. Recording of data to confirm compliance with functional requirements.
Functional requirements should ensure that barriers, safety functions or safety systems: Are suitable and fully effective for the type of identified hazards Have sufficient capacity for the duration of hazards Have adequate response time to fulfill its role Are suitable for operating conditions envelope Have sufficient availability to match the frequency of the initiating event (hazard) Examples of functional requirements for drilling, production and well servicing are given in sections 7.1, 7.2 and 7.3 respectively. To the extent possible, functional requirements should be part of operating procedures and operational activity records. This reduces duplication of efforts and increases the probability that task is carried out in diligent and efficient manner.
OISD-GDN- 232
7.0 Generic Checklists of Hazards and Risk Reduction Measures for E&P Industry
11
A checklist is generally the quickest and easiest method of hazards and risk assessment, and is very effective in the control of risk arising from standard, well understood hazards. The use of checklists based upon the requirements laid out in codes and standards is very effective in identifying compliance with standard industry practices and highlighting aspects which require further investigation. The generic checklists (annexure 1,2 and 3) listing hazards and risk reducing measures for E&P industry have been prepared for guidance. During use of these checklists following considerations should be kept in view: Checklist may be modified, depending upon the specific application. It should be conscientiously applied, in order to evaluate whether industry standard procedures are being followed and to identify aspects that requires further attention. Checklists should be reviewed and updated regularly to incorporate new experience by the company and industry, including the results from any incident investigation.
7.1
Drilling and related operations
In case of on land drilling rigs, the activities include planning and design of wells, rig transportation, rig building, drilling operations, well completion & testing and rig dismantling. In case of offshore rig operations marine operations and helicopter operations etc. are to be included in addition to above activities. Hazards and required control measures should be identified for drilling operations, jointly by the operator and rig owner / drilling contractor. Experience from similar operations and other wells in the same field should be utilised. JSA is very useful for operational safety during drilling operations. Drillers HAZOP, a version of HAZOP developed for drilling operations , can identify the hazardous or unacceptable situations (as causes of deviation from design intention i.e. normal safe operations) through operability study and hazard analysis qualifies the effects (consequences). Simultaneous operations should be carried out only after identifying hazards due to simultaneous operations and establishing control measures. Refer OISD-GDN-186 on Simultaneous Operations in E&P Industry. Screening criteria for risk acceptance can be regulatory requirements, environmental discharge limits, well barrier design, national / international industry standards and class requirements (for offshore operations). Functional requirements related to risk reducing measures should be continuously monitored during drilling operations. These include: a. Well integrity ensuring two barriers. b. Integrity and performance of well control equipment. c. Performance of safety systems hydrocarbon and toxic gas detectors, fire fighting systems. d. Fit for purpose status of drilling equipment including mast, structure and hoisting equipment. e. Emergency response measures including safe closure of well, times for mustering, mobilisation of fire fighting and rescue teams, mobilisation of man-overboard rescue
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f. g. h. i. j.
boats, evacuation and rescue procedures and mobilisation of oil-spill response facilities. Mooring and station-keeping capability vis-a-vis weather limits for particular operations. Performance and operational limits for well testing equipment and systems. Competence of personnel. Environmental discharge limits. Limitations for simultaneous operations.
Checklist for drilling and related operations is placed at annexure 1.
7.2
Production, processing and related operations
Installation specific hazard identification and required control measures should cover all the activities associated with the installation. It should include the activities at the associated facilities such as well monitoring and surveillance, well intervention, well stimulation, flow line maintenance etc. Hazardous situations or near misses encountered at the installation (and also at similar other installations of the company and other nearby companies) should form part of the hazards identification process. In case of offshore operations marine operations and helicopter operations etc. are to be included in addition to above activities. Identification of hazards and required control measures for production, processing and related operations should consider complete lifecycle including planning, design, construction / installation, commissioning, operations and decommissioning. Selection of hazard and risk assessment method should be based on the particular stage of lifecycle under consideration. HAZOP analysis should be carried out for identification of hazards during non-routine operations. During major modifications to the installation QRA may be undertaken. Hazards due to human error, incorrect operation and faulty maintenance should be imparted due consideration. Simultaneous operations should be carried out only after identifying hazards due to simultaneous operations and establishing control measures. Refer OISD-GDN-186 on Simultaneous Operations in E&P Industry. Screening criteria for risk acceptance can be regulatory requirements, environmental discharge limits and national / international industry standards. Functional requirements related to risk reducing measures should be continuously monitored. These include: a. Inspection and maintenance procedures and frequencies to ensure the required reliability and availability of the critical systems. b. Operating parameters limitations including pressures, temperatures and flowrates. c. Performance of safety systems hydrocarbon and toxic gas detectors, fire detectors, fire fighting systems, shut-down systems (including relief). d. Fit for purpose status of production equipment including vessels, storage tanks and piping and associated process control devices and safety devices. e. Fit for purpose status of underwater structure and pipelines (in offshore operations). f. Emergency response measures including times for mustering, mobilisation of fire fighting and rescue teams, mobilisation of man-overboard rescue boats, evacuation and rescue procedures and mobilisation of oil-spill response facilities. g. Limitations on hydrocarbon and other hazardous inventories. h. Competence of personnel and manning levels / manning limitations.
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i. j. k. l.
13
Environmental discharge limits. Limitations for simultaneous operations. Procedures and arrangements for control of deviations and non-conformities and records of such events along with their possible effects should be maintained. Job Safety Analysis may be carried out for non-routine jobs
Checklist for production, processing and related operations is placed at annexure 2.
7.3
W ell servicing and related operations
In case of workover rigs, the activities include, rig transportation, rig building, workover operations, well completion & testing and rig dismantling. In case of offshore operations marine operations and helicopter operations etc. are to be included in addition to above activities. Hazards and required control measures should be identified for well servicing operations, jointly by operator and rig owner / well servicing contractor. Experience from similar operations and other wells in the same field should be utilised. JSA is very useful for operational safety during well servicing operations. HAZOP analysis of well servicing and completion can also be carried out to identify specific hazards. Simultaneous operations should be carried out only after identifying hazards due to simultaneous operations and establishing control measures. Refer OISD-GDN-186 on Simultaneous Operations in E&P Industry. Screening criteria for risk acceptance can be regulatory requirements, environmental discharge limits, well barrier design, national / international industry standards and class requirements (for offshore operations). Functional requirements related to risk reducing measures should be continuously monitored during well servicing operations. These include: a. Well integrity ensuring two barriers. b. Integrity and performance of well control equipment. c. Performance of safety systems hydrocarbon or toxic gas detectors, fire fighting systems. d. Fit for purpose status of well servicing equipment including mast, structure and hoisting equipment. e. Emergency response measures including safe closure of wells, times for mustering, mobilisation of fire fighting and rescue teams, mobilisation of man-overboard rescue boats, evacuation and rescue procedures and mobilisation of oil-spill response facilities. f. Performance and operational limits for well testing equipment and systems. g. Competence of personnel. h. Environmental discharge limits. i. Limitations for simultaneous operations.
Checklist for well servicing and related operations is placed at annexure 3.
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8.0 References:
14
1. 2.
IADC: HSE Case guidelines part 4. ISO 17776 2000: Petroleum and natural gas industries Offshore production installations Guidelines on tools and techniques for hazard identification and risk assessment. ISO 31000-2009: Risk management Principles and guidelines Marine Safety Forum: Risk Assessment, MODU move operations. NORSOK standard D-010: Well Integrity in Drilling and Well Operations. NORSOK standard Z-013-2010: Risk and emergency preparedness assessment. OLF Recommended Guidelines 090-2006: Common Model for Safe Job Analysis (SJA). OSHA-U.S Department of Labor: Job Hazard Analysis OSHA 3071 2002. OISD-STD-105: Work Permit System OISD-STD-106: Process design and operating philosophies on pressure relief and disposal system OISD-STD-113: Classification of Area for electrical installations at Hydrocarbon processing and handling facilities OISD-STD-117: Fire Protection Facilities for Petroleum Depots, Terminals, Pipeline Installations and Lube Oil Installations OISD-STD-118: Layouts for Oil and Gas Installations OISD-STD-119: Selection, Operation and Maintenance of Pumps OISD-STD-120: Selection, Operation and Maintenance of Compressors OISD-STD-125: Inspection and Maintenance of Mechanical Seals OISD-STD-128: Inspection of unfired pressure vessels OISD-STD-129: Inspection of storage tanks OISD-STD-132: Inspection of pressure relieving devices OISD-STD-133: Inspection of fired heaters OISD-STD-137: Inspection of electrical equipment OISD-STD-138: Inspection of cross country pipelines Onshore OISD-STD-139: Inspection of pipelines Offshore OISD-STD-157: Recommended Practice for Transportation of Bulk Petroleum Products
3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
OISD-GDN-166: Guidelines for Occupational Health Monitoring in Oil and Gas Industry OISD-RP-174: Well Control OISD- STD-183: Standard on Logging Operations OISD- GDN-186: Simultaneous Operations in Exploration & Production industry OISD-STD-187: Care And Use Of Wire Rope OISD-STD-189: Fire Protection System For onshore Drilling Rigs, Work Over Rigs And Oil/Gas Production Installations OISD-RP-190: Derrick Floor Operations OISD-RP-201: Environment Management in Exploration & Production Sector OISD-GDN-202: Inspection of Drilling and Workover Rig Mast / Sub-Structure Inspection of Drilling and Workover Rig Mast / Sub-Structure OISD-GDN-203: Operation, Maintenance & Inspection Of Hoisting Equipment OISD-RP-205: Crane Operation, Maintenance and Testing (For upstream) OISD-GDN-206: Guidelines on Safety Management System in Petroleum Industry OISD-STD-216: Electrical Safety In Onshore Drilling And Workover Rigs OISD-GDN-218: Guidelines For Safe Rig- Up And Rig- Down Of Drilling And WorkOver Rigs OISD-GDN-227: Emergency Response and Preparedness in E&P Industry
OISD-GDN- 232
Annexure 1 Checklist for drilling and related operations
Activity: Drilling and Completion S. No. 1. Sub activity Planning of well Selection of rig Drilling and completion operations Anticipated Hazards 1. Loss of containment / uncontrolled flow of well fluid due to: Risk Reducing measures Preventive 1.
16
Analyse offset well data and review pressure prediction. Review well design & well drilling program, ensuring kick tolerance. BHA design should minimise swabbing / surging. Ensure two independent barriers during all phases of well drilling /completion; for details on barriers refer NORSK standard D-010. Assessment of drilling contractor procedures, rig equipment and manpower competency before selection of rig & contractor, and performance monitoring during drilling operations. Ensuring availability of required competent personnel, during planning and operations. Also ensuring competence of crew to recognise influx into well bore as early as possible (having accredited well control training & certification and carrying out drills). Monitoring of pore pressure indicators and drilling fluid properties / parameters (pit volume, flow rate, Specific gravity etc.). Alarms should be set at appropriate levels and tested periodically. Adherence to well control policy / procedures (refer OISD-RP-174): Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards (refer OISDRP-174). Well control equipment / BOPs tested as per industry standards (refer OISD-RP-174). Special considerations during tripping - trip tank, trip sheet records, flow check, control of tripping speed etc. (refer OISD-RP-174). Carrying out LOT / PIT for each section.
2.
a. Improper well
design or programme including mud policy 3.
b. Drilling into
unexpected high pressure formation 4.
c. Loss of
hydrostatic pressure due to mud loss 5.
d. Failure to fill the

well during tripping / casing lowering
6.
e. Swabbing /
surging
f.
Casing integrity failure
7.
g. Gas absorption /
gas cut mud leading to loss of hydrostatic pressure
h. Failure of well
control equipment
i.
Inadequate competence of personnel Loss of position
j.
OISD-GDN- 232
17
Adequate stock of weighing material at the rig. Procedures for safe closure of well and procedures to handle trapped gas / hydrate formation in riser. Testing of casing integrity. Procedures to prevent casing damage. Procedures for handling absorbed gas should include use of MGS and degasser, gas detection in drilling fluid area and level alarms (MGS). Periodic well control drills. Control of ignition sources by ensuring fit for purpose status of electrical equipment in hazardous areas.
k. Trapped gas in
riser / BOP stack 2. Ignition of uncontrolled flow / blow out leading to hydrocarbon fire.
8. 9.
10. Job Safety Analysis.
Mitigating 11. Emergency preparedness as per OISDGDN-227. 12. Emergency preparedness to include: Capability to mobilise own resources or / and agreement with the well control company (having required resources) for the required equipment and services Closure of well as per procedure Escape to muster area HC gas detectors Mobilising fire fighting system Evacuation procedures
Release of toxic gas (H2S)
Well kill procedures. Preventive 1. Well design should include measures for handling H2S gas hazards in H2S known areas. 2. The rig equipment should be appropriate (meet requirements of industry standards
OISD-GDN- 232
18
NACE MR-01 75 / ISO 15156) for drilling wells in H2S known areas. 3. Competent personnel, trained for handling H2S environment. 4. Equipment for monitoring of H2S. For guidance refer industry standards API-RP-49 and OISDRP-201.
Mitigating 5. Emergency preparedness to include: Toxic gas detectors Adequate availability of breathing apparatus for rig crew Medical facilities at the rig 6. Evacuation equipment including medevec. Shallow gas uncontrolled release of gas Preventive 1. Check offset data 2. Conduct shallow seismic survey / Check seismic for any anomaly. 3. Avoid drilling in shallow gas area by considering relocation of well, if possible, otherwise prepare contingency plan. 4. Contingency plan use of diverter / drilling pilot hole / controlled ROP / gas bubble watch by ROV / use of float valve in drill string. and procedures
Mitigating 5. Emergency preparedness to include: Dynamically killing of the well Drop string and move to safe location HC detectors installed and operational at the rig. 1. Occupational hazards such as: Preventive 1. For general guidance refer OISD-RP-190 and
OISD-GDN- 232
a. Noise b. Slip and fall c. Electric shock
2. Man overboard (offshore operations) Mitigating 3. 2. API-RP-54.
19
SOP / JSA for offshore operations to cover man overboard scenario.
S. No. 2.
Sub activity Rig movement and rig dismantling / building (for onshore) and rig move and placement (for offshore)
Anticipated Hazards 1. Occupational hazards such as:
Emergency preparedness for man overboard. Emergency preparedness to include: a. Rescue boat at the installation b. Competent and trained crew to manage rescue boat Risk Reducing measures Preventive 1. Rig movement planning (onshore) including route and site preparation survey, selection of vehicles, cranes and lifting gear (such as wire rope slings, lifting eye, lifting rope for mast etc). 2. Electrical safety procedures including for enroute overhead electrical lines. 3. Adherence to safe operating procedures including driving practices. For detailed guidance refer OISD-STD-187, OISD-GDN202, OISD-GDN-203, OISD-RP-205, OISDSTD-216, and OISD-GDN-218. 4. Job safety analysis to address (refer OISDGDN-218): Check and secure all objects (which can fall) on the mast before raising / lowering of mast Use tag line
a. Fall of material b. Fall of person

from height
c. Road accident d. Electrocution e. Personnel getting

entangled in lines during raising of Mast.
f.
Being struck by swinging objects.
2. In case of offshore rigs, hazards include:
a. Change in
weather conditions wind speed, current, wave height
b. Seabed conditions
/ stability
c. Punch through (in

case of jack up rigs)
d. Water depth e. Mooring / station

keeping systems
5. Rig movement planning (offshore) including updated seabed survey, accurate field survey data, location history, defined weather limits, long term and short term weather forecast, traffic survey, mooring analysis, review of procedures - JSA / HAZOP, fit for purpose equipment / towing vessel requirements / capabilities clearly defined, vessel meets the required specifications / have fitness certificate (class or other), limitations of vessel, breakout limits and strategies defined, minimum separations and distances defined, agreed and adhered to, integrated communication,
OISD-GDN- 232
f.
Other nearby assets such as platform structure, piping at platform, pipelines at seabed and flowing wells at platform etc.
20
clear roles and responsibilities, competent personnel familiar with operations, water tight integrity checks, rig loading plan, joint emergency procedures etc. 6. Pre move meeting (for offshore) attended by operator representative, rig contractor, surveyor and other service providers. 7. Shut down of wells on platform (offshore) during rig move and proper preloading guidelines to be adhered to. 8. Competent persons including crane operator, trailer drivers, slingers, rig building crew, supervisors, and marine competence for MODU / towing vessel. 9. Working at height use of fall prevention devices, man overboard precautions for offshore operations. 10.Safe handling of chemicals. 11.Use of specified PPE.
g. Dynamic loading h. Towing operation

fitness of tug boat and anchor handling equipment, vessel collision
i. j.
Lack of marine competence Inadequate procedures
k. Man overboard l.
Coordination failure communication failure, accountability not defined
Mitigating 12.Emergency procedures should include interfacing with contractors / service providers. Risk Reducing measures Preventive 1. For JSA refer Tubular Handling appraisal procedure guidelines of IADC, drill floor safety document of Step Change in Safety and OISD-RP-190. 2. Use of body harness / safety belt
S. No. 3.
Sub activity Derrick floor Operations
Anticipated Hazards During handling of tubular, occupational hazards due to:
a. Swinging blocks
hitting derrick
b. Swinging pipe c. Rolling / falling of

tubular from pipe rack
Mitigating 3. Emergency preparedness should include medical facilities and medical evacuation procedures.
d. Fall of object e. Hit by moving

object
f.
Slip / trip of person at derrick floor
OISD-GDN- 232
21
g. Fall of person
from derrick floor / monkey board
h. Trapped in
between moving objects
i.
Pinch points at pipe, elevator links, elevator and slip handles
Strain while lifting slips During making / breaking a connection, Occupational hazards due to:
j.
Preventive 1. For JSA refer Tubular Handling appraisal procedure guidelines of IADC, drill floor safety document of Step Change in Safety and OISD-RP-190.
a. Swinging pipe b. Pinch points at slip

handles
c. Pinch points at
pipe, elevator links, elevator, slip handles and tongs
2. Adherence to safe operating procedures. For detailed guidance refer OISDSTD-187, OISD-RP-190.
d. Strain while lifting

slips
e. Slipping / swinging
of tong
f. Breaking of tong
lines
g. Fall of object h. Hit by moving

object
d. Slip / trip of person

at derrick floor
i. Trapped in
j. Chemical hazards
due to mud splash During tripping, occupational hazards due to: Preventive 1. For JSA refer Tubular Handling appraisal
OISD-GDN- 232
22
procedure guidelines of IADC, drill floor safety document of Step Change in Safety and OISD-RP-190. 2. Adherence to safe operating procedures. For detailed guidance refer OISD-STD-187, OISDRP-190. 3. Ensure that Crown-o-matic / twin stop device is installed and working properly. (Regularly check the device for effective functioning) 4. Inspection and maintenance of draw works main drum brake, hydromatic / eddy current brake, tongs, slips, wire ropes, elevators etc. 5. Use of mechanical equipment such as pipe spinner, automatic slips, pipe handling equipment, kelly spinner or top drive etc. to eliminate the occupational hazards. 6. Emergency Escape Device (EED). 7. Slip resistance surface at derrick floor. 8. Before breaking out Kelly, stop mud pump, close mud saver valve on kelly, use mud bucket, use pipe wiper etc. 9. Fall prevention at monkey board and mast ladder. 10.Competent personnel.
a. Swinging blocks
hitting derrick
b. Swinging pipe c. Pinch points at


slips
of tong
f. Breaking of tong
lines
e. Fall of object f. Hit by moving

object
g. Slip at derrick floor h. Fall of person

including falling from mast ladder / monkey board
i. Trapped in
between moving objects 11.Keeping hole full during tripping; for details refer OISD-RP-174. 12.Good housekeeping and use of specified PPE.
j. Chemical hazards
due to mud splash 1. Travelling block hitting the Crown block / derrick floor 2. Failure of hydromatic / eddy current brake 3. Failure of drum brake main
Mitigating 13.Emergency preparedness should include medical facilities and medical evacuation procedures.
4. Rotary movement, in case rotary table is used to spin drill string 5. Uncontrolled flow of well fluid / blow out
OISD-GDN- 232
23
S. No. 4.
Sub activity Handling of drilling fluid
Anticipated Hazards Occupational hazards due to:
Risk Reducing measures Preventive 1. Proper design / specifications of equipment.
a. Chemical
exposure 2. Inspection and maintenance of equipment. 3. SOP / Job safety analysis 4. Competent personnel 5. H2S detection system 6. MSDS and use of specified PPE 7. Proper design / specifications of equipment.
b. Mechanical hazard
of moving / rotating equipment
c. Noise d. Material handling e. Toxic gas (H2S)
Mitigating 8. Emergency preparedness should include provisions of face showers, medical facilities and medical evacuation procedures. Preventive 1. Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards. 2. Adherence to well control policy / procedures. 3. Keep close watch on well during logging for any indication of well activity. 4. Only competent personnel to carry out job. 3. Mechanical failure of wire line / equipment 5. SOP /JSA including procedures for handling well control situations. 6. For recommended practices refer OISD- STD183. 7. Restricted work area 8. Use of specified PPE
5.
Logging
1. Uncontrolled flow of well fluid / blow out during logging operation 2. Occupational hazards due to:
a. Neutron radiation b. Gamma rays
Mitigating 9. Emergency preparedness 6. Perforation 1. Uncontrolled flow of well fluid / blow out during perforation operation Preventive 1. Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards.
OISD-GDN- 232
24
2. Occupational hazards during handling of explosives due to:
2. Adherence to well control policy / procedures. 3. SOP /JSA including procedures for handling well control situations. 4. For recommended practices refer OISD- STD183 and API-RP-67. 5. Only competent personnel to carry out job. 6. Procedures should include: Switching off equipment wireless communication
a. Uncontrolled
detonation / surface detonation
b. Explosion
Electrical isolation Restricted operations Monitoring equipment for stray currents Protection for lightening Proper gun design Weather conditions Adequate communication Restricted work area
7. Use of specified PPE Mitigating 8. Emergency preparedness. 7. Cementation 1. Uncontrolled flow of well fluid / blow out during cementation operation 2. Occupational hazards due to: Preventive 1. Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards. 2. Inspection, maintenance and testing equipment including cementing lines. of
a. Chemical
exposure / respiratory hazard
3. Operating within the pressure limit / provision of PSV. 4. Securing high pressure lines.
moving / rotating equipment 5. Adherence to well control policy / procedures. 6. SOP and JSA
c. Slip, trip and fall d. Noise
7. Competent personnel 8. Use of specified PPE
OISD-GDN- 232
25
e. Material handling,
falling of material Mitigating 3. Liquid at pressure 8. Well testing 1. Loss containment to: of due 9. Emergency preparedness Preventive 1. Design of the equipment as per industry standards. 2. Inspection, equipment. maintenance and testing of
a. Well equipment
failure including packer
b. Testing
equipment failure
3. Adherence to well control policy / procedures. 4. SOP / JSA
c. Swabbing d. Loss of completion

fluid. 2. Loss of containment leading to fire and explosion. 5. For recommended practices refer OISD- GDN182 and API-RP-54. 6. Procedures should include: Safe handling of well fluid considering flow restrictions, if any (due to separator capacity / flare capacity / pressure safety valve discharge capacity).
7. Use of specified PPE
Mitigating 8. Emergency preparedness 9. Electrical 1. Electric shock due to: Preventive 1. Effective grounding as per industry standards (refer OISD-STD-216) 2. Requirements of Indian electricity rules 1956 with respect to electric lighting should be met. 3. Effective insulation
a. Unsafe
equipment
b. Unsafe
environment
c. Unsafe work
practices 2. Fire
4. Equipment in protective environment meeting area classification requirements. 5. Inspection of protective devices / tripping devices such as relays / fuses / circuit breakers (refer OISD-STD-137). 6. SOP including: Safe distances from live parts / overhead lines De-energising and energising for maintenance and testing activities Tag out / lock out to prevent accidental
OISD-GDN- 232
26
start Periodic inspection and testing procedures Interfacing of electrical lock out permit with cold / hot work permit
7. Trained competent personnel 8. Earth leakage protection device with sensitivity < 30mA (for time < 1 sec) for all lighting and socket outlet circuits. 9. Use of specified PPE
Mitigating 10.Emergency preparedness S. No. 10. Sub activity Miscellaneou s drilling related activities. Anticipated Hazards During handling diesel fuels: 1. Loss containment 2. Fire of Risk Reducing measures Preventive 1. Inspection / health check, maintenance and testing of storage tanks and associated equipment including hoses / pipelines. 2. SOP should include safe receipt / unloading of diesel from tanker / vessel. For SOP and JSA refer OISD-STD-157 and OISD-STD-216. 3. Competent personnel 4. Use of specified PPE
of
Mitigating 5. Emergency preparedness should include: Secondary containment Fire fighting system During handling of pressurised gas cylinders: 1. Loss containment 2. Explosion of 2. Safe storage of cylinders. 3. SOP and JSA 4. For recommended practices refer API-RP-54 Preventive 1. Inspection / health check of cylinders and gas cutting equipment.
Mitigating 5. Emergency preparedness For Lines under Preventive
OISD-GDN- 232
pressure: 1. Over pressure loss of containment
27
1. Selection of vessels and pipeline of required pressure rating based on the design as per applicable industry standards. 2. Inspection (including periodic health check) and testing of lines. 3. Operating within design pressure envelope. Provision of pressure safety valves at appropriate locations. 4. Inspection, calibration and testing of PSVs. 5. SOP and JSA 6. Ensure personnel stand clear of pressurized lines during cementation / well control / testing procedures. 7. Use of specified PPE
Mitigating 8. Emergency preparedness In case of personnel working at height: 1. Fall of person Preventive 1. Fall prevention equipment full body harness, life jacket, life line / retractable line, tag line etc. 2. SOP / JSA
Mitigating 3. Emergency preparedness In case of overhead: objects Preventive 1. SOP / JSA 1. Fall of objects 2. Personnel should stay clear of suspended, hoisted or moving loads. 3. Tag lines should be used, where appropriate. 4. Competent personnel Mitigating 5. Emergency preparedness During Welding: 1. Burn injury Preventive 1. Safe welding area / hot work permit refer OISD-STD-105
OISD-GDN- 232
2. Fire 2. SOP / JSA
28
3. For recommended practices refer API-RP-54 or ANSI Z 49. 4. Use of specified PPE (head to toe protection). 5. Ventilation 6. Monitoring of Hydrocarbons 7. Competent personnel 8. Fire watch
Mitigating 9. Emergency preparedness should include fire watch and fire protection. In case of equipment with rotating or moving parts: 1. Pinch points at power tongs, elevators and slips. 2. Unguarded moving parts of air winch, draw works. 3. Travelling block During crane / lifting operations: 1. Unrestrained / swinging loads 2. Overload 3. Equipment failure 4. Unsuitable lifting equipment 5. Space constraints 6. Abnormal weather 7. Simultaneous operations 5. Competent personnel (all crew - supervisor / signal man / crane operator / rigger) 6. Pre-lift load inspections, pre-slung loads, certified lifting gears. 7. Pre-planned load paths / use of tag lines. 3. For recommended practices refer OISD-RP205. 4. Load indicators, load limit charts / limit switches Preventive 1. Inspection and ensuring integrity of lifting equipment. 2. Permit to work / SOP / JSA Preventive 1. SOP / JSA 2. Guards on moving parts 3. Competent personnel.
OISD-GDN- 232
29
8. Specified operations limit for rough weather. 9. Warning (signal / horn) during movement of load. 10.Effective communication. 11.Appropriate manning levels.
12.Use of specified PPE
Mitigating 13.Emergency procedures should include interfacing with contractors / service providers.
Due to conditions:
weather
Preventive 1. System of getting accurate weather forecast from two independent sources / agencies. For offshore weather reliable and functioning monitoring devices at the rig and watch keeping at bridge. 2. SOP / JSA with specified boundary conditions weather limits for safe operations. 3. Rescheduling of activities to avoid the possibility of severe weather conditions during sensitive operations.
1. Strong winds 2. Heavy rains
Mitigating 4. Emergency preparedness Health related: 1. Over exposure to noise Preventive 1. Consideration of noise levels during selection of equipment and reduction of noise level for machinery in use. 2. Minimization of time in noisy environment 3. Isolation of high noise areas and ensuring integrity of sound proofing materials (if applicable). 4. Warning signs / personnel access restrictions 5. Hearing protection / Use of specified PPE
Mitigating
OISD-GDN- 232
30
6. Medical plan - periodic hearing / audiometric tests of personnel exposed to high noise areas Working in confined spaces: 1. Hazardous gas / environment 2. Fall of person 3. Fire 3. Equipment required / respiratory protection and fall protection 4. Competent personnel 5. Buddy system / co-worker 6. Use of specified PPE Preventive 1. Work permit / SOP / JSA 2. For recommended practices refer OISD-STD105
Mitigating 7. Emergency preparedness as per OISD-GDN227. During marine operations, vessel collision leading to: 1. Structural damage of the rig 2. Loss of rig (hull) integrity 3. Loss of vessel (supply vessel / tug boat) integrity 4. Structural damage of the platform Mitigating 5. Emergency procedures should include interfacing with contractors / service providers. During Helicopter operations, loss of control / crash of helicopter due to: 1. Extreme weather 2. Airworthiness of helicopter 2. Helicopter / equipment failure 3. Pilot error 3. Layout / orientation of rig - helideck 4. Competent personnel helideck crew / HLO Preventive 1. SOP (joint procedures with helicopter operator) / JSA for helicopter operations at the rig. Preventive 1. SOP (joint procedures with marine vessel operator) / JSA for vessel operations following industry standards with specified boundary conditions weather limits for safe operations. 2. Fit for purpose status of vessel including its station keeping ability. 3. Competent personnel at both vessel and rig to manage interface. 4. Weather forecast.
OISD-GDN- 232
4. Obstruction in landing / takeoff path 5. Helideck structure failure Mitigating 5. Communication between helicopter and rig
31
6. Availability of weather forecast and weather monitoring instruments at the rig.
7. Emergency procedures should include interfacing with contractors / service providers, fire fighting system at helideck, provision of standby vessel and all personnel trained for HUET.
OISD-GDN- 232
32
Annexure- 2 Checklist for production and related operations
S. No. 1.
Sub activity Well fluid processing and separation
Anticipated Hazards 1. Over pressure 2. Under pressure 3. Liquid overflow 4. Loss of containment due to equipment failure 5. Fire 6. Low liquid level / gas blowby
Risk Reducing measures Preventive 1. Separator should be designed as per industry standards such as API SPEC 12J. Safety devices {like High Pressure Sensor (PSH), Low Pressure Sensor (PSL), Pressure Safety Valve (PSV), High Level Sensor (LSH), Low Level Sensor (LSL), Check Valve, and High Temperature Sensor (TSH)} are installed. (Safety devices should be designed , installed and tested as per industry standard such as API-RP-14C for Offshore Installations) 2. Safety devices are maintained and calibrated at regular intervals. PSV should be maintained and calibrated as per OISD-STD132. 3. Adequately sized piping and valves (refer OISD-STD-106 and OISD-STD-109). Outlet of PSV shall be discharged safely as per OISD- STD-106. 4. Adequate ventilation or provision of combustible gas detectors to shut-off hydrocarbon source. 5. Each input source protected by safety devices like PSH, PSL and PSV. 6. Separator should be equipped with devices to control process parameters like level controller, pressure controller, and temperature controller. 7. Process control devices (Level controller, Pressure Controller, Temperature Controller) should be maintained on regular intervals. 8. Provision of make-up gas system if pressure vessel is subjected to under-pressure that could cause it to collapse. 9. Application of electrical standards and recommended practices such as API RP
OISD-GDN- 232
500, API RP 14 F.
33
10. Location of equipment as per standards such as API RP 14J. 11. Safe operating procedures 12. Integrity Management. Health check of separator and accessories should be carried out as per OISD-STD-128 to ensure its integrity. 13. Job safety analysis / SOP refer OISD GDN 206. 14. Competent personnel. 15. Confined space entry procedures work permit system (refer OISD-STD-105).
Mitigating 16. ESD /containment / blow down system. 17. Safe distances between equipment as per OISD-STD-118 (in on land operations). 18. Fire protection (cooling) as per OISD-STD189. (in on land operations) API-RP-14G or ISO 13702 for offshore operations. 19. Emergency response preparedness as per OISD-STD-227 2. Oil and Gas Transportatio n through Pipelines 1. Loss of containment, failure of pipeline due to: Preventive 1. The pipeline should be designed and installed for operating parameters (nature of fluid, pressure, temperature) following applicable industry standards. Safety devices {like High Pressure Sensor (PSH), Low Pressure Sensor (PSL), Pressure Safety Valve (PSV), and Check Valve} are installed. 2. Safety devices are maintained and calibrated at regular intervals. 3. Proper design to take care that MAWP is greater than maximum shut in pressure. The pipelines should have PSV (If required, based on design and operating parameters) and maintained & calibrated as per OISDSTD- 132.
a. Over pressure b. Corrosion /

erosion
c. Mechanical
damage 2. Damage caused by third party which includes digging (onshore) and marine hazards of vessel collision and anchors of vessels (offshore)
OISD-GDN- 232
3. Fire 4. Explosion
34
4. Integrity Management. Inspection / health check of pipelines (including status of corrosion protection systems) should be carried as per applicable industry standards including OISD-STD-138 for onshore pipelines, OISD-STD-139 for offshore pipelines and OISD-STD-130 for inspection of piping system. 5. Pipelines should be provided with external anti corrosion coating. 6. Pressure in pipelines should be monitored on regular basis. 7. Competent personnel. 8. Repair procedures as per industry standards. 9. Job safety analysis / SOP
Mitigating 10. Emergency response preparedness 11. Depending upon risk assessment provision of auto isolation / alarm in case of leakage. 12. ESD system. S. No. 3. Sub activity Heating of well fluid (in fired vessels, tube type heater) Anticipated Hazards 1. Loss of containment due to: Risk Reducing measures Preventive 1. Equipment should be designed and installed as per applicable industry standards API SPEC 12K, API SPEC 12L, API RP 12N or OISD-STD-111. Safety devices {like High Pressure Sensor (PSH), Low Pressure Sensor (PSL), Pressure Safety Valve (PSV), High Level Sensor (LSH), Low Level Sensor (LSL), Flow Sensor (FSL), Flame failure sensor (BSL), Check Valve, and High Temperature Sensor (TSH)} are installed. 2. Integrity Management. Inspection / health check of fired vessels should be carried as per applicable industry standards including OISD-STD-133. 3. Fired vessels should be equipped with pressure releasing device (PSV).
a. High temperature b. Corrosion c. Over pressure

2. Direct ignition source and excess fuel in firing chamber in case of fired component:
a. Explosion b. Backfire
OISD-GDN- 232
35
4. Safety devices are maintained and calibrated at regular intervals. PSV should be maintained and calibrated as per OISD-STD132. 5. Outlet of PSV shall be discharged safely as per OISD- STD-106. 6. Separator should be equipped with devices to control process parameters like level controller, pressure controller, and temperature controller. 7. Process control devices (Level controller, Pressure Controller, Temperature Controller) should be maintained on regular intervals. 8. Fired vessels should be equipped with level controller valve to control the level and out flow from the vessel. 9. Motor interlocks for forced draft fan motor 10. Flame in the firing chamber is monitored by BSL or TSL sensor. 11. Flame arrestor in natural draft burner. 12. Explosion proof fire chamber 13. Remote ignition system 14. Competent personnel. 15. Electrical systems should be as per applicable industry standards and meeting the requirements of Indian Electricity Rules, 1956. 16. Confined space entry procedures work permit system (refer OISD-STD-105) 17. Job safety analysis / SOP
Mitigating 18. Emergency response preparedness 19. Containment system (including fuel gas) 20. Safe distances between equipment as per OISD-STD-118 (in on land operations). 21. Fire protection (cooling) as per OISD-STDOISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of the OISD
OISD-GDN- 232
189 (in on land operations). 1. Occupational hazards Preventive
36
1. Safety features (hot surface protection in form of guards, barriers or insulation) to address possible occupational hazards including Insulation of hot surfaces.
Mitigating 2. Use of specified PPE 3. Housekeeping S. No. 4. Sub activity Crude storage Anticipated Hazards 1. Loss of containment due to: Risk Reducing measures Preventive 1. The storage tanks should be designed and installed following applicable industry standards API Spec 12D, API Spec 12F or OISD-STD-108 2. There should be two independent gauges or transmitter with the storage tanks to give audio-alarm at high level and audio alarm & tripping at high-high level. 3. Level gauges (or transmitter, where installed) should be calibrated on regular intervals. 4. The breather valve and vent to be installed and maintained on storage tanks as per OISD-STD-108 and OISD-STD-132. 5. Flame arrestor on tanks, refer OISD STD 129
a. Over flow b. Corrosion c. Over pressure

2. Fire
6. Detection system (HC and fire detection) on tanks as per OISD STD 117, where applicable. 7. Storage tanks should have instrumentation as per the requirements of OISD-STD-108. 8. Inspection and health check (including status of corrosion protection systems) of storage tanks and associated equipment should be as per OISD-STD-129. 9. Crude oil should be stabilized before taking into storage tanks. 10. Electrical systems (including control of stray
OISD-GDN- 232
currents) should standards. be as per
37
industry
11. Competent personnel. 12. Confined space entry procedures work permit system (refer OISD-STD-105).
Mitigating 13. Secondary containment / dyke system as per OISD-STD- 118 (in on land operations). Keeping dyke free of vegetation / good housekeeping 14. Fire protection (cooling) as per OISD-STD189 (in on land operations) 15. Safe distances between equipment as per OISD-STD-118 (in on land operations). 16. Emergency response preparedness 1. Occupational hazards such as slip / fall etc. Preventive 1. Safety features to occupational hazards. address possible
Mitigating 2. 3. 5. Gas Compression 1. Over pressure (suction) 2. Over pressure (discharge) 3. Loss of containment due to: Use of specified PPE Housekeeping
Preventive 1. The compressors should be designed and installed following applicable industry standards; refer OISD-STD-120. Safety devices {like High Pressure Sensor (PSH), Low Pressure Sensor (PSL), Pressure Safety Valve (PSV), High Temperature Sensor (TSH Check Valve and Shut down valve} are installed. 2. Gas detectors (if installed in closed enclosed space) to shutoff process inflow and blow down the compressor. 3. Casing vents and drains routed to safe location.
a. Overpressure b. Corrosion c. Seal failure d. Mechanical

damage
OISD-GDN- 232
e. Failure of safety
systems
38
4. Effective sealing system during operations and idle condition (enhanced safety features such as tandem / double dry gas seals, liquid film seals and mechanical (contact) shaft seals); refer OISD-STD-125. 5. Alarms and trips to detect seal failures. Fire loop and thermal detector to shutoff process inflow and blowdown the compressor. 6. Safe routing of leaked gases from sealing system 7. Protection against back pressure from flare / vent line 8. Low lube oil pressure temperature protection and high lube
4. Fire 5. Explosion
6. Excess temperature
9. Abnormal process condition surge, limits for pressure and temperature, relief and safety devices 10. Protection against reverse rotation for rotary / centrifugal compressor. 11. Purging before start up. 12. Noise hazards - display warning signs; refer OISD-GDN-166. 13. Competent personnel 14. Job safety analysis / SOP 15. Electrical systems (including control of stray currents) should be as per industry standards / area classification.
Mitigating 16. Safe distances between equipment as per OISD-STD-118 (in on land operations). 17. ESD / blow down system 18. Fire protection (cooling) as per OISD-STD189 (in on land operations). 19. Emergency response preparedness 1. Occupational hazards Preventive 1. Safety features to address possible
OISD-GDN- 232
39
occupational hazards (including noise and hot surfaces) Mitigating 2. Use of specified PPE 3. House keeping
S. No. 6.
Sub activity Depressurisa tion / blow down
Anticipated Hazards 1. Loss of containment due to:
Risk Reducing measures Preventive 1. Design and installation of depressurisation / blow down system should be as per the industry standards OISD- STD-106 and OISDSTD-109. 2. Provision of KOD and suitable evacuation of liquid from KOD as applicable. 3. Flare stack should have remote ignition system as per the requirements of DGMS (for on land operations) / OISD-STD-106. 4. Safe distances as per OISD-STD-118 (in on land operations). 5. Stack height should meet requirements of MoEF guidelines (in on land operations). 6. Purging should be done before start up. 7. Appropriate system such as water seal / assist flame / molecular seal should be provided to maintain flame front. 8. Competent personnel. 9. Job safety analysis / SOP.
a. Over pressure b. Carryover of

liquid with gas
c. Failure due to
corrosion
d. Mechanical
failure
2. Explosion 3. Fire
Mitigating 10. 7. Ignition 1. Fire hazards due to ignition sources Emergency response preparedness
Preventive 1. Control of ignition sources such as a. Hot surfaces b. Generation of electrostatic energy due to high velocity of fluid
OISD-GDN- 232
c. Mechanical spark d. Electrical spark e. Open flame f. Electronic gadgets such as mobile phone
40
2. All the appliances installed in the installation should be as per area classification zones in line with OISD-STD-113 or API RP 500. 3. All equipment (vessels, piping, well manifolds, pumps, separators etc) and metallic structures should have double independent / distinct earthing and maintained as per Indian Electricity Rules / OISD-STD- 137.
Mitigating 4. Emergency response preparedness 5. Fire protection (cooling) as per OISD-STD-189 (in on land operations). 8. Electrical 1. Electric shock due to: Preventive 1. Effective grounding as per standards (refer OISD-STD-137) industry
a. Unsafe equipment b. Unsafe

environment 2.
Requirements of Indian electricity rules 1956 with respect to electric lighting should be met. Effective insulation Equipment in protective environment / guarding; if required, meeting area classification requirements. Inspection of protective devices / tripping devices such as relays / fuses / circuit breakers (refer OISD-STD-137). SOPs including: Safe distances from live parts / overhead lines De-energising and energising for maintenance and testing activities Tag out / lock out to prevent accidental start Periodic inspection and testing procedures Trained competent personnel
c. Unsafe
practices
work
3. 4.
2. Fire 5.
6.
7.
OISD-GDN- 232
8.
41
Earth leakage protection device with sensitivity < 30mA (for time < 1 sec) for all lighting and socket outlet circuits. Housekeeping
9.
Mitigating 11. Emergency response preparedness 12. Electrical shock chart should be displayed at strategic location S. No. 9. Sub activity Well - head operation Anticipated Hazards 1. Over pressure 2. Loss containment 3. Occupational hazards of Risk Reducing measures Preventive 1. The well head and associated equipment should be designed and installed as per applicable industry standards API SPEC 6A or ISO 10423. Proper design to take care that MAWP is greater than maximum shut in pressure. Safety devices are maintained calibrated at regular intervals. and
2.
3.
Integrity Management. Inspection, maintenance and testing of well head and associated equipment should as per SPEC 6A or ISO 10423. Well design should have system of sub surface closure based on risk assessment; refer API SPEC 14A and API RP 14B. Annuli (including outer annuli), tubing head pressures and ABP should be monitored on regular basis for safety critical parameters. Competent personnel Job safety analysis / SOP (refer OISD-GDN182). For simultaneous operation, refer OISD GDN 186. Use of specified PPE House keeping
4.
5.
6. 7.
8.
9. 10.
OISD-GDN- 232
Mitigating 11. 10. Well maintenance operation like scrapping, activation and stimulation jobs 1. Loss containment to: of due Emergency response preparedness
42
Preventive 1. Vehicles should be placed at safe distance (in on land operations). 2. Wire line assembly including BOP should be installed and tested as per DGMS (in on land operations) / OISD guidelines. 3. Job safety analysis / SOP refer OISD-GDN182. 4. Competent personnel
a. Equipment failure b. Failure of well

material
c. Unsafe
operation. 2. Fire
5. Pressure of compressor line up to annulus should be tested before applying the compressor. 6. Pressure from annulus should be released by using choke to prevent erosion of the seat of annulus valve. 7. Suitability of well head assembly, casing and tubing should be assessed during planning of stimulation job.
Mitigating 8. Emergency response preparedness 9. Safe disposal of chemicals stimulation should be ensured. 3. Occupational hazards Preventive 1. Occupational hazards such as handling of chemical / noise / slip / fall / falling of object etc. should be taken care of by taking preventive measures such as availability and display of MSDS and use of appropriate PPE. used for
Mitigating 2. Use of specified PPE 3. House keeping
OISD-GDN- 232
11. Oil pumping 1. Over pressure 2. Loss containment 3. Fire of Preventive
43
1. Equipment designed as per applicable industry standard OISD-STD-119 and OISDSTD-121. Safety devices {like High Pressure Sensor (PSH), Low Pressure Sensor (PSL), Pressure Safety Valve (PSV), Check Valve and Shut down valve} are installed. 2. Safety devices are maintained and calibrated at regular intervals. 3. Flow dampener and pressure relief valve in positive displacement pumps 4. Casing vents and drains routed to safe location 5. Sufficient protection low pressure and high temperature in case of pressurized lubrication system. 6. In case of gas engine, procedure should include control of hazards associated with fuel gas, during start-up and operations. 7. Equipment maintained as per industry standard OISD-STD-119 and OEM guidelines 8. Competent personnel 9. Job safety analysis / SOP 10. For recommended practices refer OISD-STD119
Mitigating 11. Emergency response preparedness 4. Occupational hazards Preventive 1. Coupling guard removable, non-sparking material, capable of withstanding foreseeable external impact. 2. Insulation of hot surfaces. S. No. 12. Sub activity Miscellaneou s production related activities. Anticipated Hazards In case of personnel working at height: 1. Fall of person Risk Reducing measures Preventive 1. Fall prevention equipment full body harness, life jacket, tag line etc.
OISD-GDN- 232
44
2. SOP / JSA
Mitigating 3. Emergency preparedness During Welding: 1. Burn injury 2. Fire 2. SOP / JSA Preventive 1. Safe welding area / hot work permit (refer OISD-STD-105).
3. For recommended refer API-RP-54 or ANSI Z 49. 4. Use of specified PPE (head to toe protection). 5. Ventilation 6. Monitoring of Hydrocarbons 7. Competent personnel 8. Fire watch
Mitigating 9. Emergency preparedness including fire watch and fire protection. During crane / lifting operations: 1. Unrestrained / swinging loads 2. Overload 3. Equipment failure 4. Unsuitable lifting equipment 5. Space constraints 6. Abnormal weather 7. Simultaneous operations Preventive 1. Inspection and ensuring integrity of lifting equipment. 2. Permit to work / SOP / JSA refer OISD-RP205. 3. Load indicators, load limit charts / limit switches 4. Competent personnel (crew members supervisor / signal man / crane operator / rigger) 5. Pre-lift load inspections, pre-slung loads, certified lifting gears. 6. Pre-planned load paths / use of tag lines. 7. Specified operations limit in rough weather. 8. Warning (signal / horn) during movement of load.
OISD-GDN- 232
45
9. Effective communication. 10.Appropriate manning levels. 11.Use of specified PPE
Mitigating 12.Emergency preparedness procedures should include interfacing with contractors / service providers. Due to conditions: weather Preventive 1. System of getting accurate weather forecast from two independent sources / agencies. For offshore weather reliable and functioning monitoring devices at the installation. 2. SOP / JSA with specified boundary conditions weather limits for safe operations. 3. Rescheduling of activities to avoid the possibility of severe weather conditions during sensitive operations.
Mitigating 6. Medical plan - periodic hearing / audiometric tests of personnel exposed to high noise areas Working in confined spaces: Preventive
OISD-GDN- 232
46
1. Work permit (refer OISD-STD-105) / SOP / JSA 2. Equipment required: respiratory protection and fall protection 3. Competent personnel 4. Buddy system / co-worker 5. Use of specified PPE Mitigating 6. Emergency preparedness During marine operations, vessel collision leading to: 1. Structural damage of the platform 2. Loss of integrity 3. Loss of integrity 4. Loss of integrity well Preventive 1. SOP (joint procedures with marine vessel operator) / JSA for vessel operations following industry standards with specified boundary conditions weather limits for safe operations. 2. Fit for purpose status of vessel including its station keeping ability. 3. Competent personnel at both vessel and platform to manage interface. Responsibilities of key persons are defined. 4. Weather forecast.
1. Hazardous gas / environment 2. Fall of person 3. Fire
vessel
process
Mitigating 5. Emergency preparedness procedures should include interfacing with contractors / service providers. During offshore operations including platform and vessels: 1. Man over board Mitigating Preventive 1. SOP / JSA
2. Emergency preparedness keeping. During Helicopter operations, loss of control / crash of helicopter due to: 1. Extreme weather 2. Airworthiness of helicopter 2. Helicopter / equipment failure Preventive
including
watch
1. SOP (joint procedures with helicopter operator) / JSA for helicopter operations at the platform.
3. Layout / orientation of platform- helideck
OISD-GDN- 232
47
3. Pilot error 4. Obstruction in landing / takeoff path 5. Helideck structure failure
4. Competent personnel helideck crew / HLO 5. Communication platform between helicopter and
6. Availability of weather forecast and weather monitoring instruments at the platform.
Mitigating 7. Emergency preparedness as per OISD-GDN227. Emergency procedures should include interfacing with contractors / service providers, fire fighting system at helideck, provision of standby vessel and all personnel trained for HUET.
OISD-GDN- 232
48
Annexure- 3 Checklist for well servicing and related operations
S. No. 1.
Sub activity
Anticipated Hazards
Risk Reducing measures
1. Planning for well servicing 2. Selection of service provider including workover rig.
1.
Loss of containment / uncontrolled flow of well fluid due to:
Preventive 1. Analyse well data including offset well data of same field and review pressure prediction. Review well servicing program, ensuring kick tolerance. Ensure two independent barriers during all phases of well servicing, for details on barriers refer NORSK standard D-010. Assessment of well servicing contractor procedures, rig equipment and manpower competency before selection of rig & contractor, and performance monitoring during well servicing operations. Ensuring availability of required competent personnel, during planning and operations. Also ensure competence of key crew members to recognise influx into well bore as early as possible (having accredited well control training and certification and carrying out drills). Monitoring completion fluid properties / parameters (Pit volume, flow rate, Specific gravity etc.). Adherence to well control policy / procedures (refer OISD-RP-174): Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards (refer OISDRP-174). Well control equipment / BOPs tested as per industry standards (refer OISD-RP-174). Special considerations during tripping - trip tank, trip sheet records, flow check, control of tripping speed etc. (refer OISD-RP-174). Adequate stock of completion fluid at the rig.
2.
a. Improper well
servicing programme including well barrier policy 3.
3. Well servicing operation s
b. Loss of
hydrostatic pressure due to loss of well fluid
4.
c. Failure to fill the

well during tripping
5.
d. Failure of well
hardware including casing integrity failure
e. Failure of well
control equipment
6.
2.
Ignition of uncontrolled flow / blow out leading to hydrocarbon fire.
7.
OISD-GDN- 232
8. 9. Procedures for safe closure of well. Testing of casing integrity. Procedures to prevent casing damage. Periodic well control drills.
49
Control of ignition sources by ensuring fit for purpose status of electrical equipment in hazardous area.
10. Job Safety Analysis.
Mitigating 11. Emergency preparedness as per OISDGDN-227. 12. Emergency preparedness to include: Availability of own resources or agreement with the well control company (having required resources) for the required equipment and services Closure of well as per procedure Escape to muster area HC gas detectors Mobilising fire fighting system Evacuation procedures Well killing procedures.
2. Handling of completion fluid 1. Occupational hazards due to:
Preventive 1. Proper design / specifications of equipment.
a. Chemical
exposure 2. Inspection and maintenance of equipment. 3. SOP / Job safety analysis 4. Competent personnel 5. H2S detection system 6. MSDS / Use of specified PPE
c. Noise d. Material handling e. Toxic gas (H2S)
Mitigating 7. Emergency preparedness including provisions
OISD-GDN- 232
of face showers S. No. 3. Sub activity Rig movement and rig dismantling / building (for onshore) and rig move and placement (for offshore) Anticipated Hazards 1. Occupational hazards such as: Risk Reducing measures Preventive
50
a. Fall of material b. Fall of person

from height
1. Rig movement planning (onshore) including route and site preparation survey, selection of vehicles, cranes and lifting gear (such as wire rope slings, lifting eye, lifting rope for mast etc). 2. Electrical safety procedures including enroute overhead electrical lines. for
c. Road accident d. Electrocution e. Personnel getting

entangled in lines during raising of Mast.
3. Adherence to safe operating procedures including driving practices. For detailed guidance refer OISD-STD-187, OISD-GDN202, OISD-GDN-203, OISD-RP-205, OISDSTD-216, and OISD-GDN-218. 4. Job safety analysis to address (refer OISDGDN-218): Check and secure all objects (which can fall) on the mast before raising / lowering of mast Use tag line
f.
Being struck by swinging objects.
2. In case of offshore rigs, hazards include:
a. Change in
weather conditions wind speed, current, wave height
b. Seabed conditions
/ stability
c. Punch through (in

case of jack up rigs)
d. Water depth e. Mooring / station

keeping systems
f.
Other nearby assets such as platform structure, piping at platform, pipelines at seabed and flowing wells at platform etc.
5. Rig movement planning (offshore) including updated seabed survey, accurate field survey data, location history, defined weather limits, long term and short term weather forecast, traffic survey, mooring analysis, review of procedures - JSA / HAZOP, fit for purpose equipment / towing vessel requirements / capabilities clearly defined, vessel meets the required specifications / have fitness certificate (class or other), limitations of vessel, breakout limits and strategies defined, minimum separations and distances defined, agreed and adhered to, integrated communication, clear roles and responsibilities, competent personnel familiar with operations, water tight integrity checks, rig loading plan, joint emergency procedures etc. 6. Pre move meeting (for offshore) attended by operator representative, rig contractor, surveyor and other service providers. 7. Shut down of wells on platform (offshore) during rig move and proper preloading
g. Dynamic loading h. Towing operation
OISD-GDN- 232
fitness of tug boat and anchor handling equipment, vessel collision guidelines to be adhered to.
51
i. j.
Lack of marine competence Inadequate procedures
8. Competent persons including crane operator, trailer drivers, slingers, rig building crew, supervisors, and marine competence for MODU / towing vessel. 9. Working at height use of fall prevention devices, man overboard precautions for offshore operations. 10.Safe handling of chemicals. 11.Use of specified PPE.
k. Man overboard l.
Coordination failure communication failure, accountability not defined
Mitigating 12.Emergency procedures should include interfacing with contractors / service providers. Risk Reducing measures Preventive 1. For JSA refer Tubular Handling appraisal procedure guidelines of IADC, drill floor safety document of Step Change in Safety and OISD-RP-190. 2. Use of body harness / safety belt
S. No. 4.
Sub activity Derrick floor Operations
Anticipated Hazards During handling of tubular, occupational hazards due to:
a. Swinging blocks
hitting derrick
b. Swinging pipe c. Rolling / falling of

tubular from pipe rack
d. Fall of object e. Hit by moving

object
f.
Slip / trip of person at derrick floor
g. Fall of person
from derrick floor / monkey board
h. Trapped in
i.
Pinch points at pipe, elevator
OISD-GDN- 232
links, elevator and slip handles Strain while lifting slips During making / breaking a connection, Occupational hazards due to:
52
j.
Preventive 1. For JSA refer Tubular Handling appraisal procedure guidelines of IADC, drill floor safety document of Step Change in Safety and OISDRP-190.
a. Swinging pipe b. Pinch points at slip

handles
c. Pinch points at
2. Adherence to safe operating procedures. For detailed guidance refer OISDSTD-187, OISDRP-190.

slips
of tong
f. Breaking of tong
lines
g. Fall of object h. Hit by moving

object
k. Slip / trip of person

at derrick floor
i. Trapped in
j. Chemical hazards
due to splash of completion fluid During occupational due to: tripping, hazards Preventive 1. For JSA refer Tubular Handling appraisal procedure guidelines of IADC, drill floor safety document of Step Change in Safety and OISDRP-190. 2. Adherence to safe operating procedures. For detailed guidance refer OISD-STD-187, OISDRP-190. 3. Ensure that Crown-o-matic / twin stop device is installed and working properly. (Regularly
a. Swinging blocks
hitting derrick
b. Swinging pipe c. Pinch points at

OISD-GDN- 232
check the device for effective functioning)
53

slips
of tong
4. Inspection and maintenance of draw works main drum brake, hydromatic / eddy current brake, tongs, slips, wire ropes, elevators etc. 5. Use of mechanical equipment such as pipe spinner, automatic slips, pipe handling equipment, kelly spinner or top drive etc. to eliminate the occupational hazards. 6. Emergency Escape Device (EED). 7. Slip resistance surface at derrick floor. 8. Before breaking out Kelly, stop mud pump, close mud saver valve on kelly, use mud bucket, use pipe wiper etc. 9. Fall prevention at monkey board and mast ladder. 10.Competent personnel. 11.Keeping hole full during tripping; for details refer OISD-RP-174. 12.Good housekeeping and use of specified PPE.
f. Breaking of tong
lines
l. Fall of object m. Hit by moving

object
n. Slip at derrick floor o. Fall of person

including falling from mast ladder / monkey board
p. Trapped in
q. Chemical hazards
due to mud splash 1. Travelling block hitting the Crown block / derrick floor 2. Failure of hydromatic / eddy current brake 3. Failure of drum brake main
Mitigating 13.Emergency preparedness should include medical facilities and medical evacuation procedures.
4. Rotary movement, in case rotary table is used to spin drill string 5. Uncontrolled flow of well fluid / blow out 1. Uncontrolled flow of well fluid / blow out during cementation operation 2. Occupational hazards due to:
5.
Cementation
Preventive 1. Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards. 2. Inspection, maintenance and testing equipment including cementing lines. of
a. Chemical
3. Operating within the pressure limit / provision of PSV.
OISD-GDN- 232
exposure / respiratory hazard
54
4. Securing high pressure lines. 5. Adherence to well control policy / procedures. 6. SOP and JSA 7. Competent personnel 8. Use of specified PPE
moving / rotating equipment
c. Slip, trip and fall d. Noise e. Material handling,

falling of material 3. Liquid at pressure 6. Perforation 1. Uncontrolled flow of well fluid / blow out during perforation operation 2. Occupational hazards during handling of explosives due to:
Mitigating 9. Emergency preparedness Preventive 1. Installation, maintenance and inspection of well control equipment / BOP stacks as per applicable industry standards. 2. Adherence to well control policy / procedures. 3. SOP /JSA including procedures for handling well control situations. 4. For recommended practices refer OISD- STD183 and API-RP-67. 5. Only competent personnel to carry out job. 6. Procedures should include: Switching off equipment wireless communication
a. Uncontrolled
detonation / surface detonation
b. Explosion
Electrical isolation Restricted operations Monitoring equipment for stray currents Protection for lightening Proper gun design Weather conditions Adequate communication Restricted work area
7. Use of specified PPE Mitigating 8. Emergency preparedness.

OISD-GDN- 232
55
7.
Well testing
1. Loss containment to:
of due
Preventive 1. Design of the equipment as per industry standards. 2. Inspection, equipment. maintenance and testing of
a. Well equipment
failure including packer
b. Testing
equipment failure
3. Adherence to well control policy / procedures. 4. SOP / JSA
c. Swabbing d. Loss of completion

fluid. 2. Loss of containment leading to fire and explosion. 5. For recommended practices refer OISD- GDN182 and API-RP-54. 6. Procedures should include: Safe handling of well fluid considering flow restrictions, if any (due to separator capacity / flare capacity / pressure safety valve discharge capacity).
Mitigating 8. Emergency preparedness 8. Electrical 1. Electric shock due to: Preventive 1. Effective grounding as per industry standards (refer OISD-STD-216) 2. Requirements of Indian electricity rules 1956 with respect to electric lighting should be met. 3. Effective insulation
a. Unsafe
equipment
b. Unsafe
environment
c. Unsafe work
practices 2. Fire
4. Equipment in protective environment meeting area classification requirements. 5. Inspection of protective devices / tripping devices such as relays / fuses / circuit breakers (refer OISD-STD-137). 6. SOP including: Safe distances from live parts / overhead lines De-energising and energising for maintenance and testing activities Tag out / lock out to prevent accidental start Periodic inspection and testing procedures Interfacing of electrical lock out permit
OISD-GDN- 232
with cold / hot work permit 7. Trained competent personnel
56
8. Earth leakage protection device with sensitivity < 30mA (for time < 1 sec) for all lighting and socket outlet circuits. 9. Use of specified PPE
Mitigating 10.Emergency preparedness 9. Miscellaneou s well servicing related activities During handling diesel fuels: 1. Loss containment 2. Fire of Preventive 1. Inspection / health check, maintenance and testing of storage tanks and associated equipment including hoses / pipelines. 2. SOP should include safe receipt / unloading of diesel from tanker / vessel. For SOP and JSA refer OISD-STD-157 and OISD-STD-216. 3. Competent personnel 4. Use of specified PPE
of
Mitigating 5. Emergency preparedness should include: Secondary containment Fire fighting system During handling of pressurised gas cylinders: 1. Loss containment 2. Explosion of 2. Safe storage of cylinders. 3. SOP and JSA 4. For recommended practices refer API-RP-54 Preventive 1. Inspection / health check of cylinders and gas cutting equipment.
Mitigating 5. Emergency preparedness For Lines pressure: under Preventive 1. Selection of vessels and pipeline of required pressure rating based on the design as per applicable industry standards. 2. Inspection (including periodic health check)
1. Over pressure loss of containment
OISD-GDN- 232
and testing of lines.
57
3. Operating within design pressure envelope. Provision of pressure safety valves at appropriate locations. 4. Inspection, calibration and testing of PSVs. 5. SOP and JSA 6. Ensure personnel stand clear of pressurized lines during cementation / well control / testing procedures. 7. Use of specified PPE
Mitigating 8. Emergency preparedness In case of personnel working at height: 1. Fall of person Preventive 1. Fall prevention equipment full body harness, life jacket, life line / retractable line, tag line etc. 2. SOP / JSA
Mitigating 3. Emergency preparedness In case of overhead: objects Preventive 1. SOP / JSA 1. Fall of objects 2. Personnel should stay clear of suspended, hoisted or moving loads. 3. Tag lines should be used, where appropriate. 4. Competent personnel Mitigating 5. Emergency preparedness During Welding: 1. Burn injury 2. Fire 2. SOP / JSA 3. For recommended practices refer API-RP-54 or ANSI Z 49. Preventive 1. Safe welding area / hot work permit refer OISD-STD-105
OISD-GDN- 232
58
4. Use of specified PPE (head to toe protection). 5. Ventilation 6. Monitoring of Hydrocarbons 7. Competent personnel 8. Fire watch
Mitigating 9. Emergency preparedness should include fire watch and fire protection. In case of equipment with rotating or moving parts: 1. Pinch points at power tongs, elevators and slips. 2. Unguarded moving parts of air winch, draw works. 3. Travelling block During crane / lifting operations: 1. Unrestrained / swinging loads 2. Overload 3. Equipment failure 4. Unsuitable lifting equipment 5. Space constraints 6. Abnormal weather 7. Simultaneous operations 5. Competent personnel (all crew - supervisor / signal man / crane operator / rigger) 6. Pre-lift load inspections, pre-slung loads, certified lifting gears. 7. Pre-planned load paths / use of tag lines. 8. Specified operations limit for rough weather. 9. Warning (signal / horn) during movement of load. 10.Effective communication.
Preventive 1. SOP / JSA 2. Guards on moving parts 3. Competent personnel.
Preventive 1. Inspection and ensuring integrity of lifting equipment. 2. Permit to work / SOP / JSA
3. For recommended practices refer OISD-RP205. 4. Load indicators, load limit charts / limit switches
OISD-GDN- 232
59
11.Appropriate manning levels.
12.Use of specified PPE
Mitigating 13.Emergency procedures should include interfacing with contractors / service providers.
Due to conditions:
weather
Preventive 1. System of getting accurate weather forecast from two independent sources / agencies. For offshore weather reliable and functioning monitoring devices at the rig and watch keeping at bridge. 2. SOP / JSA with specified boundary conditions weather limits for safe operations. 3. Rescheduling of activities to avoid the possibility of severe weather conditions during sensitive operations.
Mitigating 6. Medical plan - periodic hearing / audiometric tests of personnel exposed to high noise areas Working in confined spaces: Preventive 1. Work permit / SOP / JSA
OISD-GDN- 232
1. Hazardous gas / environment 2. Fall of person 3. Fire
60
2. For recommended practices refer OISD-STD105 3. Equipment required / respiratory protection and fall protection 4. Competent personnel 5. Buddy system / co-worker 6. Use of specified PPE
Mitigating 7. Emergency preparedness as per OISD-GDN227. During marine operations, vessel collision leading to: 1. Structural damage of the rig 2. Loss of rig (hull) integrity 3. Loss of vessel (supply vessel / tug boat) integrity 4. Structural damage of the platform Mitigating 5. Emergency procedures should include interfacing with contractors / service providers. During Helicopter operations, loss of control / crash of helicopter due to: 1. Extreme weather 2. Airworthiness of helicopter 2. Helicopter / equipment failure 3. Pilot error 4. Obstruction in landing / takeoff path 5. Helideck structure failure
Preventive 1. SOP (joint procedures with marine vessel operator) / JSA for vessel operations following industry standards with specified boundary conditions weather limits for safe operations. 2. Fit for purpose status of vessel including its station keeping ability. 3. Competent personnel at both vessel and rig to manage interface. 4. Weather forecast.
Preventive 1. SOP (joint procedures with helicopter operator) / JSA for helicopter operations at the rig.
3. Layout / orientation of rig - helideck 4. Competent personnel helideck crew / HLO 5. Communication between helicopter and rig 6. Availability of weather forecast and weather monitoring instruments at the rig.
OISD-GDN- 232
Mitigating
61
7. Emergency procedures should include interfacing with contractors / service providers, fire fighting system at helideck, provision of standby vessel and all personnel trained for HUET. S. No. 10. Sub activity Well stimulation operations Anticipated Hazards 1. Loss of containment 2. Occupational hazards due to: Risk Reducing measures Preventive 1. Job safety analysis / SOP refer OISD-GDN182 2. Inspection, equipment maintenance and testing of
a. Chemical
exposure
3. Competent personnel
of moving / rotating equipment 4. MSDS / Use of specified PPE, safe handling and disposal of chemicals 5. Mechanised handling of material 6. Good house keeping
c. Noise d. Material handling e. Fluid at pressure
Mitigating 7. Emergency response preparedness
11.
Coiled tubing operation
1. Loss of containment 2. Occupational hazards due to:
Preventive 1. Job safety analysis / SOP 2. Inspection, equipment maintenance and testing of
a. Chemical
exposure 3. Competent personnel 4. MSDS / Use of specified PPE, safe handling and disposal of chemicals 5. Mechanised handling of material
6. Good house keeping 7. Well control procedures should include handling of well control situations with coiled tubing equipment.
Mitigating 8. Emergency response preparedness 12. Nitrogen application 1. Loss of containment Preventive
OISD-GDN- 232
1. Job safety analysis / SOP 2. Occupational hazards due to: 2. Competent personnel 3. Inspection, equipment maintenance and testing
62
a. Cold burn b. Mechanical hazard

of
4. MSDS / Use of specified PPE 5. Good house keeping
6. Insulation of cold surfaces / restricted area
13.
Hot oil operations
1. Loss of containment 2. Occupational hazards due to:
Preventive 1. Job safety analysis / SOP 2. refer OISD-182 3. Competent personnel 4. Inspection, equipment maintenance and testing of
a. Mechanical hazard
b. Noise c. Material handling d. Fluid at pressure e. Burn

14. Wireline operations 1. Loss of containment due to: Preventive 1. Vehicles should be placed at safe distance. 2. Wire line assembly including BOP should be installed and tested as per DGMS / OISD guidelines. 3. Job safety analysis / SOP Mitigating 5. Emergency response preparedness
a. Equipment failure b. Failure of well

material
c. Unsafe operation.
4. Competent personnel, trained on well control procedures for wire line system 5. Inspection, equipment. maintenance and testing of
OISD-GDN- 232
15. Compressed air application 1. Loss of containment 2. Occupational hazards due to: Preventive 1. Job safety analysis / SOP 2. Competent personnel 3. Inspection, equipment maintenance and testing
63
a. Mechanical hazard
of
b. Noise
5. Good house keeping
c. Fluid at pressure
Mitigating 6. Emergency response preparedness 16. Offshore well servicing operations carried out by vessels 1. Loss of position of the vessel Preventive 1. SOP (joint procedures with marine vessel operator) / JSA for vessel operations following industry standards with specified boundary conditions weather limits for safe operations. 2. Fit for purpose status of vessel including its station keeping ability. 3. Competent personnel at both vessel and platform to manage interface. 4. Weather forecast.
2. Vessel collision leading to:
a. Structural damage
of the platform
b. Loss of well
integrity
Mitigating 5. Emergency preparedness procedures should include interfacing with contractors / service providers.
OISD-GDN- 232
17. Offshore well servicing operations carried out by modular rigs / platform rigs 1. Structural failure 2. Hazards (fire, noise, vibration) for personnel, living on the platform 3. Major collision of rig move vessel (with dismantled modular rig parts on the boat deck) with other vessel in transit Preventive
64
1. Evaluation of load bearing capacity of platform structure on which modular rig is deployed. 2. Fit for purpose status of structures, rig equipment. 3. Pre-move meeting 4. Weather consideration during movement 5. Marine procedures during rig move 6. Safe location and design of living quarters. 7. Fire detection, suppression system and use of fire retardant material. 8. Noise control and vibration monitoring.
Mitigating 9. Emergency preparedness procedures should include interfacing with contractors / service providers.

Oisd GDN 232

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Draft 3 OISD- GDN- 232 First Edition

For Restricted Circulation Only

Identification of Hazards and Control Measures in E&P Industry

OISD GDN 232

Though every effort

Guidelines for Identification of Hazards and Control Measures in E&P Industry

Shri Pankaj Goswami

Oil India Limited

Shri H.C. Taneja

Oil Industry Safety Directorate

Guidelines for Identification of Hazards and Control Measures in E&P Industry

7.0 7.1 7.2 7.3

Guidelines for Identification of Hazards and Control Measures in E&P Industry

Mitigation Limitation of the undesirable effects of a particular event

Process of Hazard Identification and Risk Assessment

Risk Management Process: ISO 31000:2009 / NORSOK Standard Z-013:2010

Establishing the Context

Communication and Consultation

Analysis of potential initiating events

Analysis of potential Consequences

Risk Evaluation / Establishing Risk Picture

Monitoring, review and update

Risk matrix framework (from ISO 17776):

Has occurred in E&P Industry

Has occurred in the operating company

Occurr ed several times a year in the operati ng compa ny

Occurr ed several times a year at the locatio n

Manage for continued improvement (Low risk hazards)

Risk reduction measures

Control measures in place

Risk Level (Low / Mediu m/ High)

Job safety analysis

Drilling and related operations

Checklist for drilling and related operations is placed at annexure 1.

Production, processing and related operations

Checklist for production, processing and related operations is placed at annexure 2.

W ell servicing and related operations

Checklist for well servicing and related operations is placed at annexure 3.

d. Failure to fill the

Casing integrity failure

Inadequate competence of personnel Loss of position

10. Job Safety Analysis.

Release of toxic gas (H2S)

SOP / JSA for offshore operations to cover man overboard scenario.

Anticipated Hazards 1. Occupational hazards such as:

a. Fall of material b. Fall of person

c. Road accident d. Electrocution e. Personnel getting

Being struck by swinging objects.

2. In case of offshore rigs, hazards include:

c. Punch through (in

d. Water depth e. Mooring / station

g. Dynamic loading h. Towing operation

Lack of marine competence Inadequate procedures

Sub activity Derrick floor Operations

Anticipated Hazards During handling of tubular, occupational hazards due to:

b. Swinging pipe c. Rolling / falling of

d. Fall of object e. Hit by moving

Slip / trip of person at derrick floor

Pinch points at pipe, elevator links, elevator and slip handles

a. Swinging pipe b. Pinch points at slip

d. Strain while lifting

g. Fall of object h. Hit by moving

d. Slip / trip of person