IOG1 Element 1

24/2/2014
Element 1
Health, Safety and
Environmental Management in
Context
NEBOSH
International Technical
Certificate in
Oil and Gas
Operational Safety
Learning From Incidents

Hazards Inherent in Oil and Gas
Risk Management Techniques Used in The
Oil and Gas Industries
An Organisations Documented Evidence
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RRC Training
Learning from Incidents

Types of Incident:
Why investigate accidents

and near-misses?
Should we apply the same
level of investigation for
each?
Near miss
Accident
Injury accident
Damage only accident
Dangerous occurrence
Ill-health
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FIRST: Treat Injured, Secure/make safe

Step 1: Gathering Information
Basic Investigation Procedures

Step 1: Gather facts.
Step 2: Analyse to determine immediate and root causes.
Step 3: Identify suitable corrective measures.
Secure the scene.
Identify and Interview witnesses.
Collect factual information.
Check documentation.
Step 4: Plan the remedial actions.
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Step 2: Analysing Information

Step 4: Plan the Remedial Actions
Draw conclusions about the immediate and root causes.

Immediate causes
E.g. a worker slips on a puddle of oil
spilt on the floor immediate causes
are the slip hazard (unsafe
condition) and the worker walking
through it (unsafe act).
Recommended
action
Underlying or root causes
Priority
Timescale
Responsible
person
E.g. the failure to adequately

supervise workers or provide
appropriate PPE.
Step 3: Identify Suitable Control Measures

To remedy immediate and underlying (root) causes.
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The Importance of Learning from Major Incidents
Cost of the remedial actions

Remedial Costs
Buying personal protective
equipment
Ongoing Costs
Carrying out regular inspections
Replacing PPE as it wears, etc.
Providing adequate storage

Putting in place inspection and
maintenance programmes.
Maintaining the storage facility,

with ongoing training for
operators.
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Piper Alpha incident:
Permit-to-Work systems
Safety Management
Rig Design
Maintenance Systems
Safety Training
Safety Audits
RRC Training
Piper Alpha incident:
The outcomes of other previous incidents include:
Permit-to-Work systems
Safety Management
Bhopal, India, Toxic gas release (1985). 2,700

dead; 50,000 seriously affected; 1,000,000 others
less seriously affected.
Rig Design
Maintenance Systems
Buncefield, UK (2005). 40 injuries; widespread

damage.
Safety Training
Deepwater Horizon Oil Spill, Gulf of Mexico

(2010). 11 dead; Major oil spill.
Safety Audits
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Safety culture
Flash Point the lowest temperature at which

sufficient vapour is given off to flash when a source of
ignition is applied.
Vapour Density mass per unit volume of vapour
Vapour Pressure the pressure exerted by a vapour

in equilibrium with its liquid (or solid).
Shared attitudes and beliefs and a way of behaving.

Good safety culture:
High regard for health and safety
Good perception of risk shared by all workers
All adopting the same positive attitudes
Ownership (taking responsibility for H&S).
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Flammability Limits
Classification of Flammability
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Flammable classification
Flash Point
Extremely Flammable
Below 0o C
Highly Flammable
0o 21oC
Flammable
22o 55oC
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Explosive atmosphere situations
Toxicity
Explosions have occurred under the following

circumstances:
Ability of a chemical molecule to

cause injury after it has reached a
susceptible site in the body, and also
applies to the quantitative study of
the bodys response to toxic
substances.
During hot work, i.e. welding, grinding

Where naked flames have occurred
Where metal tools have created sparks
Where electrical equipment has created sparks
Where static electricity has created sparks
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Substances and preparations which...

Very toxic
in very small quantities can cause death or acute or

chronic damage to health when inhaled, swallowed or
absorbed through the skin.
Substances or preparations which, if they are

inhaled or ingested or penetrate the skin...
Sensitising
are capable of eliciting a reaction by hypersensitisation (on further exposure to it characteristic

adverse effects are produced). May be sensitising
by inhalation or sensitisation by skin contact.
Toxic
in small quantities can cause death or acute or chronic

damage to health when inhaled, swallowed or absorbed
through the skin.
Carcinogenic
may induce cancer or increase its incidence.
Harmful
cause death, acute or chronic damage to health when

inhaled, swallowed or absorbed through the skin.
Mutagenic
may induce heritable genetic defects or increase

its incidence.
Corrosive
may, on contact with living tissues, destroy them.
Irritant
non-corrosive substances or preparations which through

immediate, prolonged or repeated contact with the skin or
mucous membrane, can cause inflammation.
Toxic for
reproduction
may induce or increase its incidence of nonheritable adverse effects in the progeny and/or an
impairment of male or female reproductive functions
or capacity.
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Properties and Hazards of Gases
Methane (natural gas)
Hydrogen (catalyst regenerator. In petroleum refining)
Highly flammable/explosive (explosive range 5% 15%)
Low density (Explosive mixtures can form below low

ceilings, etc.)
Easily ignited
highly flammable/explosive (explosive range 4.9 75%)
Colourless and odourless
Low density
Low ignition energy
Not toxic but asphyxiant in high concentrations
Simple asphyxiant
Reacts vigorously with oxidants
Odorising agent added
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LPG (Liquefied Petroleum Gas) as Propane/Butane (fuel)
LNG (Liquefied Natural Gas) (fuel).
Easily liquefied gas
Liquid gas easily vaporises
highly flammable
highly flammable/explosive gas
Denser than air, collecting at low level
Easily ignited
Explosive mixtures form, often readily flashing back to the source of a leak
Simple asphyxiant but non-toxic
Easily ignited
Simple asphyxiant and inhalation can lead to drowsiness
Contact with liquefied form will cause frostbite (Very cold (boiling at 161C))
Reacts explosively with chlorine
Volume increases 630 times on vaporisation
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Nitrogen
Non-flammable gas
Colourless, odourless and tasteless
Used to inert flammable and explosive atmospheres (vessels)

Hydrogen sulphide
Flammable gas
Colourless with intense smell of rotten eggs
Denser than air, accumulates at low levels
Used as cover layer of gas on top of flammable and explosive

substances
Can travel long distances and flash back when spark is applied
Used to freeze pipes and pipeline purging
Toxic, irritates eyes, skin and respiratory tract and can lead to
respiratory paralysis
Nitrogen in the blood decreases oxygen-carrying capacity of the

blood
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Oxygen

Anti-foaming agents - used in process and cooling liquids
to reduce problems caused by foam, dissolved or trapped
air, such as:

Non-flammable but supports combustion
Oxygen enrichment can lead to fires and explosions
Reacts violently with oils and greases
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Cavitation, reducing pump efficiency (and creating noise)

Reducing the capacity of pumps and storage tanks
Bacterial growth in the fluids
Dirt and debris formation and surface flotation
Reducing the effectiveness of the fluids in use
Longer downtime for cleaning and maintenance
Clogging of filtration equipment
Shortened fluid replenishment times and added costs
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Micro-biocides anti-bacterial treatments.
Anti-wetting agents waterproof barrier coatings.
Oil-system biocides in oil production and water injection systems
Protection against water ingress in harsh environments

Some protection against corrosion.
Water injection system biocides
Corrosion preventatives for fuel systems and process pipelines.
Fuel preserving biocides
Refrigerants, e.g. propane, ammonia, sulphur dioxide and

methane.
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Water system biocides for salt and fresh water systems.

Special biocides e.g. to reduce sulphate reducing bacterial in
drilling and process platform structures and pipelines.
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Hazards and Risk Controls for Additives
Water and Steam:
Hazards:
Used in system cooling, lubrication (drilling muds), fire deluge

systems, advanced hydrocarbon recovery methods.
Depends on inherent chemical hazard, physical form and route of

entry into the body
Risk Controls:
Hazardous substance Risk assessment

Automated dosing instead of hand-dosing
Safe storage and handling procedures
Suitable PPE (chemical resistant clothing, goggles, RPE)
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The hazards
- pressure injection of fluids into the body
- severe steam burns (including of lungs)
- asphyxiation
Safe handling
- Special procedures
- water and heat-proof clothing.
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Mercaptans (a group of sulphur containing chemicals)
Offensive odours (can be used as odorising agents)
H2S and mercaptans removed in oil refineries and natural gas
processing plants

Drilling muds (drilling fluids)
Used in deep holes in oil and gas extraction:
Lubricant (reduces friction and heat and reduces the
chances of friction-related complications).
Carrier for the materials through which drilling takes place
Headaches, nausea, coughing, irritation of the lungs and eyes.

Very high concentrations - breathing difficulties, cyanosis (turning
blue), loss of consciousness and muscle spasms.
Appropriate respiratory protective equipment (RPE) is to be worn
where potentially harmful levels may be present.
Different muds for different circumstances (viscosity and

density).
Aqueous (water) based, non-aqueous (oil) based, or gaseous
fluids
Mineral or synthetic in nature.
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Hazards
Contact with additives (e.g. diesel oil
and fumes, anti-foaming agents)
Fire/explosion (Natural gases and
flammable materials that can be
returned to the drilling work areas).
Controls

Sludges (drilling wastes)
Low Specific Activity (LSA) sludges may contain naturally occurring
radioactive materials (NORM), e.g. uranium, thorium , radium,
strontium.
Radiation monitoring in settling-out areas
Removal of LSA scale from production equipment (specialist
dispersal chemicals or high-pressure water flushing).
Protection of personnel (from contact and inhalation) may need
restricted, controlled areas and classified workers for high radiation
levels.
Fire safety precautions

Pyrophoric* iron - special control measures to dispose of it
Suitable PPE
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Risk Management Techniques

Used in The Oil and Gas Industries
In oil and gas production, LSA scale is typically found in:

The Purposes and Uses of Risk Assessment Techniques
The production well
The 5 Steps approach to risk assessment is:
Safety valves
Well heads
Production manifolds
Inside separators
Step 1
Identify the hazards
Step 2
Identify who might be harmed and how
Step 3
Evaluate the risks and decide on precautions
Step 4
Record your findings and implement them
Step 5
Review your assessment and update if necessary
Water separators
Degree of rigour proportionate to the risk - more depth and technical input
needed for more complex risks associated with oil and gas processes.
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The UK Offshore Installations (Safety Case) Regulations 2005
requires:

Hazard identification the CORE of risk assessment.
The main stages are:
Hazard identification
All hazards with the potential to cause a major accident have

been identified.
Risk estimation
and ranking of risks
All major accident risks have been evaluated, and

Measures have been, or will be, taken to control the major
accident risks to ensure compliance with the law that is, a
compliance demonstration.
Identification
of possible
additional
risk
reduction
Risk evaluation and implementation

of risk reduction to ensure
compliance with law
Review
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Determining the Right Method of Risk Assessment
Qualitative vs. Quantitative Risk Assessment
Qualitative (Q)
Qualitative (Q)
Use this method if it is adequate for deciding on appropriate controls.

Record the findings and recommendations.
Using qualitative methods to determine frequency and severity

If not adequate,
then use
Semi-qualitative (SQ)
Semi-Quantitative (SQ)
Where frequency and severity are approximately quantified within

ranges
Quantified risk assessment (QRA)
Where full quantification is demonstrated
Use this if it is adequate for deciding on appropriate controls.
Record findings and recommendations.

If not adequate, first increase the depth of modelling of the risk assessment and see if it now meets
requirements.
If it does, record the findings and recommendations.
(Continued)
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The Starting Point Approach examples:
If not adequate,
then use
Large integrated platforms or nodal platforms in the North Sea - likely to

need QRA.
Quantified Risk Assessment (QRA)
If adequate, use QRA.
If not, increase depth of the risk assessment model until it answers all questions.
Less complex installations and those with smaller workforces, e.g.

drilling installations, normally unattended installations (NUIs) - SQ could
be suitable.
Record findings and recommendations
Where clear standards/benchmarks for design and risk reduction, Q

often sufficient.
In their Offshore Information Sheet No 3/ 2006, the UK HSE give more
industry specific guidance on how to determine which risk assessment
method is appropriate.
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Risk Estimation and Ranking of Risks
Know your risks and what you

should be doing about them
Plan, prioritise, implement risk controls
Risk
Management
Make sure risk controls remain effective
Review and learn


Systems approach - Managing Hazards and Risks at each stage
The HS(G)65 SMS:

P Policy
O Organising
P Planning
MMeasuring
A Auditing
R Review
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Risk control of INPUTS (covering design, selection, installation
etc):

RISK CONTROL of PROCESS
Area of Process Risk
Examples
RCS needed for:
Examples
Production workplace
PHYSICAL RESOURCES
rigs, safety critical

equipment, substances
Field, rig, facilities, support

systems, access, welfare
Plant & Substances
Recruitment/selection of staff
& contractors
Oil/gas drilling, pumping,

storage
Procedures
Shifts, job design
H&S laws and standards
People
Leadership, competence
HUMAN RESOURCES
INFORMATION


Other Risk Management Tools - HAZOP
Reducing
Risks to
ALARP
Purpose - to identify any deviations from design intent, their

causes and consequences.
Useful at design stage of hazardous installations/processes.
Multi-disciplinary team and brainstorming
Uses guide words to identify deviations e.g. MORE, LESS
Devise actions to reduce risk down to acceptable level.
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FMEA
How can each component fail?
HAZID
Purpose - to identify all hazards for later risk assessment
Cause?
Uses brainstorming, aided by key words.
Effects on system as a whole?
Useful when considering changes to existing plant layout.
How serious?
Can the failure be detected before effects become serious?

Industry Related Process Safety Standards
Promote concepts of Inherently safe and risk based design
i.e. design it out
Design it Out principles Examples
Hazard elimination
Consequence reduction
Likelihood Reduction
Discontinue, substitute (nonhazardous)

Substitution (less hazardous),
reduced inventory, spill
containment, separation/isolation
Simplify, clarify, redundant
systems, ignition source removal

Sources of Written, Recognised Good Practice include:
(UK) HSE Guidance and ACoPs
National or local government guidance
International or national standards (BS, CEN, CENELEC,
ISO, IEC, etc.)
Industry specific or sector guidance from trade federations,
professional institutions, etc.
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The Concept of Hazard Realisation What If?, e.g. Loss of
containment leading to Hydrocarbon Release
Issue to consider from
HCRs
Major Sources
Operational causes
Procedural causes
Examples
system piping, flanges, valves,
SBTs, instrumentation
Wrongly fitted equipment (gas
compression), incorrect operation
(human)
Non-compliance with procedure
(human)

CONSIDER WORST CASE:
What?
Major HCR (> 25kg)
Where?
From piping/instrumentation
On gas compression unit, close to
accommodation.
With uncontrolled ignition sources
Highest occupancy; deluge system on manual
When?
How?

Poorly maintenance, incorrect fittings and not

correctly tightened.

Taking it further
No PPM
1
No Fire
Fighting
Equipment
No
Detection
Equipment
Why?
No
Emergency
Plan
Poor
leadership
4
Poor
response
Poor fire
training
HCR ignited by electrical fault

Explosion and fire engulf the canteen
All 34 workers in canteen lost
Gas compression unit destroyed by blast
Gas process operation lost long downtime
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No
warning of
HCR
No EER
plan
No water
for deluge

Working down the possibilities in each scenario, begin to
eliminate some or reduce some of the consequences and
probability, e.g.
IF
No trained
response
team
Why?
Personnel
elsewhere
Long
release
duration
Fire
fighting
media not
available

The Concept of Risk Control Barrier Models bow-tie
THEN
Accommodation NOT next to .we may not lose 50% of

compression plant
our crew
fire deluge system is NOT on Water will be available
manual override,
automatically to deal with the
fire

The Swiss-cheese barrier model
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The Use of Modelling (software) for Risk Identification
Can estimate, e.g.
The evaporation rate of flammable liquids.
The dispersion patterns of leaking vapours/gases,
The likely types, effects and scale of any fires and
explosions - the rate of pressure rise, maximum pressure,
intensity of thermal radiation, blast zones

Typical Examples: Safety Case (offshore), Safety Report
(Onshore)
Typical Legal Requirements/Good Practice:
Notification required to regulator at design stage (or when
moved or change of use).
Regulators require safety case/safety report submission for
each installation type.
Installation cannot operate until SC/SR accepted by regulator
(regulator will inspect installation)

The Purpose of Documented Evidence such as Safety
Cases and Safety Reports
To ensure that duty holders design/operate their facilities
safely.
i.e. Measures in place to identify potential for, prevent and
mitigate major accidents.
The Typical Content of Safety Cases and Safety Reports

Identify major accident hazards use risk assessments, bow-tie
diagrams, design calculations etc.
1
Each hazard scenario
threats to safety and their causes
barriers to prevent those threats
consequences of each threat were it to be realised
recovery measures required
factors that could escalate the hazard or its consequences
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Evaluate major accident risks and measures taken (or to be
taken).
1
Arrangements for audits and audit reports
Identify each hazard/incident scenario
Adequate SMS in place

2
3
4
5
Assess frequency criteria

Assess consequence criteria
Assess EER facilities and requirements
Identify and assess risk control measures against ALARP
Major accident prevention policies (in the case of safety

reports)
Identify safety critical elements in place to manage major
accident hazards
Details of the emergency plan.
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24/2/2014

Learning From Incidents

Learning from Incidents

Learning from Incidents

Why investigate accidents

Damage only accident

Learning from Incidents

Learning from Incidents

FIRST: Treat Injured, Secure/make safe

Basic Investigation Procedures

Secure the scene.

Identify and Interview witnesses.

Collect factual information.

Step 4: Plan the remedial actions.

Learning from Incidents

Learning from Incidents

Draw conclusions about the immediate and root causes.

Underlying or root causes

E.g. the failure to adequately

Step 3: Identify Suitable Control Measures

Learning from Incidents

The Importance of Learning from Major Incidents

Cost of the remedial actions

Providing adequate storage

Learning from Incidents

Maintaining the storage facility,

Piper Alpha incident:

Learning from Incidents

Learning from Incidents

Piper Alpha incident:

The outcomes of other previous incidents include:

Bhopal, India, Toxic gas release (1985). 2,700

Buncefield, UK (2005). 40 injuries; widespread

Deepwater Horizon Oil Spill, Gulf of Mexico

Learning from Incidents

Hazards Inherent in Oil and Gas

Flash Point the lowest temperature at which

Vapour Density mass per unit volume of vapour

Vapour Pressure the pressure exerted by a vapour

Shared attitudes and beliefs and a way of behaving.

High regard for health and safety

Good perception of risk shared by all workers

All adopting the same positive attitudes

Ownership (taking responsibility for H&S).

Hazards Inherent in Oil and Gas

Hazards Inherent in Oil and Gas

Hazards Inherent in Oil and Gas

Hazards Inherent in Oil and Gas

Explosive atmosphere situations

Explosions have occurred under the following

Ability of a chemical molecule to

During hot work, i.e. welding, grinding

Hazards Inherent in Oil and Gas

Hazards Inherent in Oil and Gas

Substances and preparations which...

in very small quantities can cause death or acute or

Substances or preparations which, if they are

are capable of eliciting a reaction by hypersensitisation (on further exposure to it characteristic

in small quantities can cause death or acute or chronic

may induce cancer or increase its incidence.

cause death, acute or chronic damage to health when

may induce heritable genetic defects or increase

may, on contact with living tissues, destroy them.

non-corrosive substances or preparations which through