iog1 element 1
DESCRIPTION
IOG1 Element 1TRANSCRIPT
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RRC Training
NEBOSHInternational Technical
Certificate inOil and Gas
Operational Safety
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Element 1Health, Safety and
Environmental Management in Context
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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Why investigate accidents and near-misses?
Learning from Incidents
Should we apply the same level of investigation for each?
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Types of Incident:
Near miss
Accident Injury accident
Damage only accident
Learning from Incidents
Dangerous occurrence
Ill-health
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Basic Investigation Procedures
Step 1: Gather facts.
Step 2: Analyse to determine immediate and root causes.
Step 3: Identify suitable corrective measures.
Step 4: Plan the remedial actions.
Learning from Incidents
FIRST: Treat Injured, Secure/make safe
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Step 1: Gathering Information
Secure the scene.
Identify and Interview witnesses.
Collect factual information.
Check documentation.
Learning from Incidents
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Step 2: Analysing Information
Draw conclusions about the immediate and root causes.
Learning from Incidents
Immediate causes Underlying or root causes E.g. a worker slips on a puddle of oil spilt on the floor immediate causesare the slip hazard (unsafe condition) and the worker walking through it (unsafe act).
E.g. the failure to adequately supervise workers or provide appropriate PPE.
To remedy immediate and underlying (root) causes.
Step 3: Identify Suitable Control Measures
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Step 4: Plan the Remedial Actions
Recommended action
Priority Timescale Responsible person
Learning from Incidents
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Cost of the remedial actions
Learning from Incidents
Remedial Costs Ongoing Costs
Buying personal protective equipment
Providing adequate storage
Putting in place inspection and maintenance programmes.
Carrying out regular inspections
Replacing PPE as it wears, etc.
Maintaining the storage facility, with ongoing training for operators.
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The Importance of Learning from Major Incidents
Learning from Incidents
Piper Alpha incident:
Permit-to-Work systems
Safety Management
Rig Design
Maintenance Systems
Safety Training
Safety Audits
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Piper Alpha incident:
Permit-to-Work systems
Safety Management
Rig Design
Maintenance Systems
Safety Training
Safety Audits
Learning from Incidents
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The outcomes of other previous incidents include:
Bhopal, India, Toxic gas release (1985). 2,700 dead; 50,000 seriously affected; 1,000,000 others less seriously affected.
Buncefield, UK (2005). 40 injuries; widespread damage.
Deepwater Horizon Oil Spill, Gulf of Mexico (2010). 11 dead; Major oil spill.
Learning from Incidents
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Safety culture
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).
Learning from Incidents
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Hazards Inherent in Oil and Gas
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).
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Classification of Flammability
Flammable classification Flash Point
Extremely Flammable Below 0o C
Highly Flammable 0o 21oC
Flammable 22o 55oC
Hazards Inherent in Oil and Gas
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Flammability Limits
Hazards Inherent in Oil and Gas
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Explosive atmosphere situations
Explosions have occurred under the following circumstances:
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
Hazards Inherent in Oil and Gas
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Toxicity
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.
Hazards Inherent in Oil and Gas
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Hazards Inherent in Oil and Gas
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.
Toxic in small quantities can cause death or acute or chronic damage to health when inhaled, swallowed or absorbed through the skin.
Harmful cause death, acute or chronic damage to health when inhaled, swallowed or absorbed through the skin.
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.
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Hazards Inherent in Oil and Gas
Substances or preparations which, if they are inhaled or ingested or penetrate the skin...
Sensitising are capable of eliciting a reaction by hyper-sensitisation (on further exposure to it characteristic adverse effects are produced). May be sensitising by inhalation or sensitisation by skin contact.
Carcinogenic may induce cancer or increase its incidence.Mutagenic may induce heritable genetic defects or increase
its incidence.Toxic for reproduction
may induce or increase its incidence of non-heritable adverse effects in the progeny and/or an impairment of male or female reproductive functions or capacity.
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Hydrogen (catalyst regenerator. In petroleum refining)
highly flammable/explosive (explosive range 4.9 75%)
Colourless and odourless
Low density
Low ignition energy
Not toxic but asphyxiant in high concentrations
Reacts vigorously with oxidants
Hazards Inherent in Oil and Gas
Properties and Hazards of Gases
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Methane (natural gas)
Highly flammable/explosive (explosive range 5% -15%)
Low density (Explosive mixtures can form below low ceilings, etc.)
Easily ignited
Simple asphyxiant
Odorising agent added
Hazards Inherent in Oil and Gas
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LPG (Liquefied Petroleum Gas) as Propane/Butane (fuel)
Easily liquefied gas
highly flammable
Colourless and odourless
Denser than air, collecting at low level
Explosive mixtures form, often readily flashing back to the source of a leak
Easily ignited
Simple asphyxiant and inhalation can lead to drowsiness
Reacts explosively with chlorine
Hazards Inherent in Oil and Gas
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LNG (Liquefied Natural Gas) (fuel).
Liquid gas easily vaporises
highly flammable/explosive gas
Colourless and odourless
Easily ignited
Simple asphyxiant but non-toxic
Contact with liquefied form will cause frostbite (Very cold (boiling at -161C))
Volume increases 630 times on vaporisation
Hazards Inherent in Oil and Gas
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Nitrogen
Non-flammable gas
Colourless, odourless and tasteless
Used to inert flammable and explosive atmospheres (vessels)
Used as cover layer of gas on top of flammable and explosive substances
Used to freeze pipes and pipeline purging
Nitrogen in the blood decreases oxygen-carrying capacity of the blood
Hazards Inherent in Oil and Gas
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Hydrogen sulphide
Flammable gas
Colourless with intense smell of rotten eggs
Denser than air, accumulates at low levels
Can travel long distances and flash back when spark is applied
Toxic, irritates eyes, skin and respiratory tract and can lead to respiratory paralysis
Hazards Inherent in Oil and Gas
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Oxygen
Colourless and odourless
Non-flammable but supports combustion
Oxygen enrichment can lead to fires and explosions
Reacts violently with oils and greases
Hazards Inherent in Oil and Gas
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Anti-foaming agents - used in process and cooling liquids to reduce problems caused by foam, dissolved or trapped air, such as:
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
Hazards Inherent in Oil and Gas
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Anti-wetting agents waterproof barrier coatings.
Protection against water ingress in harsh environments Some protection against corrosion.
Hazards Inherent in Oil and Gas
Corrosion preventatives for fuel systems and process pipelines.
Refrigerants, e.g. propane, ammonia, sulphur dioxide and methane.
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Micro-biocides anti-bacterial treatments.
Oil-system biocides in oil production and water injection systems
Water injection system biocides
Hazards Inherent in Oil and Gas
Fuel preserving biocides
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
Hazards:
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)
Hazards Inherent in Oil and Gas
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Water and Steam:
Used in system cooling, lubrication (drilling muds), fire deluge systems, advanced hydrocarbon recovery methods.
Hazards Inherent in Oil and Gas
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)
Hazards Inherent in Oil and Gas
H2S and mercaptans removed in oil refineries and natural gas processing plants
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.
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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
Different muds for different circumstances (viscosity and density).
Aqueous (water) based, non-aqueous (oil) based, or gaseous fluids
Mineral or synthetic in nature.
Hazards Inherent in Oil and Gas
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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
Fire safety precautions
Suitable PPE
Hazards Inherent in Oil and Gas
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Sludges (drilling wastes)
Low Specific Activity (LSA) sludges may contain naturally occurring radioactive materials (NORM), e.g. uranium, thorium , radium, strontium.
Hazards Inherent in Oil and Gas
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.
Pyrophoric* iron - special control measures to dispose of it
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In oil and gas production, LSA scale is typically found in:
The production well
Safety valves
Well heads
Production manifolds
Inside separators
Water separators
Hazards Inherent in Oil and Gas
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The Purposes and Uses of Risk Assessment Techniques
Risk Management Techniques Used in The Oil and Gas Industries
The 5 Steps approach to risk assessment is:
Degree of rigour proportionate to the risk - more depth and technical input needed for more complex risks associated with oil and gas processes.
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
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The UK Offshore Installations (Safety Case) Regulations 2005 requires:
All hazards with the potential to cause a major accident have been identified.
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.
Risk Management Techniques Used in The Oil and Gas Industries
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Hazard identification
Hazard identification the CORE of risk assessment. The main stages are:
Risk estimation and ranking of risks
Risk evaluation and implementationof risk reduction to ensure
compliance with law
Review
Identificationof possible additional
riskreduction
Risk Management Techniques Used in The Oil and Gas Industries
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Qualitative vs. Quantitative Risk Assessment
Risk Management Techniques Used in The Oil and Gas Industries
Using qualitative methods to determine frequency and severity
Qualitative (Q)
Where frequency and severity are approximately quantified within ranges
Semi-qualitative (SQ)
Where full quantification is demonstrated
Quantified risk assessment (QRA)
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Semi-Quantitative (SQ)
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.
Risk Management Techniques Used in The Oil and Gas Industries
Determining the Right Method of Risk AssessmentQualitative (Q)
Use this method if it is adequate for deciding on appropriate controls. Record the findings and recommendations.
If not adequate, then use
(Continued)
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Risk Management Techniques Used in The Oil and Gas Industries
Quantified Risk Assessment (QRA)
If adequate, use QRA.
If not, increase depth of the risk assessment model until it answers all questions.
Record findings and recommendations
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.
If not adequate, then use
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The Starting Point Approach examples:
Large integrated platforms or nodal platforms in the North Sea - likely to need QRA.
Less complex installations and those with smaller workforces, e.g. drilling installations, normally unattended installations (NUIs) - SQ could be suitable.
Where clear standards/benchmarks for design and risk reduction, Qoften sufficient.
Risk Management Techniques Used in The Oil and Gas Industries
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Risk Management Techniques Used in The Oil and Gas Industries
Risk Estimation and Ranking of Risks
RiskManagement
Know your risks and what youshould be doing about them
Plan, prioritise, implement risk controls
Make sure risk controls remain effective
Review and learn
Risk Management Techniques Used in The Oil and Gas Industries
P Policy OOrganisingP PlanningMMeasuringA AuditingR Review
The HS(G)65 SMS:
Risk Management Techniques Used in The Oil and Gas Industries
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Risk Management Techniques Used in The Oil and Gas Industries
Systems approach - Managing Hazards and Risks at each stage
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Risk Management Techniques Used in The Oil and Gas Industries
Risk control of INPUTS (covering design, selection, installation etc):
RCS needed for: Examples
PHYSICAL RESOURCES rigs, safety critical equipment, substances
HUMAN RESOURCES Recruitment/selection of staff & contractors
INFORMATION H&S laws and standards
RISK CONTROL of PROCESS
Risk Management Techniques Used in The Oil and Gas Industries
Area of Process Risk Examples
Production workplace Field, rig, facilities, support systems, access, welfare
Plant & Substances Oil/gas drilling, pumping, storage
Procedures Shifts, job design
People Leadership, competence
Risk Management Techniques Used in The Oil and Gas Industries
Reducing Risks to ALARP
Other Risk Management Tools - HAZOP
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.
Risk Management Techniques Used in The Oil and Gas Industries
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HAZID
Purpose - to identify all hazards for later risk assessment
Uses brainstorming, aided by key words.
Useful when considering changes to existing plant layout.
Risk Management Techniques Used in The Oil and Gas Industries
FMEA
Risk Management Techniques Used in The Oil and Gas Industries
How can each component fail?
Cause?
Effects on system as a whole?
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
Risk Management Techniques Used in The Oil and Gas Industries
Design it Out principles Examples
Hazard elimination Discontinue, substitute (non-hazardous)
Consequence reduction Substitution (less hazardous), reduced inventory, spill containment, separation/isolation
Likelihood Reduction 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.
Risk Management Techniques Used in The Oil and Gas Industries
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The Concept of Hazard Realisation What If?, e.g. Loss of containment leading to Hydrocarbon Release
Risk Management Techniques Used in The Oil and Gas Industries
Issue to consider from HCRs
Examples
Major Sources system piping, flanges, valves, SBTs, instrumentation
Operational causes Wrongly fitted equipment (gas compression), incorrect operation (human)
Procedural causes Non-compliance with procedure (human)
CONSIDER WORST CASE:
Risk Management Techniques Used in The Oil and Gas Industries
What? Major HCR (> 25kg)Where? From piping/instrumentation
On gas compression unit, close to accommodation.With uncontrolled ignition sources
When? Highest occupancy; deluge system on manualHow? Poorly maintenance, incorrect fittings and not
correctly tightened.
Risk Management Techniques Used in The Oil and Gas Industries
Why?
No PPM
No Detection Equipment
No Emergency
Plan
Poor fire training
Poor response
Poor leadership
No Fire Fighting
Equipment
Taking it further
Risk Management Techniques Used in The Oil and Gas Industries
1 HCR ignited by electrical fault
2 Explosion and fire engulf the canteen
3 All 34 workers in canteen lost
4 Gas compression unit destroyed by blast
5 Gas process operation lost long downtime
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Risk Management Techniques Used in The Oil and Gas Industries
Why?
No warning of
HCR
No water for deluge
Long release duration
Fire fighting
media not available
Personnel elsewhere
No trained response
team
No EER plan
Working down the possibilities in each scenario, begin to eliminate some or reduce some of the consequences andprobability, e.g.
Risk Management Techniques Used in The Oil and Gas Industries
IF THEN
Accommodation NOT next to compression plant
.we may not lose 50% of our crew
fire deluge system is NOT on manual override,
Water will be available automatically to deal with the fire
Risk Management Techniques Used in The Oil and Gas IndustriesThe Concept of Risk Control Barrier Models bow-tie
The Swiss-cheese barrier model
Risk Management Techniques Used in The Oil and Gas Industries
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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
Risk Management Techniques Used in The Oil and Gas Industries
Typical Legal Requirements/Good Practice:
Regulators require safety case/safety report submission for each installation type.
Installation cannot operate until SC/SR accepted by regulator (regulator will inspect installation)
Notification required to regulator at design stage (or when moved or change of use).
An Organisations Documented Evidence
Typical Examples: Safety Case (offshore), Safety Report (Onshore)
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.
An Organisations Documented EvidenceThe Typical Content of Safety Cases and Safety Reports
Identify major accident hazards use risk assessments, bow-tie diagrams, design calculations etc.
An Organisations Documented Evidence
1 Each hazard scenario
2 threats to safety and their causes
3 barriers to prevent those threats
4 consequences of each threat were it to be realised
5 recovery measures required
6 factors that could escalate the hazard or its consequences
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Evaluate major accident risks and measures taken (or to be taken).
An Organisations Documented Evidence
1 Identify each hazard/incident scenario
2 Assess frequency criteria
3 Assess consequence criteria
4 Assess EER facilities and requirements
5 Identify and assess risk control measures against ALARP
Arrangements for audits and audit reports
Adequate SMS in place
An Organisations Documented Evidence
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.