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Element 1 Health, Safety and Environmental Management in Context
NEBOSH International Technical Certificate in Oil and Gas Operational Safety
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Lear Learni ning ng From From Incide ncident nts s Haza Hazards rds Inhe Inhere rent nt in in Oil Oil and and Gas Risk Risk Manage Managemen mentt Techni Techniques ques Used in The Oil and Gas Industries An Orga Organi nisa sati tion’ on’s s Docume Documente nted d Evid Eviden ence ce
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Learning from Incidents
Learning from Incidents Types of Incident:
Why investigate accidents and near-misses? Should we apply t he same level level of investigation for each?
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Near Near m iss
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Acc id ent Injury accident
Damage only accident
• Dangerous Dangerous occurrence • Ill-health
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Learning from Incidents
Learning from Incidents
FIRST: Treat Injur ed, Secure/make s afe Step 1: Gatheri ng Information
Basic Investigation Procedures Step 1: Gather facts. Step 2: Analyse t o determine immediate and r oot causes. Step 3: Identify suitable corrective measures.
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Secure the scene.
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Identify and Interview witnesses.
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Collect factual information.
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Check documentation.
Step 4: Plan the remedial actions.
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Learning from Incidents Step 2: Analysi ng Information
Learning from Incidents Step 4: Plan the Remedial Act ions
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
P r io r it y
T im es c al e
Re sp o ns ib l e 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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Learning from Incidents
The Importance of Learning from Major Incidents
Cost of the remedial acti ons 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.
Learning from Incidents
• Maintaining the storage facility, with ongoing training for operators.
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Piper Alpha incident:
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Permit-to-Work systems
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Safety Management
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Rig Design
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Maintenance Systems
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Safety Training
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Safety Audit s
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Learning from Incidents Piper Alpha incident: •
Permit-to-Work systems
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Safety Management
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Rig Design
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Maintenance Systems
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Safety Training
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Safety Audits
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Learning from Incidents 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.
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Buncefield, UK (2005). 40 injuries; widespread damage.
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Deepwater Horizon Oil Spill , Gulf of Mexic o (2010). 11 dead; Major oil spill.
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Learning from Incidents Safety cul ture
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.
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Vapour Density –mass per unit volume of vapour
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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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Hazards Inherent in Oil and Gas
Hazards Inherent in Oil and Gas Flammability Limit s
Classification of Flammability
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Fl ammable cl assifi cation
Fl ash Poi nt
Extremely Flammable
Below 0 o C
Highly Flammable
0 o – 21oC
Flammable
22o – 55oC
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Hazards Inherent in Oil and Gas
Hazards Inherent in Oil and Gas
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 body’s response to toxic substances.
During Where Where Where Where
hot work, i.e. welding, grinding naked flames have occurred metal tools have created sparks electrical equipment has created sparks static electricity has created sparks
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Hazards Inherent in Oil and Gas
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.
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 produc ed). 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 t hrough immediate, p rolonged 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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Hazards Inherent in Oil and Gas
Hazards Inherent in Oil and Gas
Properties and Hazards of Gases
Methane – (natural gas)
Hydrogen – (catalyst regenerator. In petroleum refining)
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Highly flammable/explosive (explosive range 5% 15%)
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Low density (Explosive mixtures can form below low ceilings, etc.)
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Easily ignit ed
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highly flammable/explosive (explosive range 4.9 – 75%)
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Colourless and odourless
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Low density
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Low i gni ti on ene rgy
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Not toxic but asphyxiant in high concentrations
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Simple asphyxiant
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Reacts vigorously with oxidants
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Odorising agent added
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Hazards Inherent in Oil and Gas
Hazards Inherent in Oil and Gas
LPG (Liquefied Petroleum Gas) as Propane/Butane – (fuel)
LNG (Liquefied Natural Gas) – (fuel).
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Eas il y liq uef ied gas
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Liquid gas easily vaporises
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highly flammable
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highly flammable/explosive gas
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Colourless and odourless
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Colourless and odourless
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Denser than air, collectin g at low level
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Easily ignited
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Explosive mixtures form, often readily flashing back to the source of a leak
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Simple asphyxiant but non-toxic
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Easily ignited
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Simple asphyxiant and inhalation can lead to drowsin ess
Contact with liquefied form will cause frostbite (Very cold (boiling at 161C))
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Reacts explosively with chlorine
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Volume increases 630 times on vaporisation
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Hazards Inherent in Oil and Gas Nitrogen • Non-flammable gas • Colourless, odourless and tasteless • Used to ‘inert’ flammable and explosive atmospheres (vessels)
Hazards Inherent in Oil and Gas 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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Hazards Inherent in Oil and Gas Oxygen
Hazards Inherent in Oil and Gas Ant i- fo ami ng agent s - used in process and cooling liquids to reduce problems caused by foam, dissolved or trapped air, such as:
• Colourless and odourless • 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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Hazards Inherent in Oil and Gas
Hazards Inherent in Oil and Gas Micro-biocides anti-bacterial treatments.
Anti -wet ti ng agent s – 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 b iocides
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 Inherent in Oil and Gas
Hazards Inherent in Oil and Gas
Hazards and Risk Controls for Add itives
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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Hazards Inherent in Oil and Gas Mercaptans (a group of sulphur c ontaining chemicals) • Offensive odours (can be used as odorising agents) • H2S and mercaptans removed in oil refineries and natural gas processing plants
Hazards Inherent in Oil and Gas 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 Inherent in Oil and Gas 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
Hazards Inherent in Oil and Gas 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. • Pyrophoric* iron - special control measures to dispose of it
• Suitable PPE © RRC Training
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Hazards Inherent in Oil and Gas
Risk Management Techniques Used in The Oil and Gas Indust ries
In oil and gas production, LSA scale is typi cally found in: The Purposes and Uses of Risk Assessment Techniques • The production well The 5 –Steps approach to risk assessment is:
• Safety valves • W el l he ads • 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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Risk Management Techniques Used in The Oil and Gas Indus tries The UK Offshore Installations (Safety Case) Regulations 2005 requires:
Risk Management Techniques Used in The Oil and Gas Indust ries • 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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Risk Management Techniques Used in The Oil and Gas Indust ries
Risk Management Techniques Used in The Oil and Gas Indust ries Determining the Righ t Method of Risk Assessment
Quali tative vs. Quantit ative Risk A ssessment
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
U se th is if it is adequate for deciding on appropriate controls. • Record findin gs and recommendations. If not adequate, first increase the depth of modelling of the risk assessment and see if it no w meets requirements. • If it does,record the findings and recommendations. •
Quantified risk assessment (QRA)
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• Where full quantification is demonstrat ed
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Risk Management Techniques Used in The Oil and Gas Indus tries
Risk Management Techniques Used in The Oil and Gas Indust ries The Starting Point Appro ach – examples:
If not adequate,
then use
• Large integrated platforms or nodal platforms in the North Sea - likely to need QRA.
Quantified Risk Ass essment (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. © RRC Training
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Risk Management Techniques Used in The Oil and Gas Indust ries
Risk Management Techniques Used in The Oil and Gas Indust ries
Risk Estimati on and Ranking of Risks
Know your ri sks and what you should be doing about them Plan, priori tise, implement ri sk controls Risk Management Make sure risk controls r emain effective Review and l earn
Risk Management Techniques Used in The Oil and Gas Indus tries
Risk Management Techniques Used in The Oil and Gas Indust ries 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 Management Techniques Used in The Oil and Gas Indust ries Risk control of INPUTS (covering design, selection, installation etc):
Risk Management Techniques Used in The Oil and Gas Indust ries RISK CONTROL of PROCESS
Ar ea of Pr oces s Ris k
Examp les
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
Risk Management Techniques Used in The Oil and Gas Indus tries
Risk Management Techniques Used in The Oil and Gas Indust ries Other Risk Management Tools - HAZOP
Reducing Risks to AL ARP
Purpose - to identify any deviations fr om 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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Risk Management Techniques Used in The Oil and Gas Indust ries
Risk Management Techniques Used in The Oil and Gas Indust ries FMEA How can each component fail?
HAZID Purpose - to identify all hazards for later risk assessment
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Cause?
Uses “brainstorming”, aided by key words.
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Effects on system as a whole?
Useful when considering changes to existing plant layout.
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How serious?
Can the failure be detected before effects become serious?
Risk Management Techniques Used in The Oil and Gas Indus tries 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
Discontinue, substitute (nonhazardous)
Consequence reduction
Substitution (less hazardous), reduced inventory, spill containment, separation/isolation
Likelihood Reduction
Simplify, clarify, redundant systems, ignition source removal
Risk Management Techniques Used in The Oil and Gas Indust ries Sources of Wri tten, Recognised Good Practi ce 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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Risk Management Techniques Used in The Oil and Gas Indust ries The Concept of Hazard Realisati on – What If?, e.g. Loss of cont ainment leading to Hydr ocarbon Release 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)
Risk Management Techniques Used in The Oil and Gas Indust ries CONSIDER WORST CASE :
W hat?
Major HCR ( > 2 5kg)
Where?
From piping/instrumentation On gas compression unit, close to accommodation. With uncontrolled ignition sources
When?
Highest occupancy; deluge system on manual
How?
Poorly maintenance, incorrect fittings and not correctly tightened.
Risk Management Techniques Used in The Oil and Gas Indus tries
Risk Management Techniques Used in The Oil and Gas Indust ries Taking it fur ther
No PPM
1 No Fire Fighting Equipment
No Detection Equipment
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Why?
No Emergency Plan
Poor leadership
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4 Poor response
Poor fire training
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• 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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Risk Management Techniques Used in The Oil and Gas Indust ries No warning of HCR No EER plan
No water for deluge
Risk Management Techniques Used in The Oil and Gas Indust ries 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
Risk Management Techniques Used in The Oil and Gas Indus tries The Concept of Risk Contro l 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…
Risk Management Techniques Used in The Oil and Gas Indust ries The Swiss-cheese barrier model
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Risk Management Techniques Used in The Oil and Gas Indust ries The Use of Modelling (software) for Risk Identific ation Can estimate, e.g. The evaporation rate of flammable liquids. The dispers ion 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
An Organi satio n’s Doc ument ed Evi dence Typical Examples: Safety Case (offshore), Safety Report (Onshore) Typical Legal Requir ements/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)
An Organi satio n’s Doc ument ed Evi dence An Org ani satio n’s Docum ent ed Evi den ce 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
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• threats to safety and their causes
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• barriers to prevent those threats
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• consequences of each threat were it to be realised
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• recovery measures required
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• factors that could escalate the hazard or its consequences
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An Org ani satio n’s Doc um ented Evi den ce An Organi satio n’s Doc ument ed Evi dence Evaluate major accident risk s and measures taken (or to be taken). 1
2 3
4 5
Arrangements for audits and audit reports
• Identify each hazard/incident scenario
Adequate SMS in place • Ass ess frequency criteria • Ass ess consequence criteria • Ass ess EER facilities and requirements • Identify and assess risk control measures against ALARP
Major accident prevention policies (in the case of safety reports) Identify safety cri tical elements in place to manage major accident hazards Details of the emergency plan.
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