Introduction to Oil and Gas Operational Safety: for the NEBOSH International Technical Certificate in Oil and Gas Operational Safety

229 Pages·2015·8.26 MB·English

Introduction to Oil and Gas Operational Safety
Introduction to Oil and Gas Operational Safety is aligned directly to the NEBOSH International Technical
Certificate in Oil and Gas Operational Safety.
Concisely written by a highly experienced team, this full-colour reference provides complete coverage of the
syllabus, including chapters on fire hazards, risk management and emergency response. It will ensure that you
are fully equipped with the knowledge and understanding to respond and deal with the daily hazards you may
face whilst working in the oil and gas industry.
Complete with tables, case studies and self-test questions, this book will guide you through the principles of
how to manage both offshore and onshore operational risks to prepare you for your exam and beyond.
Wise Global Training is a company dedicated to providing quality health and safety training in a variety of
formats, including eLearning and classroom-based courses as well as webinars.
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Introduction to Oil and Gas
Operational Safety
For the NEBOSH International Technical
Certificate in Oil and Gas Operational Safety
Wise Global Training
Routledge
Taylor & Francis Group
LONDON AND NEW YORK
OIL AND GAS MANUAL 9780415730778.indb iii 09/10/2014 08:58
First edition published 2015
by Routledge
2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN
and by Routledge
711 Third Avenue, New York, NY 10017
Routledge is an imprint of the Taylor & Francis Group, an informa business
© 2015 Wise Global Training Ltd
The right of Wise Global Training to be identified as author of this work has been asserted by
them in accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilized in any form
or by any electronic, mechanical, or other means, now known or hereafter invented, including
photocopying and recording, or in any information storage or retrieval system, without permission
in writing from the publishers.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and
are used only for identification and explanation without intent to infringe.
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging-in-Publication Data
Introduction to oil and gas operational safety: for the NEBOSH international technical certificate in
oil and gas operational safety / Wise Global Training.
pages cm
Includes bibliographical references and index.
1. Petroleum industry and trade--Safety measures--Examinations–Study guides. 2. Petroleum
engineering--Safety measures--Examinations--Study guides. 3. Petroleum engineers–
Certification. 4. National Examination Board in Occupational Safety and Health--Examinations–
Study guides.
TP690.6I64 2014
338.2’728--dc23
2014014632
ISBN: 978-0-415-73077-8 (pbk)
ISBN: 978-1-315-84992-8 (ebk)
Typeset in Univers LT by
Servis Filmsetting Ltd, Stockport, Cheshire
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Contents
Preface .........................................................................viii 3.5 The concept of risk control using barrier models .30
A cknowledgements .......................................................ix 3.6 Use of modelling such as thermal radiation
Illustrations credits ........................................................xi output, blast zones for risk identification .............31
List of abbreviations ....................................................xiv
Introduction to learning outcomes and command 4 Health, safety and environmental
words .......................................................................xvi management in context: an organization’s
How to use this book and what it covers ....................xvii documented evidence to provide a
convincing and valid argument that a
1 Health, safety and environmental system is adequately safe .................................35
management in context: learning from 4.1 Where documented evidence is used .................36
incidents ...............................................................1 4.2 The purpose of documented evidence such
1.1 Investigating incidents, effective as safety cases and safety reports ......................36
identification of the root causes, and making 4.3 The typical content of documents such as
recommendations for improvements ....................2 safety cases and safety reports ...........................36
1.2 Importance of learning lessons from major
incidents, management, culture and technical 5 Hydrocarbon process safety 1: contract
failures that may lead to such incidents .................9 management ......................................................43
5.1 Scale of contractor use ........................................43
2 Health, safety and environmental 5.2 Contract management, ownership and site
management in context: hazards inherent supervision/representation ...................................44
in oil and gas ......................................................11 5.3 Contractor responsibilities ...................................46
2.1 Meaning and relevance of various words and 5.4 Safe handover: understanding the hazards ..........46
phrases associated with hazards inherent in
oil and gas ............................................................12 6 Hydrocarbon process safety 1: process
2.2 Properties and hazards of various gases safety management ...........................................49
associated with the oil and gas industry ..............14 6.1 The controls available in process safety
2.3 Properties and hazards of associated management ........................................................49
products and their control measures ...................15 6.2 Management of change controls .........................55
3 Health, safety and environmental 7 Hydrocarbon process safety 1: role and
management in context: risk management purpose of a permit- to- work system ...............57
techniques used in the oil and gas 7.1 Role and purpose of a permit- to- work system .....58
industries ............................................................21 7.2 The key features of a permit- to- work system ......58
3.1 The purpose and uses of risk assessment 7.3 Types of permit ....................................................61
techniques, qualitative and quantitative 7.4 Interfaces with adjacent plant ..............................63
techniques ...........................................................22 7.5 Interfaces with contractors ..................................64
3.2 How risk management tools are applied 7.6 Lock out, tag out and isolation .............................64
in process safety risk identification and
assessment, application in project phases 8 Hydrocarbon process safety 1: key
from concept, design, start up, the concept principles of safe shift handover ......................67
of ALARP and the management of major 8.1 Placing greater reliance on written
incident risks ........................................................25 communication between handover of 12-
3.3 Industry related process safety standards, hour shifts ............................................................67
inherent safe and risk based design 8.2 Two- way communication at handover with
concepts, engineering codes and good practice ..29 both participants taking joint responsibility ..........68
3.4 The concept of hazard realization .........................30 8.3 What shift handover should include .....................69
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Contents
9 Hydrocarbon process safety 1: plant 14.2 Floating roof tanks, landing the roof, sinking
operations and maintenance ............................71 the roof and rim seal fires/failures ...................115
9.1 Asset integrity, including inspection, 14.3 Fixed roof storage tanks, pressure and
testing, maintenance, corrosion prevention, vacuum hazards ...............................................117
competency and training ......................................72 14.4 Bunding of storage tanks including volume
9.2 Risk based maintenance and inspection strategy 75 and area sizing, construction and valving
9.3 Techniques, principles and importance arrangements ...................................................118
of safe operation, standard operation 14.5 Filling of tanks, overfilling/alarms/tanker
procedures and maintenance ...............................76 connections ......................................................119
9.4 Control of ignition sources during 14.6 Pressurized/refrigerated vessels for Liquid
maintenance and operations ................................77 Petroleum Gas (LPG), Liquid Natural Gas
9.5 Cleaning and gas freeing; purging; venting; (LNG) and carbon dioxide (CO ) .......................120
2
draining of water, product, oxygen and non- 14.7 Loss of containment and consequences .........121
condensables and inerting ...................................79 14.8 Decommissioning of plant and associated
facilities ............................................................125
10 Hydrocarbon process safety 1: start- up 14.9 Management of simultaneous operations .......125
and shutdown ..................................................81
10.1 Hazards and controls associated with safe 15 Hydrocarbon process safety 2: fire
start- up and shutdown .......................................81 hazards, risks and controls ...........................127
10.2 Hazards and controls associated with water 15.1 Lightning ..........................................................128
and hydrates, their presence and removal .........84 15.2 Fire triangle and potential consequences of
10.3 Hazards and controls associated with explosions and thermal radiation .....................128
testing, commissioning and hook up .................86 15.3 Electrostatic charges ........................................129
15.4 The identification of ignition sources ...............131
11 Hydrocarbon process safety 2: failure 15.5 Zoning/hazardous area classification and
modes ...............................................................91 selection of suitable ignition protected
11.1 Introduction and terminology .............................92 electrical and mechanical equipment and
11.2 Failure modes ....................................................93 critical control equipment .................................132
11.3 What is meant by a safe operating envelope .....95
11.4 Use of knowledge of failure modes in initial 16 Hydrocarbon process safety 2: furnace
design, process and safe- operating procedure ..96 and boiler operations ....................................135
11.5 Failure of the annular rim (bottom rim of 16.1 Use of furnace and boiler operations ...............135
storage tank) ......................................................96 16.2 Hazards and risks of operating boilers
and furnaces, in particular those arising
12 Hydrocarbon process safety 2: other from loss of pilot gas supply, over- filling,
types of failures ................................................97 flame impingement, firebox overpressure,
12.1 Weld failures – the need for regular weld low tube flow or control of Tube Metal
inspection and non- destructive inspection Temperature (TMT) ..........................................137
techniques .........................................................97
17 Fire protection and emergency response:
13 Hydrocarbon process safety 2: safety fire and explosion in the oil and gas
critical equipment controls ...........................101 industries ........................................................143
13.1 Emergency Shutdown (ESD) equipment and 17.1 Leak and fire detection systems ......................144
systems ...........................................................101 17.2 Passive fire protection .....................................147
13.2 Safety Integrity Levels (SIL) for 17.3 Active fire protection systems – water
instrumentation ................................................105 based extinguishing systems ...........................148
13.3 Procedures for bypassing Emergency 17.4 Active fire protection systems – chemical/
Shutdown (ESD) systems ................................105 foam based extinguishing systems .................149
13.4 Blow down facilities, flare types ......................106 17.5 Active fire protection systems – inert based
13.5 Close and open drain headers, sewers, extinguishing systems .....................................151
interceptors ......................................................108 17.6 Examples of equipment- specific types
of fire protection system and their
14 Hydrocarbon process safety 2: safe functions ..........................................................151
containment of hydrocarbons ......................111
14.1 Hazards and risks including overfilling, 18 Fire protection and emergency response:
effects of vacuum, overloading of emergency response .....................................157
foundations and failure modes for tank 18.1 Emergency plan ...............................................158
shells and associated pipework .......................112 18.2 Alarms – importance of response ....................160
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Contents
18.3 Medical emergency planning, tiered 19.3 Control of marine operations, certification of
response, medical evacuation procedures vessels, inspection and approvals ....................174
and back up resources .....................................160 19.4 Roles and responsibilities of marine co-
18.4 Principles of escape, evacuation and rescue ordinators, masters and crew ..........................174
from onshore facilities and offshore 19.5 Personnel transfers and boarding
platforms ..........................................................162 arrangements ...................................................175
18.5 Roles and operation of fire teams onshore 19.6 Personal protective equipment
and offshore in upstream and downstream suitability ..........................................................179
facilities ............................................................164 19.7 Diver operations ...............................................179
18.6 Training and drills .............................................164
18.7 External support agencies and resource 20 Logistics and transport operations: land
liaison, including municipal and offshore .........165 transport .........................................................181
18.8 Liaison with emergency services .....................166 20.1 Road tankers ....................................................181
20.2 Traffic management .........................................184
19 Logistics and transport operations: 20.3 Rail ...................................................................185
marine transport ............................................169
19.1 Hazards of vessels and working Revision and assessment guide .................................189
over water ........................................................170 Index ...........................................................................205
19.2 Loading and unloading of vessels at marine
terminals ..........................................................172
vii
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Preface
This book aims to provide a sound breadth of types of training, and our contact details can be found
underpinned knowledge that will give the reader a in the introduction to the Revision and Assessment
foundation of understanding how to manage operational Guide on page 189. The book’s breadth of coverage
risks effectively within the oil and gas industry. It and depth of understanding is the result of the quality
is aimed at those people who work, or who have of input from a team of highly qualified people with
aspirations to work, in the oil and gas sector either many years of hands- on experience working at the ‘well
onshore or offshore. head’. The book’s style of writing portrays the author’s
desire to convey a technically challenging subject in a
This book mirrors the NEBOSH International Technical
way that most people, regardless of background, will
Certificate in Oil and Gas Operational Safety syllabus,
find comfortable to read and absorb. Extensive use of
and anyone wishing to study for this qualification
case studies and uncomplicated explanations of various
will find this book a useful element of their learning
issues reflect this style.
programme. It is recommended that such a learning
programme should also include a tutor- supported In order that the reader can assess their understanding
course to enhance understanding of the subject matter. of the issues covered, we have included a number
This can be either an eLearning or classroom course of assessment questions at the end of each chapter,
where interaction with highly experienced tutors will the indicative answers to which can be found in the
potentially greatly improve examination pass rates. Wise Revision and Assessment Guide section.
Global Training, as the author of this book, provides both
viii
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Acknowledgements
Peter Donoghue, Managing Director of Wise Global Jennifer Newgass, Financial Director of Wise Global
Training Ltd. Peter has been a successful entrepreneur Training Ltd. Jennifer has contributed greatly in sourcing
and business adviser for the past thirty- five years. He copyright permissions, constructing illustrations and
acknowledges that his greatest satisfaction has come assisting in resolving technical issues relating to images
from those occasions when he has been able to pass in general.
on to others knowledge and experience, knowing it
will help them to improve their own situation or further
their career. This was his main motivation for agreeing
to manage the writing of this publication. Peter would
like to take this opportunity to thank, on behalf of Wise
Global Training Ltd, all those people mentioned here,
without whose help this publication would never have
seen the light of day.
David Newgass, Operations Director of Wise Global
Training Ltd. David has contributed greatly in providing
the technical support necessary in the sourcing
of information, the writing of the content and the
communications needed to complete this publication.
He has also assisted in sourcing and editing various
images used in this publication.
Pamela Donoghue, Course Development Director
of Wise Global Training Ltd. Pamela has contributed
greatly in sourcing information, constructing and writing
content, setting type standards and proofreading drafts
at various stages of development.
ix
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