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NEBOSHInternational Technical

Certificate inOil and Gas

Operational Safety

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Element 2Hydrocarbon Process Safety 1

• Contractor Management

• Process Safety Management (PSM)

• Permit-to-Work Procedures

• Key Principles of a Safe Shift Handover

• Plant Operations and Maintenance

• Start Up and Shut Down

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The Scale of Contractor Use

• Support vessels

• Diving services

• Work on drilling and exploration rigs

• Etc.

Contractor Management

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To achieve safe working with contractors:

• Risk assess the contractor’s job

• Make sure contractors follow site rules

• Good comms - ensure all contractor employees know identity of site contact person (and how to contact)

• Include contractors in safe working procedures/PTW systems


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Contractor Management – 5 Steps

1 •Planning

2 •Choosing a contractor

3 •Contractors working on site

4 •Keeping a check

5 •Reviewing the Work

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Assessing contractor competence:

• Experienced in the type of work?

• Trained in offshore safety requirements?

• Any recent enforcement action taken against them?

• Etc.


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Safe Shift Handover – Understanding the Hazards/Issues

• Enough time allowed?

• Formal meetings held?

• Conflict between the shifts (how much the off-going shift actually achieved, etc.) ?

• Off-going shift left work they don’t want to do?

• Included contractors?

• Etc.


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Process Safety Management (PSM)Some methodologies used to classify Fire and Explosion risk:

• Dow Fire and Explosion Hazard Index (DF&EI) • Mond Fire and Explosion and Toxicity Index (MFETI)

Risk Classifications from the Dow index

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How the Dow Index works:

Awards a characteristic for each factor in the fire/explosion hazard analysis:

• Main items (material factor): MF

• General process hazards factor: F1

• Special process hazards factor: F2

• Process unit hazards factor: F3 (F3 = F1 x F2)

• Fire & Explosion Index (F&EI) = F3 x MF

Process Safety Management

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Dow IndexAdvantages Disadvantages

Reproducible Intended for designer use at early stages

Requires evaluation of all aspects of a process unit that increases the potential severity of a fire or explosion

harder to apply to existing plant

Easy to use Not good at determining normal expected loss

Based on actual loss experience Interpretation requires judgement

Recognised by industry as good for ranking chemical process risks

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Some PSM controls:

• Inventory control

• Spacing of operating plant

• Positioning and protection of control rooms and critical equipment (isolation)

• Administrative controls, e.g. Management of change (MoC)

Process Safety Management (PSM)

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MoC control will be needed when, e.g.

• equipment is replaced with non-identical parts

• new items or equipment is added to the system

• changes are made to the operating procedures (if outside established design basis and safe operating envelope).


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MoC Procedures should identify:

• the scope of the changes (what needs to change)

• the roles and responsibilities of those managing and making the changes

• how risk analysis is to be undertaken

• methods used to communicate the changes

• training of personnel involved


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Some documentation that may be involved in the MoC evaluation:

• Original process system designs (basis for design)

• Process flow diagrams

• Cause and effect diagrams

• List of control, alarm and trip settings

• Equipment specifications

• Drawings detailing classification of hazardous areas


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Roles and Responsibilities –Making The Change

• Map the organisational changes (prevent gaps)

• Match personnel and skills to the task (further training?)

• Phase the changes.


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Change proposal document design elements and issues:

• Description of the proposed change

• Date of proposal

• Reasoning for the change (why needed etc).


• Authorisation (personnel) for different types of change

• Involve competent personnel to assess changes

• Monitoring of adherence to procedures

• Independent auditing of SMS

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The Role and Purpose of a Permit-to-Work System

• To ensure non-routine/hazardous work is assessed, planned, authorised and carried out safely.

Permit-to-Work Procedures

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The Typical Features of a Permit-to-Work Document

• Title and permit number • Reference to other permits/isolation certificates in place• Equipment, distribution board, circuit or job location; plant

identification• Description of job• Hazards identified and precautions necessary • Protective equipment and PPE required• Authorisation• Date, time and duration of the permit• Identification of employees in control of the work • Permit acceptance• Extension/Handover arrangements (e.g. shift handover)• Returning to service on completion of work• Cancellation


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Roles and Responsibilities of those using Permits-to-Work:

• Permit applicant

• Issuing authority

• Performing Authority

• Permit user


NB need for Training and Competence in use of system.

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Types of Permits-to-Work

Separate permits are required for different tasks, e.g.:

• Hot work• Live electrical or high voltage work• Working at height• Working over water• Work in confined spaces

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Interfaces with Adjacent Plant

Need to consider implications/interactions e.g.

• Permit issued to shut down one item of plant when another, exactly the same, is already shut down for work.

(Remember Piper Alpha disaster!)


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Interfaces with Contractors

Treat contractors as employees in the permit-to-work system.


Work role PTW Role

Contractor Permit user

Manager appointing contractor Issuing authority

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Safe Isolation, Lock-Out and Tag-Out Systems


Principal requirements:

• Removal (isolation) of energy sources

• Method of prevention of accidental re-application of the energy source

• Adequate warnings and safeguards for those working on isolated equipment and machinery

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SAFE ISOLATION STEPS

• Stop machine/plant normally.

• Discharge residual energy.

• Stop all moving parts (in safe position)

• Switched OFF main electrical isolator.

• Fit lock (labelled/coded) to isolator to secure in OFFposition.


Safe isolation must always be proven before commencing the work to be done.

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LOCK-OUT / TAG-OUT SYSTEMS (for multiple lock-offs)

• Safety clamp – where > 1 person requires access

• A warning notice


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Fuse removal – if TOTAL SEPARATION from an electricity supply is needed.


Other energy sources may need -

• Pipe disconnection• Blanking (with locks)• Locking of valves

Other considerations

Physical restraints to prevent fall” of machinery parts after isolation of the power

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RE-CONNECTION PROCEDURE

• Tidy away all tools used• Correctly refit removed items

• Lock ‘owner’ unlocks and removes it (may need alternative for shift change-over)

• Remove clamp (if multiple locks)

• Warning notice ‘owner’ removes it

• Person who carried out isolation to check if safe to re-connect the energy source(s).

• Reconnect


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Shift Handover communication problems:• During plant maintenance running across > 1 shift.

• Where safety systems may have been over-ridden (e.g. fire deluge switched onto manual).

• During deviations from normal working (e.g. breakdowns).

• During extended absences by workers.

• Handover between experienced and inexperienced staff.

Key Principles of Safe Shift Handover

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To make handovers more effective:

• Make shift change-over comms a high priority

• Conduct handovers face-to-face

• 2-way - ensure BOTH shift crews take joint responsibility for information accuracy

• Allow sufficient TIME

• Use verbal and written

• Analyse information needs of incoming crew

• Etc.

Key Principles of Safe Shift Handover

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Asset Integrity

The ability of an ‘asset’ to carry out its intended function effectively and efficiently over its planned lifecycle, at the same time safeguarding the health and safety of those exposed and the operating environment.

Plant Operations and Maintenance

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Plant Operations and MaintenanceLifecycle phase Example

deliverables/activities

Design Safety studies

Construction and hook up Procurement quality plans

Commission Function test

Operation Maintenance

Modification MoC process

Decommission Decommissioning plan

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Inspection and testing often legal requirement (e.g. lifting equipment) but generally required:


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• Pressure vessels (including pipelines) – in accordance with a written scheme of examination. Safety of pressure vessels, internal and external inspection and hydraulic testing every 10 years.

• Lifting equipment – six monthly if persons carried ; 12 months for other, unless specified in written scheme by the operator.


Examples of Inspection/Testing requirements

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Maintenance Strategies:

• Emergency / Breakdown maintenance• Opportunity maintenance• Working adjustments


• Running repairs• Servicing and inspection• Shutdown maintenance• Planned preventive maintenance (PPM)• Routine condition-monitoring

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Some Corrosion Types:

• General wastage of material (uniform corrosion)• Galvanic corrosion (dissimilar metals in contact)• Pitting (localised attack)• Intergranular corrosion• Stress corrosion• Erosion corrosion• Corrosion fatigue• High temperature oxidation• Hydrogen embrittlement


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Corrosion control practice and procedures include:

• Selection of (inherently corrosion resistant) materials, e.g. C-Mnsteel of offshore vessels and pipework

• Chemical treatments e.g. corrosion inhibiters in pipelines

• Surface coatings e.g. paints

• Cathodic protection

• Process and environmental controls

• Initial design

• Monitoring/inspection/testing for corrosion


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Corrosion Inspection and monitoring will include risk-based assessment of:

• The operating environment• The composition of produced fluids• Metal wastage• Pitting corrosion• Erosion caused corrosion• Cracking• Assessment of the corrosivity of fluids• Development of biological activity


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Three monitoring system types:

In-line systems – devices placed in the system that have to be removed for monitoring, such as corrosion (weight-loss) coupons, bio-studs, etc.

On-line techniques – using corrosion monitoring devices fixed in the system or process equipment

Off-line monitoring – which requires inspection and non-destructive testing


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Asset Integrity Competency and Training, e.g. for:

• Asset integrity managers e.g. performance standards for SCEs

• Others, e.g. corrosion awareness


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Plant Operations and MaintenanceRisk based Maintenance and Inspection Strategy

1• Ensure the risks are reduced to ALARP

2• Optimise the inspection schedules

3• Inspect the most critical items of plant, equipment

and components

4• Use the most appropriate inspection methods

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Techniques, Principles and Importance of Safe Operation Procedures and Maintenance

Safe Operation

Safe operation requires planned activities, controlled timetables and full operational guidelines to be in place.


Standard Operation Procedures

Day-to-day procedures (“standards of performance”) to ensure that “normal” activities are conducted safely.

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Control of Ignition Sources in Maintenance and Operations

• Electrical equipment –routine inspection and testing

• Smoking – restrict to designated areas

• Cooking and heating appliances – designated areas (galley), master (gas) isolator valve clearly visible (gas).

• Mechanical overheating – maintenance

• Arson – security

• Hot work (welding, burning etc) – use of permit-to-work


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Hot Work Permit Requirements• Area safety inspection

• Fire-fighting equipment available

• Location and nature of the work

• Name of the person in charge

• Permitted time-span of the activity and the level of supervision required

• Actions to be taken when the work is finished e.g. fire checks

• If done in confined space – then additional precautions!


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• Cleaning and Gas Freeing (‘degassing’)

• Purging

• Venting

• Draining of water, product, oxygen and non-condensibles (NCD)

• Inerting

Plant Operations and MaintenanceOther Activities undertaken:

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Safe Start up/shut down of HC-containing equipment

For maintenance – usually controlled within permit-to-work system (described earlier)

Start Up and Shut Down

Water and Hydrates Presence and Removal

• Hydrates may cause blockages in gas systems - removal may require shut down and venting

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Testing, Commissioning and Hook-Up

• Tests on pressures, temperatures and flow-rates may be required, and assurance that relief valves, diverter valves, bursting discs, etc. are functioning correctly.

• Leak testing

• NDT e.g. on weld integrity

• Commissioning and hook up may require PTW system

Start Up and Shut Down

iog1 element 2

Documents

hydrocarbon process

f2 process unit hazards

contractor employees

explosion risk

offshore safety requirements

sure contractors

contractors job

contractor3 contractors