Part 3.3 Production Safety

Objectives After reading the chapter and reviewing the materials presented the students will be able to: Understand safety in all aspects of the production process Examine hazards that commonly occur in production Analyze factors in monitoring process conditions Discuss common production hazards

Most Common Hazards The implementation of strict safety standards and effective training programs helps ensure that every job is performed safely. 1. Driving: Vehicle accidents are the leading cause of serious injuries in the oilfield. Many roads leading to leases have gravel or dirt surfaces that make travel difficult in inclement weather. 2. Struck by an object: A loose pipe or piece of equipment that breaks away from tie down or a pipe wrench falling off an elevated walkway are examples of situations where objects could strike workers and cause injury. 3. Falls: Falls are more likely when surfaces become slippery or when workers are not properly secured when elevated. 4. Fire and explosions: Leaks, maintenance operations, and equipment failure can easily lead to a fire.

Most Common Hazards 5. Mechanized equipment: Unguarded equipment can entangle a worker or a serious injury could occur if the hand is improperly placed around pinch points. 6. Electrical: Being shocked or electrocuted is possible if proper controls are not put in place. 7. Process conditions: Pressure: High pressure gas or liquid escaping from a valve or fitting can injure personnel. Temperature: Heater-treaters and other equipment can be extremely hot and cause burns to unprotected skin. Noise: hearing damage can occur if workers do not use ear protection around noisy equipment. Chemical: Workers can be exposed to chemicals when filling containers, testing or conducting maintenance.

Controlling Hazards Companies mitigate risks by implementing a comprehensive safety program that addresses common workplace hazards. In this way, workers learn how to remain safe no matter what type of job they are performing. A company will typically have a more specialized safety rules and requirements to deal with specific high risk jobs such as cleaning a tank or repairing a line containing hydrogen sulfide gas.

Controlling Hazards Programs to cover the more common production hazards generally include: 1. Personal protective equipment (PPE): Basic equipment consists of a hardhat, steel toed shoes, ear plugs, and safety glasses. Other types of PPE are needed when handling chemicals, welding, and working at heights. 2. Fire and Safe/Hot Work permits: Leaks for gas or other flammable materials must be located and safety measures taken before any welding, sparks, or open flames can be permitted. 3. In-service welding and hot tapping: Often it is necessary to weld pipes in service while well fluids are flowing through them. Procedures have been developed to allow this type of work under special circumstances. 4. Working at heights: Working over 4 feet for general industry and 6 feet for construction requires use of some type of fall protection device. Fall protection harnesses connected using a lanyard to an anchor point are commonly used.

Controlling Hazards 5. Tagging and flagging: Tags and flags signal workers whether valves and other devices are in temporary positions, require maintenance, are unsafe to use, or do not function properly. 6. Lockout/tagout: Each worker is required to put a lockout on the device when necessary to ensure it does not activate during maintenance. Tags are also required to signal others as to why the device is locked out. 7. Blindings: Blinds are used on pipes and vessels to positively isolate work from process fluids. 8. Confined space entry: Safety procedures have been developed to make sure the tank or vessel has been taken out of service (for cleaning) effectively, that safe breathing air is available, and that rescue people are standing by in the event of an emergency.

Controlling Hazards 9. Excavations and trenching: The local dig alert agency is called first to determine if there are any buried pipelines, power lines, or cables in the area where work is to be done. Procedures for excavations and trenches depends on the type of soil and depth of the excavation or trench. 10. Management of change: All affected parties must know about all operational changes being made. 11. Driving safety: Safe driving programs include defensive driving programs and instructions on driving rules and reaction to emergencies. 12. Hazard communication: Hazard communication programs include training on using Material Safety Data Sheets (MSDS) for chemicals, conducting a job safety analysis prior to starting a job, and remaining alert to changing conditions.

Summary Most Common Hazards: 1. Driving: Vehicle accidents are the leading cause of serious injuries in the oilfield. Many roads leading to leases have gravel or dirt surfaces that make travel difficult in inclement weather. 2. Struck by an object: A loose pipe or piece of equipment that breaks away from tie down or a pipe wrench falling off an elevated walkway are examples of situations where objects could strike workers and cause injury. 3. Falls: Falls are more likely when surfaces become slippery or when workers are not properly secured when elevated. 4. Fire and explosions: Leaks, maintenance operations, and equipment failure can easily lead to a fire. 5. Mechanized equipment: Unguarded equipment can entangle a worker or a serious injury could occur if the hand is improperly placed around pinch points. 6. Electrical: Being shocked or electrocuted is possible if proper controls are not put in place. 7. Process conditions: Pressure: High pressure gas or liquid escaping from a valve or fitting can injure personnel. Temperature: Heater- treaters and other equipment can be extremely hot and cause burns to unprotected skin. Noise: hearing damage can occur if workers do not use ear protection around noisy equipment. Chemical: Workers can be exposed to chemicals when filling containers, testing or conducting maintenance. Companies mitigate risks by implementing a comprehensive safety program that addresses common workplace hazards. Programs to cover the more common production hazards generally include: 1. Personal protective equipment (PPE): Basic equipment consists of a hardhat, steel toed shoes, ear plugs, and safety glasses. Other types of PPE are needed when handling chemicals, welding, and working at heights. 2. Fire and Safe/Hot Work permits: Leaks for gas or other flammable materials must be located and safety measures taken before any welding, sparks, or open flames can be permitted. 3. In-service welding and hot tapping: Often it is necessary to weld pipes in service while well fluids are flowing through them. Procedures have been developed to allow this type of work under special circumstances. 4. Working at heights: Working over 4 feet for general industry and 6 feet for construction requires use of some type of fall protection device. Fall protection harnesses connected using a lanyard to an anchor point are commonly used. 5. Tagging and flagging: Tags and flags signal workers whether valves and other devices are in temporary positions, require maintenance, are unsafe to use, or do not function properly. 6. Lockout/tagout: Each worker is required to put a lockout on the device when necessary to ensure it does not activate during maintenance. Tags are also required to signal others as to why the device is locked out. 7. Blindings: Blinds are used on pipes and vessels to positively isolate work from process fluids. 8. Confined space entry: Safety procedures have been developed to make sure the tank or vessel has been taken out of service (for cleaning) effectively, that safe breathing air is available, and that rescue people are standing by in the event of an emergency. 9. Excavations and trenching: The local dig alert agency is called first to determine if there are any buried pipelines, power lines, or cables in the area where work is to be done. Procedures for excavations and trenches depends on the type of soil and depth of the excavation or trench. 10. Management of change: All affected parties must know about all operational changes being made. 11. Driving safety: Safe driving programs include defensive driving programs and instructions on driving rules and reaction to emergencies. 12. Hazard communication: Hazard communication programs include training on using Material Safety Data Sheets (MSDS) for chemicals, conducting a job safety analysis prior to starting a job, and remaining alert to changing conditions.

Home Work 1. What is the most common hazard and why? 2. How do companies mitigate risks? 3. What does basic personal protective equipment consist of?