NEBOSH

International Technical Certificate in Oil and Gas Operational Safety

Unit IOG1: Management of international oil and gas operational safety

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Element
1:1:Health,
andenvironmental
environmental
management
in
Element
Health,safety
safety and
management
in context
context
exam question

Risk management tools and techniques are used to minimise hazardous events
associated with oil and gas exploration and production activities.
(a)

Identify risk management tools and techniques.

6 marks

(b)

Identify the steps of risk management AND

outline EACH of the steps identified.

8 marks

(c)

Identify project phases where risk management

applies.

6 marks

answer expected by examiners

(a)

Suitable tools and techniques include:

bow-tie analysis
hazard and operability studies (HAZOP)
Swiss cheese model
job hazard analysis (JHA)
fault tree analysis (FTA)
failure modes effects analysis (FMEA)
hazard realisation.

(b)

The steps of risk management are as follows.

Identifying hazards an outline of a range of hazards is required.
Evaluating risk an outline of determining the acceptability of a specific risk
is required.
Risk reduction measures an outline of mitigating measures, setting
functional requirements and necessary risk reduction measures is required.
Review an outline of a review is required.

(c)

Suitable phases include:

design
construction
commissioning
start-up
shut down
decommissioning.

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Element 1: Health, safety and environmental management in context

exam question

Outline the following terms.

(a)

Upper flammable limit (UFL).

2 marks

(b)

Lower flammable limit (LFL).

2 marks

(c)

Flashpoint.

2 marks

(d)

Highly flammable liquids.

2 marks

answer expected by examiners

(a)

The highest concentration of a flammable substance in air that will ignite when
exposed to an ignition source. Above the UFL the mixture is too rich to burn.

(b)

The lowest concentration of a flammable substance in air that will ignite when
exposed to an ignition source. Below the LFL the mixture is too lean to burn.

(c)

The minimum temperature to which a material must be heated for the vapours
emitted to ignite in the presences of a flame.

(d)

Substances which remain liquid under pressure and having a flashpoint lower than
21C.

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Element 1: Health, safety and environmental management in context

exam question

Many major oil/gas incidents have occurred in recent years, for example, Texas City,
Mumbai High.
(a)

Outline FOUR reasons why such incidents should be

investigated by employers.

4 marks

(b)

Identify FOUR parties, other than the employer, who

may want to investigate these types of incident.

4 marks

answer expected by examiners

(a)

Reasons include:
preventing re-occurrence
meeting legal requirements
gathering evidence to defend against legal action
determining costs.

(b)

Interested parties include:

the local authority
the police
the coroner
insurance companies.

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Element 1: Health, safety and environmental management in context

exam question

(a)

Identify the hazardous properties of liquid petroleum gas (LPG).

4 marks

(b)

Outline the risks associated with liquid petroleum gas (LPG).

4 marks

answer expected by examiners

(a)

The hazardous properties of LPG include:

low temperature
it is a gas at normal temperature and pressure
it is colourless and odourless
readily liquefied under pressure
LPG is highly flammable
it is a fuel gas
reacts explosively with chlorine.

(b)

The risks associated with LPG include:

the potential for cylinders to form a BLEVE
that it is denser than air and collects at low level, in drains & sewers creating a risk of fire
& explosion
that it readily forms an explosive mixture with air
that in weak concentrations can be easily ignited flashing back to the source of
a leak
that inhalation can lead to drowsiness and that it is an asphyxiant
that contact with cold pipework can cause frost burns
that cylinders may create a manual handling risk.

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Element 1: Health, safety and environmental management in context

exam question

Safety cases and safety reports provide documented evidence that an oil and gas
installation is safe.
Outline the typical content of these types of documents.

8 marks

answer expected by examiners

The typical content of these documents includes:

Identification of major accident hazards through risk assessment (Q, SQ, QRA), bowtie diagrams, information from previous operations and incident reports and input
from design drawings and calculations.
Evaluation of major accident risks and the measures in place, or to be introduced, to
control such risks. This will detail all existing designed-in precautions and safety
measures, and reference into previous or existing risk controls.
Arrangements for auditing and audit reporting setting out a schedule of the type and
frequency of auditing, locations to be covered, how the audit will be conducted,
reporting mechanisms for recommendations, arrangements for monitoring
completion of action plans and overall responsibility for their completion.
Safety management system in place, including controls for the management of
contractor, and sub-contractor personnel and activities.
Major accident prevention policies that are in place to support the safety
management system and vice versa.
Identification of safety critical elements in place to manage major accident hazards
scenarios, possible causes, preventative/mitigating controls and recovery systems.
Details of emergency plans including plans of the installation detailing locations of
emergency and safety equipment, location of control room or points, isolation and
shutdown controls, safe access and escape routes, access to and arrangements for
crewing rescue boats and their launch procedures.

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Element 1: Health, safety and environmental management in context

exam question

An employee was seriously injured in an accident at work within an oil and gas installation.
Identify the documented information that might be used by the
investigating team to determine the causes of this accident.

8 marks

answer expected by examiners

The documented information that might be used includes the following.

Company health & safety policy.
RIDDOR reports (if UK).
Risk assessments & method statements.
Training records.
Safe systems of work.
Permits-to-work.
Maintenance records.
Disciplinary records.
Internal accident report forms.
Log book entries.
Computer records/printouts relevant to the situation.
Diagrams, pictures and sketches of the area.
Environmental & weather conditions/records.

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Element 2: Hydrocarbon process safety 1

exam question
(a) Give the meaning of the term standard operating procedure.
Element
2: Hydrocarbon process safety 1

2 marks

(b)

Outline the benefits of a standard operating procedure.

4 marks

(c)

Describe the style in which a standard operating procedure

should be written to aid understanding.

2 marks

answer expected by examiners

(a)

A sequenced set of written instructions that is accessible to workers.

(b)

Benefits include:
the promotion of operational quality
minimising variation between workers
compliance with government procedures
provision of a reference source for modifications of plant.

(c)

The procedures should be unambiguous.

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Element 2: Hydrocarbon process safety 1

exam question
Within an oil and gas production platform, effective shift handovers can prevent incidents.
Outline practical operational issues that should be communicated
at shift handover.

8 marks

answer expected by examiners

Issues to be communicated include:

an update on ongoing permits
any issues with process over previous days
a physical demonstration of plant isolations
any overrides on instrumentation
any instances of plant going out of commission
any ongoing trials
the preparation of relevant documentation
any abnormal events during the shift.

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Element 2: Hydrocarbon process safety 1

exam question

Outline fire precautions that may be included in a hot work permit.

8 marks

answer expected by examiners

Precautions include:
the provision of a standby / fire watcher
the isolation of flammable services
the removal of combustible material
having fire-fighting equipment available
gas cylinders being fitted with regulators and flashback arrestors
wearing of fire resistant PPE.

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Element 2: Hydrocarbon process safety 1

exam question

Many serious accidents or incidents, including the Piper Alpha disaster in 1988, involve
root causes associated with shift handover.
An outgoing operator is handing over to an incoming operator at the end of a shift.
(a)

Explain the key principles of safe shift handover. Information

on specific operational issues is not required in part a.

10 marks

(b)

Outline the main operational issues communicated at shift

handover.

10 marks

answer expected by examiners

(a)

The key principles of safe shift handover are to:

make communication effectiveness at shift change-over a high priority
include communication skills in the selection criteria for shift workers and train all
staff to communicate well
conduct handovers face-to-face with staff from both shifts taking part
ensure communication is two-way, using questions to confirm understanding
ensure all forms of communication use unambiguous language
ensure BOTH parties (on-coming and off-going crews) take joint responsibility for
making all information accurate, using both verbal and written communication
place an emphasis on written communication
base all information communicated at handover on a pre-determined analysis of
what detail the incoming shift need to have, consider using a pre-determined
format/structure
use structured headings in hand-over reports and logs
ensure good operator support, by the use of shift-logs, maintenance records,
information displays, etc. all based on operators' needs
take ideas for required information and effective information transfer from the
shift-teams, so they can then ensure they get the information they need
allow as much time as is necessary to ensure that communication is accurate and
understood.

continued on next page

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Element
C1: General
workplace

answer
expected
byissues
examiners

(b) The main operational issues communicated at shift hand-over include:

the operational status of the installation or process
what maintenance operations have been carried out and completed
what maintenance issues have begun but NOT been completed
clearance of permits-to-work
hand-over of permits-to-work still open
situations where safety systems have been overridden (e.g. fire deluge
system switched to manual operation)
deviations from normal working, such as breakdowns or lack of spare parts
or replacement equipment
emergencies that may have occurred during the shift
incidents or injuries following accidents during the shift
what operational issues will occur in the on-coming shift, routine & non
routine
what maintenance operations are planned during the on-coming shift
what events (drills or exercises) are planned during the on-coming shift
the absence/availability of key personnel knowledgeable in specific tasks
any isolations that are in place or to be removed.

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Element 2: Hydrocarbon process safety 1

exam question
Outline FOUR types of work activity associated with an oil
platform that might require a permit-to-work AND give a reason in
EACH case for the requirement.

8 marks

answer expected by examiners

Hot work welding, burning, grinding, etc. because such work might provide a
source of ignition in the presence of fuels, leading to fire. It ensures adequate fire
precautions are taken during and after the work.
Live or high voltage work to ensure competent (electrical) employees, correct
safe isolation and live working procedures are followed, safe equipment and tools
used, etc. as appropriate.
Working at height to ensure that a proper safe working at height plan is followed,
safe systems of work are followed, safe equipment used and rescue facilities are in
place where appropriate.
Working over water to ensure that appropriately trained operatives are
employed, together with all adequate precautions, such as life preservers, rescue
boats, etc. being in place.
Work in confined spaces to ensure adequate safe entry precautions are taken, air
monitoring where appropriate, use of safe tools and equipment (especially in what
may be flammable or explosive atmospheres); safe isolation is ensured and rescue
arrangements in place to recover persons.
Special maintenance permits where maintenance is of particularly high risk, or
conditions such that very close control must be maintained, especially where a shift
system may change during the work being carried out.
Simultaneous operations to ensure the interactions, hazards & risk implications
of a number of activities that are to be carried out at the same time are controlled &
scheduled to minimize risk.

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Element 2: Hydrocarbon process safety 1

exam question

A large oil company is proposing to build a new oil and gas installation in the North Sea. The
Process Safety Management Team is analysing past incidents and database records from the
Oil and Gas Industry.
Excluding active and passive fire protection systems, outline physical
design features of the platform that would minimise risk to operating
personnel in the event of a major incident.

8 marks

answer expected by examiners

Suitable design features would include the following.

Strength and integrity of main structural features.
Spacing & segregation of operating plant, so that one fire cannot affect all units in
operation (e.g. storage vessels, item of plant, drilling floor, unloading facility).
Isolating critical areas from non-critical areas so that a single fire in a non-critical area
cannot adversely affect performance or operation in any other areas.
Positioning and protection of control rooms.
Positioning and protection of critical equipment, including electrical supplies.
Positioning and protection of occupied areas, particularly accommodation and welfare areas.
Provision and protection of temporary refuges.
Positioning safety critical areas are away from high risk areas, such as process and storage and
processing of flammable materials away from control rooms, fire control systems and
accommodation.
Consideration to both positioning & protection of above or below hazardous areas, as well as
beside them on the same level.
Protection includes structures built of materials that are adequately fire resistant and
blast resistant.
Having heating, ventilation and air conditioning that can be self-sustaining and
continue in operation throughout hazardous events.
Positioning & protection of escape equipment, with safe routes, refuges and access to
evacuation and rescue craft from within protected areas.

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Element3:3:Hydrocarbon
Hydrocarbon
process
safety
2
Element
process
safety
2
exam question
Outline the content of a procedure for bypassing an emergency
shutdown (ESD) system.

8 marks

answer expected by examiners

A suitable procedure should include:
assessment of alternative levels of protection
ensuring senior level authorisation for the bypass
defining the bypass period and time bounding
having clear radio communication during the bypass
informing supervisors
logging actions in operators log book
uniquely identifying the ESD to be bypassed
using a dedicated log book for ESD bypasses.

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Element 3: Hydrocarbon process safety 2

exam question

The diagram below shows a typical arrangement for receiving a pipeline inspection
gauge (PIG). A pressure gauge (P) and a PIG detector (D) exist within the receiver/trap.
The detector (D) confirms that the PIG has been received in the trap, having earlier been
launched upstream at high pressure.
Main line flow

Main line isolating

valve A

By-pass valve C

Vent valve E

D
PIG receiver/trap

Main line flow

PIG

Door

PIG receiver
isolating valve B

Drain valve D

(a)

Outline the functions of a PIG.

4 marks

(b)

Using the information and diagram above:

(i) identify TWO valves that must be closed before removing the 2 marks
PIG from the door
(ii) identify TWO valves that must be open before removing the PIG 2 marks
from the door.

answer expected by examiners

(a)

(b)

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Functions include:
cleaning
facilitating hydro-testing
relaying information
plugging of pipelines.
(i) Valve B and valve C.
(ii) Valve E and valve D.

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Element 3: Hydrocarbon process safety 2

exam question
In relation to weld failures:
(a)

give the meaning of the term non-destructive testing

(NDT)

2 marks

(b)

identify TWO NDT techniques that detect surface defects

only

2 marks

(c)

identify TWO NDT techniques that detect sub-surface

defects

2 marks

(d)

outline disadvantages of visual inspection techniques.

2 marks

answer expected by examiners

(a)

Testing of a material for defects/cracks, without affecting the integrity of the

material.

(b)

Dye penetrant and visual techniques.

(c)

Eddy current and radiography.

(d)

Only surface defects are detected and surfaces need to be clean.

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Element 3: Hydrocarbon process safety 2

exam question
Outline the following failure modes that may lead to loss of hydrocarbon containment from
storage tanks/vessels or pipelines.
(a)

Creep.

2 marks

(b)

Stress corrosion cracking.

2 marks

(c)

Thermal shock.

2 marks

(d)

Brittle fracture.

2 marks

answer expected by examiners

(a)

Creep the gradual extension of material under a steady tensile stress, typically
over a long period of time. It occurs in stages known as primary or transient creep,
secondary creep and tertiary creep. Creep is usually important at high temperatures.

(b)

Stress corrosion cracking occurs when there is a susceptible material, a

corrosive environment and enough tensile stress to induce the cracking.

(c)

Thermal shock the effect of cracking that results from rapid and extreme
temperature changes when a thermal gradient causes different parts of an object
to expand by different amounts, causing uneven expansion and cracking to occur.

(d)

Brittle fracture occurs very suddenly and without warning, allowing a rapid
release of energy. It occurs because the structure of the material does not slip, so
small cracks appear throughout so quickly that a massive failure is produced,
often promoted by low temperatures.

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Element 3: Hydrocarbon process safety 2

exam question
(a)

Identify TWO ways in which vapour clouds can be

generated.

2 marks

(b)

Outline how a vapour cloud explosion can be generated.

4 marks

(c)

Identify the physical consequences of vapour cloud

explosions.

2 marks

answer expected by examiners

(a)

Vapour clouds may be generated by:

overfilling or overflowing of a tank or vessel causing a release of
hydrocarbon fuels
fracture or failure of the tank, vessel or pipework causing a release of hydrocarbon
fuels
splash filling of tanks or vessels.
(These may occur at an outdoor vessel, which will create an unconfined vapour
cloud, or within a tank or building, creating a confined vapour cloud.)

(b)

A flammable vapour must be present

The vapour air concentration must between the upper and lower
explosive limits.
An ignition source that exceeds the minimum ignition energy is required
to ignite the vapour.
A vapour cloud explosion may be confined e.g. in a tank or vessel or
unconfined e.g. outside.
Unconfined vapour clouds may travel a considerable distance before
igniting or they may be dispersed to a concentration below the lower
explosive limit depending on conditions.

(c)

Thermal radiation & heat from the resultant fireball.

Blast/pressure wave produced.
The impact & damage caused by fragments, debris, equipment and materials
being propelled by the blast wave.

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Element 3: Hydrocarbon process safety 2

exam question

An operator is draining a flammable liquid from process pipework to a metal container.

The supervisor is concerned about the possibility of an electrostatic charge forming and
stops this operation until a risk assessment is undertaken. During this work activity:
(a)

identify factors that influence the generation of the

electrostatic charge

4 marks

(b)

outline practical ways of minimising the formation of an

electrostatic charge.

4 marks

answer expected by examiners

(a)

Potential factors include the following.

The flow rate of flammable liquids inside a pipe or vessel can build up
static electricity.
The conductivity of the materials being used, including that of the liquid,
pipework & containers.
Surface or contact area, e.g. use of filters increase surface area for friction
& the generation of a charge.
Presence of impurities or mixtures of product e.g. solids, water &
dissimilar liquids that dont dissolve within each other
Turbulence caused by large flow rates, mixing/stirring & splash filling.

(b)

Practical solutions include the following.

Good earthing and bonding of all parts of the system e.g. from process
pipework to the metal container
The addition of additives to increase conductivity of the liquid.
Reduce, minimise, & control flow rates.
Avoid splash filling by using dip tubes & bottom filling.
Ensure operatives wear conductive (anti-static) clothing/PPE.
Avoid unnecessary filtering or install filters upstream of the discharge
points to allow any static charge to be dissipated before reaching the
discharge point.

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Element4:4:Fire
Fire
protection
emergency
response
Element
protection
andand
emergency
response
exam question

(a)

Petroleum storage tank fires have been substantially

reduced by using floating roofs but a fire risk may still exist.
(i)

Outline how a fire risk may still exist with floating roof
tanks.
(ii) Identify TWO examples of a fire protection system used
on floating roof tanks.
Process modules in an oil and gas installation often contain
computer rooms that require fire protection.

(b)

Identify TWO examples of fire extinguishing media that

could be used in a computer room.

4 marks
2 marks

2 marks

answer expected by examiners

(a)

(i)

Fire risk may still exist due to:

the roof sinking if there is insufficient water drainage
the annular seal failing
ignition through static electricity.

(ii) Suitable fire protection systems include:

foam-based types
over the top systems
chemical types, such as Du Pont FE36.
(b)

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Suitable fire extinguishing media include:

CO2
water mist
inert gas.

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Element 4: Fire protection and emergency response

exam question

An oil installation contains a vessel that requires protection from fire exposure in the form of
active or passive fire protection.
(a)

Identify TWO examples of passive fire protection to protect

vessels.

2 marks

(b)

Outline why the metal legs of the vessel should be protected.

2 marks

(c)

Outline how a fixed water deluge system could provide fire

protection.

2 marks

(d)

Identify TWO additional examples of active fire protection.

2 marks

answer expected by examiners

(a)

Suitable passive fire protection could be provided by:

spray-applied coating, such as, cement-based plaster coatings and sprayapplied epoxy-based intumescent (expands under fire conditions) coatings
mineral wool/fibre jacket or lagging
earth mounds (burying the vessels beneath the ground)
physical fire barriers/walls between potential fire sources and the vessel.

(b)

The metal legs of a vessel should be protected because, if they are not, they will
heat up, expand, lose their strength and fail, losing their structural load-bearing
capability (this happens over around 400C for steel and around 200C for
aluminium). This will cause the vessel to topple and potentially rupture, escalating
any fire.

(c)

A fixed water deluge system could provide fire protection by:

directly cooling the vessel, providing the high spray rate and the volume of
water needed to cover the large surface area of the vessel
providing a water curtain between the fire and the vessel, reducing the
transmission of radiated heat.

(d)

Additional example of active fire protection include:

fire/foam sprinkler installations
gaseous inerting systems (using carbon dioxide or nitrogen)
water mist systems, water/foam monitors and hoses
dry chemical fixed installations
portable fire extinguishers.

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Element5:5:Logistics
Logistics
transport
operations
Element
andand
transport
operations
exam question
Identify EIGHT marine hazards associated with all types of floating
production, storage and offloading units (FPSOs).

8 marks

answer expected by examiners

Marine hazards associated with FPSOs include:

extreme weather conditions
long term exposure to environmental conditions
additional motions/stresses from a ship-like structure
wave loading against the ship
operational hazards of unloading
anchoring failures
collisions with passing supply vessels.

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Element 5: Logistics and transport operations

exam question

(a)

Identify THREE marine hazards associated with all types of

floating platform storage and offloading units (FPSOs).

3 marks

(b)

Identify suitable controls that minimise risk when operating

floating platform storage and offloading units (FPSOs).

5 marks

answer expected by examiners

(a)

Marine hazards associated with FPSOs are:

extreme environment such as high winds and storms, which may cause the
vessel to cut loose from its mooring or damage the structure
accelerated corrosion and wear (from the constant buffeting of the sea and the
nature of salt spray), which may cause vessel failure and loss of containment
(and also potential fire, explosion and environmental damage)
proximity of other vessels and risk of collisions
slippery surfaces resulting in slips, trips and falls , and the potential for people
falling overboard
cargo transfer operations, potential for spills, and transfer of stores and
equipment
sabotage, piracy and other security-related issues
diving operations in the vicinity of the vessel.

(b)

Suitable controls to minimise risks include:

selection and certification of the vessel (in terms of design class to withstand the
likely conditions and stresses)
design strength of moorings (to withstand likely conditions)
inspection and maintenance regime for the vessel, transfer equipment and
moorings
co-ordination of proximal activities (such as nearby tanker vessel movements)
and having an exclusion zone around the FPSO ( to exclude for example fishing
vessels)
safe personnel transfer methods (for example, bridges)
control over diving operations (permit-to-dive)
consideration of security provision to deter or react to piracy.

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