Ministry of Higher Education and Scientific Research

Al- Muthanna University

College of Engineering, Department of Chemical
Engineering
The second stage
Assistant Professor: Ali Sallh

Industrial safety in petroleum establishments

BY: Qasim Khudair Abbas
Abstract
This study aims to find out if there are scenarios about the tasks and duties of
the Occupational Safety Unit In oil companies, is there a correlation between
occupational safety management and productive efficiency and what is the
impact of occupational safety management practices on worker development.
The descriptive, analytical approach was used to arrive at the results of the study,
by relying on interviews and comparing data on machinery, operating units, and
maintenance established during the years of the research, as well as the results of
companies in which the company obtained results But it does not rise to the
need of the oil companies, but the results indicated that there is a strong
relationship between the Occupational Safety Administration and the productive
efficiency
Introduction
The concept of production efficiency is the most comprehensive concept that
determines the state's economic progress or underdevelopment. Socially and
internationally, achieving sustainable productive efficiency that generates income
and job opportunities in developing countries (and ethnicities within them)
depends on the extent of their ability to create and develop a prosperous private
or public sector that provides good job opportunities and a better level of income
and is manifested through the pursuit and work and planning of finding resources
The human resources for managing each sector, where the task of preserving and
protecting human resources from harm is considered one of the main tasks
exercised by the Occupational Safety Administration in any organization, which
calls for the organizations to pay attention to health care and the safety of those
working in it, and on the other hand, issuing any interest in the government.
Laws providing for the protection of workers ’rights and their employers’
obligations, in addition to defining their duties and responsibilities towards
employers and the penalties that may be applied to them in case they violate
work regulations, prompting managers to reduce the violence that occurs in the
work environment or in cases of incidence Work, and there are laws that
guarantee employee rights Where the physical and psychological, and it is
considered an incentive for many employees to meet their needs and human
rights, and managers know all levels and aspects of the importance of health and
safety standards in the organization and must ensure that they are safe from the
peace of mind Programming Effective health is maintained the health and safety
of individuals
* Preventive measures in oil installations
All oil installations take preventive measures to prevent accidents and provide
occupational safety and health for their workers. Among these measures are:
1- Conducting analytical studies of the potential risks, identifying the best
methods to confront them and minimizing their damages.
2- Providing regular maintenance for equipment and machines.
3- Providing health care and clean restaurants in the right places.
4- Providing awareness, education and training programs related to occupational
health and safety
* Working environment in oil installations
The term "work environment" means the place where the worker is in the course
of performing the work entrusted to him officially, and the engineering
specifications for this environment must be such that it provides protection for
workers in it from occupational diseases or their exposure to work injuries, and of
course the matter may not fully apply to oil installations, and that Because the
site (in the desert or seas) is the one that imposes itself, however the institution
must work to provide everything that would protect workers from risks such as:
Dangers of explosions.
- Static and mobile electricity.
Air pressure changes.
Harmful and dangerous radiation.
- lighting.
- Noise and vibrations.
HVAC systems.
* Health and safety precautions for workers
We mentioned that the work environment in oil installations has some risks to
the health and safety of workers, and for workers to avoid being victims of any
mistake of any kind, the following measures must be taken:
1- Training workers in how to deal with chemicals in a safe way, and knowing
how to act in the event of an emergency.
2- Inform workers about the facility's emergency plan and risk analysis.
3- Informing the workers of the results of the technical and administrative
reports received by the establishment about the types of accidents that occurred
and their causes.
4- Inform workers about the quantities of stocks of dangerous chemicals that
could threaten the facility.
5- Field surveys of work sites should be conducted to measure the oil fumes, and
to inspect work sites to ensure compliance with health procedures, and to
dispose of waste directly, with a need to make a lung function inspection for
workers.
6- Providing first aid to workers in the workplace and training workers on how to
do it.
7- Providing personal protective equipment for workers in the workplace, each
according to the nature of his work, and the commitment of workers to use them,
such as eye and face protection devices, hands, respirators, clothing, protective
shoes, ear plugs, gloves, head cover and protective glasses.
8- Training workers in the health procedures that must be followed to avoid the
risks surrounding them.
Several uses for petroleum
The petroleum industry includes the global processes of exploration, extraction,
refining, transporting, and marketing petroleum products, with the largest
volume products being oil and gasoline. Petroleum is also the raw material for
many chemical products. Without petroleum, we wouldn’t have gasoline,
kerosene, asphalt, some fertilisers, or some chemical regents used to make
plastics and pharmaceuticals. Other products that are lesser known for their use
of petroleum in their creation are crayons, ink, dishwashing liquids, deodorant,
eyeglasses, CDs/DVDs, tyres, and heart valve
Petroleum hazards
In order to provide such products that are part of our everyday lives, the
widespread recovery and use of petroleum can be a very intensive and dangerous
operation, employing hundreds of thousands of engineers, doctors, rig workers,
transportation employees, and other professionals. In addition, the use of
petroleum has created serious environmental problems: it is the largest industrial
source of emissions for hazardous air pollutants (HAPs) and volatile organic
compounds (VOCs) that both may contribute to health problems and other
hazards. The great quantities of petroleum that are burned as fuels generate most
of the air pollution in industrialised countries, and oil spilled from tankers and
offshore wells has polluted oceans and coastlines.With the extraction and use of
petroleum come numerous regulations and safety concerns over potential
hazards that could occur in such activities – and all employees in this field must
have a good understanding of each subject
The ten most important safety and environmental concerns about oil and a
description of their best safety practices:
1. Preventing the release of chemical hazards
Petroleum is made up of a complex mixture of hydrocarbons of various molecular
weights and other liquid organic compounds, meaning the improper release of
these chemicals may create a negative impact on the chemical’s surroundings.
Chemicals such as those in petroleum have the ability to react when exposed to
other chemicals, or certain physical conditions. According to Occupational Safety
and Health Administration (OSHA) in the United States, chemicals that are not
properly managed can have harmful or even catastrophic consequences, such as
toxic fumes, fires, and explosions that may result in injury and/or death, damage
to physical property, and severe effects on the environment.
In order to ensure the safe release of chemicals, it is imperative that facilities are
well designed, safely operated, and properly inspected and maintained. For
example, the European Union requires that barges on all rivers in Europe are
double-hull barges. It is also crucial that facilities involve an effective oil spill
emergency response capability that plans, prepares, and practises emergency
response to incidents to mitigate the consequences to the surrounding people
and the environment.
2. Environmental pollution prevention
The exploration and exploitation activities of the petroleum industry often cause
environmental degradation that has significant impact on quality of air, water,
soil, vegetation, and on health unless adequate preventive measures are planned.
Petroleum activities encompass several sources of pollution including the exhaust
of engines, generators or compressors, the discharge of natural gas directly into
the atmosphere, and the increase in surrounding temperatures and glare effects
due to flare. The cause of fugitive emissions at some facilities may be associated
with vents, leaking pipes and turbines, valves, connections, pump seals, pressure
relief valves, tanks, or open pits, and loading and unloading operations.
Exposure to petroleum-related pollutants may cause sickness or death that lead
to human and economic loss, reduced visibility, unpleasant odours, damage to
agricultural crops and plants, as well as harm to livestock.
To prevent the pollution of the environment from petroleum-related procedures
and products, environmental awareness must be integrated as a part of every job
function a worker performs. There are very specific rules and regulations
regarding the amount and types of emissions, discharges, and disposals a facility
is permitted. Make sure workers know and understand the physical and chemical
properties of the materials they handle or are exposed to.
Any debris, spilled substances or material that could pose a potential hazard
should be cleaned up immediately with proper procedures, which becomes even
more critical if this substance can be exposed to rain water. For example,
petroleum and other oil-related substances can wash away into surrounding
vegetation and water systems.
3. Valve and pipeline safety
Pipelines are the most economical way to transport large quantities of oil, refined
oil products, or natural gas over land and can be found all over the world. Nearly
half a million miles of pipeline transporting natural gas, oil, and other hazardous
liquids crisscross in the United States alone, and the USis ranked as only the third
country in the world for oil production, with Saudi Arabia being number one.
A typical petroleum pipeline runs from the gathering area, into transmission lines,
through compressor or pumping stations, to distribution lines, and finally to the
end user. Since the majority of pipeline contents and their vapours are highly
flammable, pipeline safety policies and procedures are focused on minimising
worker exposure to these substances, and controlling or eliminating sources of
ignition in the work environment.
4. Personal protective equipment for workers
Danger can be found in just about every petroleum activity, from building well
foundations and erecting lease tanks, to chemically treating or hydraulically
fracturing wells. When preferred methods like engineering controls such as
machine guards, or safe work practises are neither practical nor feasible, personal
protective equipment (PPE) must be used to reduce workers’ exposure to
potential hazards in the workplace. The employer is responsible for supplying the
PPE, but the worker is responsible for assessing their job task to identify potential
hazards that may require any necessary PPE – which they must also, of course,
know how to wear correctly.The general PPE requirements for oil and gas workers
include: eyes, face, head and extremities, protective clothing, respiratory devices,
and protective shields and barriers. In the United States, OSHA requires oil and
gas companies to apply safety standards to both their employees and any
contractors or other visitors to the site. Employers are also required by OSHA to
reassess on the job hazards and decide whether new PPE is needed each year.
In addition to the need for strong protection against all of these potential perils, it
is best if workers are able to work comfortably in their protective garments for
their entire shift. Comfort is essential – the PPE will often need to be worn
securely throughout the day without giving irritation. The correct choice of
hearing protection, for example, can avoid the danger of workers removing it due
to discomfort, exposing their ears to damaging noise. As the employer, it is also
important to be able to provide a range of protectors so that employees can
choose the one that suits them best.
5. Hazardous waste disposal
The American Petroleum Institute (API) estimates that for every foot drilled in the
United States, approximately 1.21 barrels of total drilling waste are generated,
with nearly 50% of the total being solid drilling waste. Over the course of a year,
this massive accumulation of solid drilling waste by volume is equal to
approximately 139,961,305 barrels, which is equivalent to 29,097,984 cubic yards
of solid drilling waste – enough to fill almost 9,000 Olympic swimming pools.
All of this type of waste needs to be properly recycled or disposed of, and
applicable regulations followed in order to keep the environment and the
surrounding human and animal inhabitants healthy. Waste oil can be disposed of
in different ways, including sending the used oil off site, burning used oil as a fuel,
and marketing the used oil.
When sending the used oil off site, waste needs to be treated very carefully. All
waste materials must be placed in a sealable container that will not react to the
waste that will be placed inside, and be cautious of mixing different wastes. All
containers must be labelled with the critical information clearly visible. Periodic
checks are also required during transportation and storage.
6. Corrosion problems and prevention
It is almost impossible to prevent corrosion.
The next best possible solution is to attempt to control the corrosion rate through
monitoring. By recognising and understanding the mechanisms involved in
corrosion, engineers may begin to eliminate corrosion by design.
Offshore structures are especially at risk of corrosion from the massive amounts
of rain, condensation, sea mist, and spray. To provide long term resistance to
corrosion, Corrosion Resistant Alloys (CRAs) are essential for many components
exposed to oil and gas production environments, including offshore rigs.
Components may include down-hole tubing and safety critical elements, wellhead
(structural and pressure-containing interface) components and valves, pipelines,
piping, valves, vessels, heat exchangers and many other pieces of equipment in
facilities that can be characterised by their resistance to specific environments.
7. Hazardous material security
Every day, thousands of tons of hazardous materials are safely transported by
plane, truck, train, and ship in quantities ranging from several ounces to
thousands of gallons. All over the world, employees working to transport
hazardous materials, such as petroleum and crude oil waste, are working with
their government to improve the security of such materials in their transportation
system, and must be properly trained in packing, shipping, and the security of
dangerous goods.To provide the foundation for all countries to develop
comprehensive national programmes to ensure the safe use of chemicals, in 2012
the Globally Harmonized System of Classification and Labeling of Chemicals (GHS)
was released to strengthen international efforts in classifying and communicating
hazardous chemicals. The basic goal of GHS is to provide adequate, practical,
reliable, and comprehensible information on the hazards of chemicals to ensure
preventive and protective measures for health and safety are taken around the
world, benefiting governments, companies, workers, and members of the public.
Chemical manufacturers and importers will be required to provide a label that
includes a harmonised signal word, pictogram, and hazard statement for each
hazard class and category. Precautionary statements must also be provided.
8. Process safety management
Petroleum processing facilities and extraction locations must have a
comprehensive management programme that integrates technologies,
procedures, and management practises in a careful review of what could go
wrong and what safeguards must be implemented to prevent releases of
hazardous chemicals. Unexpected releases of toxic, reactive, or flammable liquids
and gases in processes involving highly hazardous chemicals have been reported
for many years in the oil and gas industry, which uses chemicals with such
properties. Regardless of the industry that uses these highly hazardous chemicals,
there is the potential for an accidental release any time they are not properly
controlled, creating the possibility for disaster.
9. Heavy machinery safety
The use of heavy machinery is not only prevalent in the oil and gas industry, but it
is also an essential tool needed to get a diverse number of jobs done. The type of
equipment used in this industry varies from earthmoving machines in lease
preparation for explorative drilling to site preparation for large refineries and
plant sites. It also includes hoisting equipment, including forklifts and cranes, as
well as trenching equipment.While it is true that machines can greatly increase
the efficiency and ease of many work related tasks, they can also pose a
significant threat of injury or even death when poorly maintained or used
improperly. Operations with heavy equipment should always be done by highly
skilled operators who have demonstrated the ability and necessary skills to
operate safely. Ground based workers should be trained in how to work safely
around the equipment and how to stay clear.Unsafe practises by either the
operator or those around the equipment can create very dangerous situations
where serious injuries can occur if the equipment strikes a worker, or if the
equipment rolls over.
10. Emergency preparedness
Oil and gas workers are subject to some of the most hazardous industrial
conditions in the world. Given the number of people employed by the gas and oil
industry and the dangerous nature of oil and gas drilling, it is almost inevitable
that accidents will occur. Oil and gas accidents can involve explosions, incidents
while raising a pipeline, oil rig and derrick safety violations, and other incidents,
including:
• Drilling accidents
• Improper construction and maintenance
• Pipeline transportation accidents
• Storage problems, including contamination
• Salt dome accidents
Because of such accidents, it is essential to have an emergency plan or
management system that will allow for a timely response to an accident. This
includes establishing a decision framework and action plan that enables a quick
and effective response to any accident or incident, as well as working with the
relevant local and national authorities, ensuring workers have the appropriate
training, and practising exercise drills with other organisations. To signify the
importance of such plans and to prevent devastating accidents, the Energy
Committee in Europe has proposed that offshore oil and gas firms would have to
submit major hazard reports and emergency response plans before getting a
license to drill.
Growing industry with growing injuries
Understanding the affects of petroleum in the oil and gas refineries and plants
around the world is essential to uncover the risks of what workers may face and
already are facing on the job. The level of activity in the petroleum industry has
grown in recent years, resulting in an increase in employment and a
corresponding increase in both the number and rate of fatal occupational injuries.
Because of the several upstream activities that the oil and gas industry performs,
it is inevitable that the occasional accident may result from the on and offshore
exploration and production, transportation, storage, and refining of petroleum.
This happens most often when inexperienced workers are not sufficiently trained
in safety and precautionary measures, with the most common types of injuries
being burns, brain injury, spinal injury and fractures.
Remember, preventing accidents, protecting your health, and protecting the
environment depend on recognising potential hazards in your workplace,
especially when hazardous chemicals like petroleum are involved.
Hazards can exist due to the nature of the task being performed, where it is being
performed, and the equipment or material involved. Follow best safety practises
to lower the potential hazards to the industrial plant, its employees, and people
living nearby.

REFERENCES
1. Oil industry risks are bound
2. Healthy Working Lives. 2008-4-4
3. Occupational Safety and Health (Geneva).