Oil and Gas Certificate Questions and Answers

1 . An extremely flammable liquid is being transferred from a road tanker to a bulk

storage tank.

(a) Outline the control measures which would reduce the risk of ignition of the
associated vapour due to static electricity. (10)

(b) Tanker drivers are routinely required to work on top of road tankers during
transfer operations. Outline the factors that should be considered when assessing
the risk for work on top of the road tanker. (10)

Answer

Part (a)
 Controlling the pump rate and transfer speed;
 Earthing and bonding the pipeline, the tanker and the storage tank to ensure all
equipment was at zero potential after allowing sufficient relaxation time;
 The provision of an interlock between the earthing arrangements and the pump;
 The avoidance of splash filling and;
 The selection of conductive/smooth materials for the transfer system;
 Elimination of possible contamination arising for example from the presence of
water in the pipeline;
 The use of a vapour return system;
 Nitrogen blanketing of the road tanker barrel to minimize the risk of explosion;
 The provision of instrumentation, for example, to detect earth leakage and ;
 The use of anti static clothing and footwear.

Part (b)

The initial factor that should be taken into consideration is the need for access to be
gained to the top of the tanker. If this is found to be unavoidable, then the height of the
tanker, the frequency of access required, the task to be performed, for example valve or
pipe connection or valve operation, and the normal duration of the work to be carried out
would again be important factors in assessing the risk of falls.

Additional matters to be considered include the means of access provided on the tanker,
the condition of the tanker roof and the walkway and hand rails, the consequences of
falling which might indicate the need for the use of harnesses when on top of the tanker
or the provision of fall mitigation equipment such as air bags; and the availability of an
alternative existing workplace such as an overhead gantry. Other factors include the
possible exposure of the driver to inclement weather, their experience, competence,
fitness and ability to work at heights and the personal protective equipment that should be
provided such as footwear and gloves.
4 .
(a) Outline the principles of a vapour cloud explosion AND give an example of a major
incident associated with a vapour cloud explosion. (8)

(b) Outline the effects of a vapour cloud explosion. (2)

Answer

Part a) A vapour cloud explosion may be confined for example in a tank or vessel or
unconfined. Its key principles include the presence of flammable vapour at a
concentration between the upper and lower explosive limits and an ignition source that
exceeds the minimum ignition energy. 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.

Part b) The effects of vapour cloud explosions include overpressure, thermal effects and
the emission of debris. In confined explosion cases, vessel or containment rupture may
occur resulting in a rapid release of liquefied gas and toxic fume emissions. In
unconfined explosion cases, damage to people and property may be caused by the
pressure wave and thermal radiation. Suitable examples could have included
Flixborough, Grangemouth and Buncefield.
5 . You have been asked to investigate a boiler explosion at one of your company’s
sites. The maintenance manager has drawn you a sketch showing the position of the water
column isolating valves at the time of the explosion (see below).

Boiler Explosion

(a) Ignoring the safety feature on the water column, identify FOUR other safety
features that you would expect to find on the boiler. (4)
(b) Describe the chain of events that could have led to an explosion
due to the water column valve being closed. (6)
Answer
Part (a) involves other safety features such as pressure and temperature indicators, a
pressure relief valve, a low water level alarm, a bursting disc or fusible plug, and an
automatic control system incorporating a fuel cut-off.

Part b). The chain of events that could have led to an explosion, since a valve on the
water column was found to be closed, no water could enter the boiler and the column
would give a false reading. The actual water level would fall as steam was drawn on
demand, the crown would become exposed, heat transfer in that area would be
ineffective and a localised heat build up would take place. The crown would start to
yield as a result of internal pressure and a ductile failure followed by a rupture would
occur. There would be a loss of containment with an instantaneous change from water
to steam and an explosion as stored energy was released.
6 . Outline the hazards associated with a Floating Roof Tank
The hazards associated with a Floating Roof Tank are;
(8)

Working at height with associated risk of falling people, equipment and materials
Flammable vapour igniting around the rim seal being ignited by an ignition source such
as lightning and resulting a fire or possibly an explosion (though unlikely)
A leak around the Annular rim leading to a fire and/or explosion.
A catastrophic failure of the roof leading to collapse possibly due to weather (rain or
snow)
Overfilling leading to flammable liquid now sitting on the roof and causing a potential
fire/explosion risk
A failure of the containment walls causing a pollution incident – again umlikely due to
bund walls.
7. Define:
(i) Upper Explosive Limit (2)
The maximum concentration of flammable gas/vapour that when mixed
with air and a heat source applied will ignite and explode
(ii) Lower Explosive limit (2)
The minimum concentration of flammable gas/vapour that when mixed with air
and a heat source applied will ignite and explode
(iii) Flash point (2)
Is the minimum temperature at which sufficient flammable vapour is given off by
a liquid that when mixed with air and an ignition source applied will temporarily
combust (flash).
(iv) Highly Flammable (2)
o
Any liquid that has a flash point of less than 21 C. Example is petrol.
8 . Identify 4 hazards and 4 control measures associated with static electricity (8)
Hazards
 Potential ignitions source for combustible gases
 Potential ignition source for combustible liquids
 Static electrical shock to the individual
 Potential damage to sensitive electronics

Controls
 Controlling the pump rate and so the transfer speeds;
 Earthing and bonding the pipeline, the tanker and the storage tank to ensure all
equipment was at zero potential after allowing sufficient relaxation time;
 Provision of an interlock between the earthing arrangements and the pump;
 The avoidance of splash filling
9 . Water is used for cooling and heating.
Outline the hazards associated with such processes (8)

risk of legionella from the AC systems

cold burns and hypothermia from any cooling system
steam burns, steam explosions in boilers
slip hazards

10 . Outline a typical Start up and Shut down procedure. (8)

For shut down
 Cooling and de-pressurisation
 Pumping out to reduce flow process levels
 Removal of residual hydrocarbons
 Removal of toxic and corrosive materials
 Removal of water
 Blinding/Isolation operations
 Heating shutdown – release of excessive pressure
For start up
 Inter-lock system on valves
 Alarm systems
 Venting systems (HP or LP)
 Flares for burning excess gas
 Fire and gas protection systems
 Emergency shutdown systems
 Emergency power supply (UPS)
 Passive fire protection of control rooms and temporary refuge
 Trained operators
12. An operative is going to fill a road tanker with flammable liquid. His wheels are firm
on the ground. Outline other safety precautions that might be required? (8)

13. An operative is handling radioactive sludge or mud.

(i) Identify the health hazards associated with this activity (2)
(ii) Describe the precautions necessary to minimize the radiation exposure (6)

14. A plant has a storage tank without a bund.

(i) Identify the environmental hazards (2)
(ii) Outline the features of a suitable storage tank and/or storage facility? (6)

15. An operative is in contact with sludge

(i) Identify the hazards (4)
(ii) On which equipment could you find sludge (4)
Question 1 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)
(b) Outline the main operational issues communicated at shift handover. (10)

Answer
(a)
Shift handover should involve both written (one way) and face to face verbal (two way)
communication in order to ensure understanding with greater reliance on written
communications. The written documentation will provide something for the incoming
person to refer to if they are unclear about something, whereas the verbal face to face
communication will allow then to ask any questions about things that they are not clear
about or have not been covered in the written documentation such as the log.

The handover must be given a high priority and as such should allow sufficient time for
the handover – exactly how long will be determined by events during that shift as well as
the length of time the incoming person has been away from the installation. So less time
would be required if they were last on shift 12 hours ago than if they have just arrived
back from leave.

The employer needs to provide competent staff and develop their communication skills
through training – this can include both verbal and written communication skills as well
as familiarisation with the organisations procedures that specify how to conduct an
effective shift handover

Good planning for maintenance work, where it is preferred that as much as reasonably
practicable this work is completed within one shift for command and control reasons.

Good design of equipment (logs, computer displays) with operator in mind so that
information is easy to understand and use.

Use of operator logs to capture key information.

The opportunity to gain the marks available for part (b) was limited by those who
supplied a simple list of operational issues rather than the outline that was needed to
demonstrate a full understanding. Better answers included updating permits-to-work,
forthcoming maintenance preparations, plant overrides, abnormal events –
shutdowns, changes in plant parameters and routine operations for the next shift.

Question 2 (a) Identify the hazardous properties of Liquid Petroleum Gas (LPG). (4)
Hazards are that it is pressurized, and is cryogenic.
It is compressed and will expand to 250 times its liquid volume when released to
atmosphere.
The bottles are heavy
(b) Outline the risks associated with Liquid Petrol Gas (LPG). (4)
.
Because liquefied petroleum gases are extremely flammable there is a risk of fire and
explosion.

They are stored under great pressure, and hence low temperatures, to retain their liquid
state. This cryogenic hazard risks cold burns, frost bite, hypothermia in confined spaces
and freezing of the valves.

On release, liquefied petroleum gases revert to their gaseous state where the gas is at least
250 times greater in volume than when stored as a liquid. This would create a very large
vapour cloud. If there were any excavations or pits the gas would settle down there since
it is heavier than air and so could be an asphyxiant

There are manual handling risks due to the weight and size of the LPG bottles.

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)

The documented information for the accident investigation that might be used to
determine the root and underlying causes and prevent recurrence would include
Employee complaints
Absenteeism
Risk assessment for the task concerned
Operating procedures
PTW documentation,
Photographs of the scene of the accident
CCTV
Safety Committee minutes
Any written disciplinary action against the employee(s) concerned
Training and maintenance records
Manufacturers operational manuals and maintenance schedules for any work equipment
involved
Time Sheets
Operator Logs
Inspection records
Previous similar accident investigation reports
Any relevant Management of Change documentation
Appropriate legislation and any supporting Approved Codes of Practice/Guidance
Codes of Practice from Trade Associations such as IADC, OGP, ISO etc

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)
(b) outline practical ways of minimising the formation of an electrostatic charge. (4)

Part (a) The factors that would influence the generation of electrostatic charge would
include;
lack of earthing /bonding and grounding
clothing worn by the operator
air temperature/humidity
overfilling
volatility of the liquid – is it flammable or highly flammable
pour rate
whether the liquid was being poured from height

Part (b) controls would include;

The use of antistatic additives in the flammable liquid, reducing the flow speed of the
operation. Pouring the liquid as close as possible to the container and wearing antistatic
footwear.
No smoking during the operation and use of intrinsically safe equipment such as personal
monitors, communication equipment

(a) Identify TWO wm ays in which vapour clouds can be generated. (2)
(b) Outline how a vapour cloud explosion can be generated. (4)
(c) Identify the physical consequences of vapour cloud explosions. (2)

(a)Two ways in which vapour clouds can be generated are;

1. A sudden rupture of vessel due to and uncontrolled build up of pressure within the
vessel
2. loss of containment such as mechanical problems such as a stuck valve
(b) A vapour cloud is either confined/unconfined and is travelling long distances to find
sources of ignition such as in Texas City.

(c) The physical consequences would, depending whether it was supersonic or subsonic
flame propagation include;
fires which might then lead to BLEVEs
physical damage to structures
harm to persons.

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)

Physical design features used to minimise risk to personnel in the event of a major
incident would include plant separation, and protection of personnel//equipment. It would
also be important to provide and maintain a safe means of escape as well as to temporary
refuges. Other controls might include the provision of blow out panels, control and
communication equipment, such as radios, public announcement systems within the
temporary refuges and any compartmentalisation that was present. Provision of
emergency lighting and safety condition signage.

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)

The different types of work activity which would require a permit would include hot
work, high voltage electrical work, work at height, permit to enter for confined spaces.

The reasons for the requirement to hold such a permit such as complying with local legal
requirements for providing a safe place of work. It would also include control and co-
ordination of all high risk work activities. We also use permits to minimize the likelihood
and severity of any fire during hot works, access/egress, control ignition sources and
flammable materials during hot works, minimizing the likelihood and severity of any HV
electric shock during HV electrical work, protection of work area in all directions and
falling objects during work at height, plus ensuring it is safe to enter and work in a
confined space. The use of three copies is an example of good communication insofar as
the competent person has a reference document during the work, the asset owner has a
copy so they can monitor the works and the control room has a copy to ensure we are
aware of what high risk activities are taking place and here.
Outline the following failure modes that may lead to loss of hydrocarbon containment
from storage tanks/vessels or pipelines:
(a) creep; (2)
(b) stress corrosion cracking; (2)
(c) thermal shock; (2)
(d) brittle fracture. (2)

The involved in loss of hydrocarbon include;

(a) Creep which is slow movement under stress, made more severe with heat for long
periods,
especially with increases in temperature or temperatures approaching melting point.

(b) Stress corrosion cracking commonly occurs with alloys under tensile stress and is
worse in a corrosive environment especially at elevated temperatures.

(c) Thermal shock is cracking associated with rapid temperature change and different
parts of an object expanding at different rates where the stress overcomes the
strength of the material.

(d) Brittle fracture is rapid run of cracks through a stressed material with little plastic
deformation before failure caused by such things as repetition of inappropriate heating
or pressurising rates.
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)
(b) Outline why the metal legs of the vessel should be protected. (2)
(c) Outline how a fixed water deluge system could provide fire protection. (2)
(d) Identify TWO additional examples of active fire protection. (2)

(a) Two examples of typical coating materials such as mortar based, intumescing or
ablative
coatings or vessel protection in the form of mineral fibre matting.

(b) the intense thermal radiation form a serious fire would require the protection of the
steel legs to prevent buckling and so ensuring the vessel remains supported and
preventing it from releasing its contents.

(c) deluge systems provide large volumes of water over the structure. This is achieved by
automatic detection by using heat sensitive bulbs, so providing lots a vast a mount of
cooling water and starvation of oxygen.

(d) Active fire protection includes;

1. CO2 inerting systems,
2. Chemical powders
Identify THREE marine hazards associated with all types of Floating Platform Storage
Offloading Units (FPSO’s). (3)
(b) Identify suitable controls that minimise risk when operating Floating Platform
Storage Offloading Units (FPSO’s). (5)

Three marine hazards include;

(a) the environmental conditions which can cause considerable wear and tear but due
to the location there are no local repair facilities
(b) extreme weather conditions such as rough seas, fog, snow and ice
(c) Pollution of marine environment due to inadvertent spills.
(b)
i. the control of spillages
ii. routine inspection and
iii permit to work systems.

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)

The safety case or safety report is essentially an all encompassing document that is
designed to show that the installation has systems and procedures in place to minimize all
possible major accident risks.

Therefore the contents would include relevant quantitative risk assessments

which would identify, prevent, control and mitigate the hazards identified. Particular
emphasis
would need to be placed on evaluation of major accident risks. It might well have
independent verification of the QRA risk assessments conclusions.

It would also have an emergency plan which would be there to minimize the
consequences of any major accident. This would include details of relevant authorities
and emergency services
Finally it would provide details of the safety management system that would be used and
the means of periodic validation such as an audit by an independent third party e.g. DNV,
BSI.

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)
(b) Outline the main operational issues communicated at shift handover. (10)

The key principles of a safe shift handover are to recognize that this is a vital activity as
regards HSE and so should be given a high priority. It should use of face to face
communication which will involve both two way verbal communication as well as
written communication so that the incoming person will have a reference document
afterwards. There must be sufficient time taken over the handover, as the time required
will be different of the handover was to someone who was last on shift 12 hours ago
compared to someone who has just returned from leave. There should be a company
standard for shift handover that each person is familiar with. Training on both the
standard and communication skills will be required.

(b) updating on permits-to-work which are on-going, any forthcoming maintenance

preparations, any plant overrides, and abnormal events such as shutdowns, changes in
plant parameters and routine operations for the next shift.