NEBOSH

 IOG  –  Element  2:  Hydrocarbon  Process  Safety  1      

Revision  Questions  
Q1.  

What   four   factors   must   we   consider   to   ensure   that   the   work   that   contractors   do   is  
covered  by  our  own  usual  methods  of  safe  working,  to  prevent  accidents?  

Answer:  

To   make   sure   that   the   work   that   contractor’s   do   is   covered   by   the   usual   method   of   safe  
working:  

• Ensure   that   the   hazards   of   the   contractor’s   job   have   been   identified   and   steps   taken  
to  reduce  the  risks.  
• Ensure   that   a   representative   of   the   owner   or   operator   is   available   to   make   sure  
contractors  follow  the  rules  of  the  installation.  
• Ensure   that   all   contractor   employees   know   who   the   site   or   installation   contact  
person  is,  and  how  they  can  be  contacted.  
• Have  procedures  in  place  that  ensure  close  and  safe  working  with  contractors  at  all  
times.  
 

Q2.  

Identify  the  simple  “Five  Steps  to  manage  contractors.  

Answer:  

• Step  1  –  Planning.  
• Step  2  –  Choosing  a  contractor.  
• Step  3  –  Contractors  working  on  site.  
• Step  4  –  Keeping  a  check.  
• Step  5  –  Reviewing  the  work.  
 

Q3.  

What  are  the  advantages  and  disadvantages  of  the  Dow  Fire  and  Explosion  Index?  

Answer:  

Advantages  of  the  Dow  Index:  

• Methodology  can  be  easily  duplicated.  

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 • Methodology   requires   evaluation   of   all   aspects   of   a   process   unit   that   increase   the  
potential  severity  of  a  fire  or  explosion.  
• Reasonably  easy  to  use.  
• Based  on  actual  loss  experience.  
• Recognized  by  industry  as  good  for  ranking  chemical  process  risks.  

Disadvantages  of  the  Dow  Index:  

• Intended  for  designed  use  at  early  stages.  

• Harder  to  apply  to  existing  plant.  
• Not  good  at  determining  normal  expected  loss.  
• Interpretation  requires  judgment.  

Q4.  

What  are  the  four  main  areas  detailed  and  explained  in  a  permit-­‐to-­‐work?  

Answer:  

Permits-­‐to-­‐work  detail  and  explain:  

• The  work  involved.  

• The  isolation  required.  
• Hazards  in  the  work  to  be  carried  out.  
• Precautions  to  avoid  injury.  

   

Q5.    

Identify  six  types  of  work  where  a  permit-­‐to-­‐work  might  be  required.  

Answer:  

Six  areas  where  a  permit,  might  be  required  are:  

• Hot  work  (welding,  burning,  grinding,  etc).  

• Live  or  high  voltage  work.  
• Working  at  height.  
• Working  over  water.  
• Work  in  confined  space.  

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 • Special   permits   for   work   carried   out   under   special   conditions   (usually   maintenance  
work  of  a  non-­‐routine  nature).  
 

Q6.    

Identify  four  areas  other  than  electricity  where  a  safe  isolation  procedure  might  be  used.  

Answers:  

Safe  isolation  systems  are  concerned  with  the  safe  isolation  of  (only  four  required):  

• Electrical  supplies.  
• Hydraulic  (oil)  power.  
• Pneumatic  power  and  storage  energy.  
• Residual  energy.  
• Combustion  engines.  
• Natural  gravitational  forces  /  weight.  
• Steam  or  high-­‐pressure  water  systems.  
• Any  combustions  of  or  additions  to  the  above.  
 

Q7.  

Explain  the  meaning  of  the  term  “safe  isolation”  

Answers:  

Safe  isolation  –  the  interruption,  disconnection  and  separation  of  all  the  equipment’s  motive  
power   sources   in   such   a   way   that   this   disconnection   and   separation   is   secure   by   lockable  
means.  

Q8.  

What  five  key  principles  should  be  employed  to  ensure  a  safe  shift  handover?  

Answers:  

Shift  hand-­‐over  should  be:  

• High  priority,  conducted  face-­‐to-­‐face.  

• Two-­‐way  with  both  participants  taking  joint  responsibility.  
• Carried  out  using  verbal  and  written  communication.  
• Based  on  analysis  of  the  information  needs  of  the  oncoming  shift  staff.  
• Given  as  much  time  as  necessary.  

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Q9.  Identify  four  causes  of  ineffective  communications.  

Answers:  

Ineffective  communications  come  about  from  a  variety  of  causes  (only  four  required):  

• Some  information  is  missed  or  missing.  

• Unnecessary  information  is  included,  causing  confusion.  
• Information  is  inaccurate  or  misleading.  
• The  quality  of  information  is  poor.  
• Information  is  not  understood  (either  by  transmitter  or  receiver).  
• Information  is  not  carried  forward  over  successive  shifts.  

Q10.  When  are  problems  in  communication  most  likely  to  occur?  

Answer:  

The  most  problems  in  communication  occur:  

• During  plant  maintenance,  when  it  runs  across  more  than  one  shift.  
• In   areas   where   safety   system   may   have   been   over-­‐ridden   (e.g.   fire   deluge   system  
switched  to  manual).  
• During  deviations  from  normal  working,  such  as  breakdowns,  or  lack  of  spares.  
• When  members  of  the  team  have  been  absent  from  work  for  long  periods.  
• If  handover  takes  place  between  experience  and  inexperienced  staff.  

Q11.  Identify  four  corrosion  control  practices  and  procedures.  

Answer:  

Corrosion  control  practices  and  procedures  include  (only  four  required):  

• Selection  of  materials:  steels,  corrosion  resistant  alloys,  and  plastics.  

• Chemicals  treatments:  biocides  and  corrosion  inhibitors.  
• Surface  coating:  metallic,  non-­‐metallic  and  paints/organic  coatings.  
• Cathodic  protection:  galvanizing  and  impressed  current.  
• Process  and  environmental  controls:  control  of  through-­‐put,  dehumidification.  
• Initial   design:   safe   concept,   engineering   and   detail   reviews,   life   cycle   implications  
and  corrosion  risks.  

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Q12.  Risk  based  inspection  schemes  allow  a  plan  for  carrying  out  critical  inspections.  What  
four  critical  areas  is  this  based  on?  

Answer:  

The  four  critical  areas  that  risk  based  inspection  schemes  are  based  on  are:  

• Ensure  the  risks  are  reduced  to  ALARP.  

• Optimize  the  inspection  schedules.  
• Inspect  the  most  critical  items  of  plant,  equipment  and  components.  
• Use  the  most  appropriate  inspection  methods.  
 

Q13.   Identify   four   ignition   sources   that   could   arise   from   maintenance   or   operations   on   an  
installation.  

Answer:  

Ignition  source  are  (select  four  from):  

• Electrical   equipment   –   Routinely   inspect   and   test   to   prevent   faults   developing   that  
could  cause  sparks  and  over  heating.  
• Hot   work   (welding,   burning,   etc.)   –   control   with   a   permit-­‐to-­‐work   when   done   in  
sensitive  areas.  
• Smoking  –  control  and  limit  to  restricted  areas  on  site  (welfare  areas).  
• Cooking  and  heating  appliance  –  locate  safely  (confine  to  a  galley  offshore  and  use  
carefully.  
• Mechanical  heat  (over  heating)  –  control  by  good  maintenance  programmes.  
• Deliberate   ignition   (arson)   –   prevent   by   good   security,   perimeter   fences   (onshore),  
CCTV  and  security  lighting.  
 

Q14.   How   is   safe   isolation,   stoppage,   draining   down   and   blanking   of   systems   assured  
during  a  shut-­‐down?  

Answer:  

It   is   vital   for   the   safety   of   maintenance   personnel   that   services   are   stopped,   isolated,  
drained  down,  blanked,  etc.  and  remain  in  a  safe  condition  for  the  duration  of  the  work.  This  
ensured  by  the  work  being  carried  out  under  the  controls  of  a  permit-­‐to-­‐work.  The  permit  
will   have   a   completion   section   to   ensure   that   all   systems   are   put   back   into   operable  
condition  before  start-­‐up,  to  protect  maintenance  and  operations  personnel.  

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Q15.   Identify   the   main   factors   to   be   considered   when   assessing   the   health   and   safety  
competence  of  a  contractor.             (8  Marks)    

Answer:  

The  competence  of  contractors  is  assessed  using  a  checklist  covering  areas  such  as:  

• Are  they  experienced  in  the  type  of  oil  and  gas  process  work  to  be  carried  out?  
• Are  they  experienced  in  trained  in  offshore  safety  requirements?  
• Are  a  suitable  health  and  safety  policy,  organization  and  arrangements  in  place?  
• What  is  the  quality  and  extent  of  their  risk  assessments?  
• What  is  their  recent  health  and  safety  performance  (number  of  accidents,  etc)?  
• Has  any  enforcement  action  been  taken  against  them?  
• Do  they  provide  suitable,  up-­‐to-­‐date  method  statements?  
• Do  they  monitor  health  and  safety  and  carry  out  site  inspections?  
• What  are  the  qualifications  and  skills  that  they  bring  to  the  project?  
• Do  their  employees  carry  a  suitable  skills  card?  
• Are  they  members  of  a  professional  body  or  trade  association?  
• Do  they  have  employer’s  liability  and  public  liability  insurance?  
• Do  you  have  any  reference  about  them  from  previous  clients?  
• How  do  they  appraise  and  select  subcontractors?  
• What  are  their  client  liaison  arrangements?  
 

Q16.  

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)  

Answers:  

• Reliance  on  written  communication  

• 2  way  communication  
• Face  to  Face  
• Sufficient  time  allocated  
• Formal  approach  
• Provision  of  as  much  information  as  necessary  
• Design  of  Equipment  (Log/Read  outs)  

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

Answers:  

• Updating  PTW's  
• Forthcoming  maintenance  
• Plant  overrides  
• Abnormal  events  
• Planned  shutdowns  
• Change  in  plant  parameters  
• Routine  operation  for  next  shift  

Q17.  

(a)  Outline  two  functions  of  a  permit  to  work  (PTW)  system  (2  Marks)  

Answer:  

• Controls  work  activities  

• Assist  in  the  security  of  isolations  

(b)  Outline  four  of  the  elements  that  should  be  included  in  a  typical  PTW.  (4  Marks)  

Answer:  

• Task  description  
• Location  of  task  
• Precautions  to  be  taken  
• Remaining  hazards  
• Time/date  
• Authorization  signatures  

(c)  Identify  two  types  of  work  activity  that  may  require  a  PTW.  (2  Marks)  

Answer:  

• Hot  work  
• Confined  space  entry  

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Q18.  

(a)  Identify  Two  ways  in  which  vapour  clouds  can  be  generated.  (2  Marks)  

Answer:  

• Sudden  depressurisation  
• Rupture  of  vessel  
• Loss  of  containment  
• Uncontrolled  build  up  of  pressure  

(b)  Outline  how  a  vapour  cloud  explosion  can  be  generated.  (4  Marks)  

Answer:  

• Confined  /  unconfined  generation  

• Travelling  distances  to  sources  of  ignition  

(c)  Identify  the  physical  consequences  of  vapor  cloud  explosions.  (2  Marks)  

Answer:  

• Fire  
• Physical  damage  
• Supersonic  or  subsonic  flame  propagation    
 

Q19.  

A   pump   containing   flammable   corrosive   slurry   has   been   stopped   for   maintenance.   An  
operator   will   prepare   the   pump   for   maintenance   using   a   nitrogen   supply,   drain   header  
and  collection  vessel.  Using  this  Information:  

(a)   Outline   EIGHT   risks   to   the   operator   when   preparing   the   pump   for   maintenance.                      
(8  Marks)  

Answers:  

• Asphyxiation  due  to  N2  displacement  of  02  

• Fire  
• Explosion  
• Irritant/Corrosive  substance  
• Incorrect  isolation  of  valves  
• Incorrect  Lock  Out/Tag  Out  system  
• Lack  of  gas  monitoring  
• Burst  pressure  lines  causing  injury  

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Q20.  

Oil  and  gas  installations  use  water  for  cooling  and  heating  although  it  can  be  a  hazard  in  
some  situations.  

Identify  risks  with  water  AND  give  a  practical  example  in  EACH  case.   (8  Marks)  

Answer:  

• Corrosion  -­‐  leading  to  failure  

• Explosion  -­‐  Re-­‐gasification  with  LNG  
• Contaminated  residues  -­‐  potential  health  issues  
• Water  freezing  -­‐  leading  to  failure  of  equipment  

Q21.  

Outline   operational   control   measures   that   could   minimize   the   risk   of   plant   damage   or  
injury  during  start-­‐up  or  shutdown  of  a  process.   (8  Marks)  

Answer:  

• Cooling  and  depressuring  

• Cleaning  and  gas  freeing  
• Blinding  
• Physical  inspection  
• Preliminary  preparations  
• Tightness  testing  
• Preparation  of  auxiliary  services  
• Return  to  service  close  out  meeting  

Q22.  

In  relation  to  Hydrocarbon  Vapour  Clouds  Define  what  is  meant  by;  

a)   BLEVE's     (2  Marks)  

Answer:  

"BLEVE"   is   an   acronym   for   "Boiling   Liquid   Evaporating   Vapor   Explosion"   and   involves  
a   situation   where   a   liquid   in   a   container   —   often   a   compressed   liquid   such   are  
propane   -­‐   suddenly   fails,   resulting   in   a   rapid   expansion   of   the   liquid   into   a   vapor,  
releasing   energy   that   is   capable   of   hurtling   parts   of   the   tank   or   other   nearby   objects  
for   considerable   distances.   If   an   ignition   source   is   present   and   the   vapor   is  
flammable,  a  sudden  deflagration  (fire)  or  explosion  may  occur.  

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b)   CVCE's     (2  Marks)  

Answer:  

Explosion  of  a  liquefied  hydrocarbon  in  a  confined  space  

c)   UVCE's     (2  Marks)  

Answer:  

When  Hydrocarbon  air  mixture  an  ignition  source  

Q23.  

Outline   the   operational   control   measures   that   could   minimise   the   risk   of   plant   damage   or  
injury  during  start-­‐up  and  shutdown  of  a  process.     (8  Marks)  

Answer:  

• Control  system  -­‐  process  controls-­‐  intelligent  alarms  

• Suitable  procedures  and  methods  
• Trained  and  competent  employees  
• Suitable  supervision  of  the  operation  
• Detection  systems-­‐  flow/  no  flow/  overflow  
• Zone  controls  
• Use  of  flares  /  over  flow  /  over  pressure  devices    
• Maintenance  and  integrity  of  systems  
 

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