This informal CPD article ‘Offshore Safety Management: Why It Matters and How to Achieve It’, was provided by Synergen Oil and Gas UK, an independent engineering consultancy specialising in Process Safety, Technical Risk Management and Operational Safety services.
Offshore oil and gas facilities are key players in global energy production, operating in some of the most challenging environments. These facilities, including fixed platforms, Floating Production Storage and Offloading (FPSO) units, Semi-Submersible Platforms, and Floating Liquefied Natural Gas (FLNG) Platforms, are critical to the extraction, processing, storage, and transportation of hydrocarbons. However, their remote and high-risk nature makes safety management paramount. Failure to manage safety can have disastrous effects on human life, the environment, and infrastructure.
To address these challenges, offshore facilities must implement effective safety management systems throughout their lifecycle—from planning and design to construction and operation.
This article explores the importance of offshore safety management, focusing on lifecycle-based approaches and the Hierarchy of Controls to manage risks effectively.
Phase-Specific Approaches to Offshore Safety Management
1. Inherent Risk Management
Inherent risk management is a holistic approach applied throughout the lifecycle of an offshore facility, aiming to continuously reduce risk from the earliest stages of development. The key phases in a facility’s lifecycle are:
- Concept Phase
- Design Phase
- Construction and Installation Phase
- Operational Phase
Each phase applies specific risk reduction measures, with the most effective strategies typically implemented in the Concept and Design Phases. Early risk management is crucial as it allows hazards to be addressed before they escalate into larger, costlier issues during the operational phase.
2. The Hierarchy of Controls
The Hierarchy of Controls is a well-established framework that prioritizes controlling hazards at the source rather than relying on human behaviour or personal protective equipment (PPE). This system is arranged in a pyramid, with the most effective control methods at the top and the least effective at the bottom.
1. Elimination (Most Effective):
Elimination involves completely removing the hazard from the work environment. This is most feasible during the early stages of a project, particularly the Concept or Design Phases. For instance, automating valve adjustments in an offshore facility can eliminate the need for workers to operate in hazardous areas.
2. Substitution
When elimination is not possible, substitution—replacing a hazardous material, process, or equipment with a safer alternative—is the next best option. An example from offshore operations is substituting traditional drilling fluids with less hazardous alternatives, such as water-based or synthetic mud systems.
3. Engineering Controls
Engineering controls involve designing systems that isolate people from hazards, making them inherently safer as they do not rely on worker behaviour. Offshore facilities often employ engineering controls like fire and gas detection systems, emergency shutdown systems, and Blowout Preventers (BOPs) to mitigate risks.
4. Administrative Controls
Administrative controls involve changes in how people work. These include policies, procedures, and training that guide safe work practices. While necessary, administrative controls are less reliable than elimination or engineering controls because they depend on human behaviour. Permit-to-work systems and rotation schedules to prevent worker fatigue are common examples of administrative controls in offshore operations.
5. Personal Protective Equipment (PPE) (Least Effective)
PPE is considered the last line of defense and does not eliminate hazards, but it reduces the severity of exposure. Offshore workers often use PPE such as flame-resistant clothing, respiratory protection, and fall protection systems, especially when working in high-risk areas.
Applying the Hierarchy of Controls Across the Facility Lifecycle
The application of the Hierarchy of Controls varies depending on the phase of the facility’s lifecycle, with earlier phases focusing on higher-level controls like elimination and substitution, and later phases emphasizing engineering, administrative controls, and PPE.
Early Stages: Concept and Design Phases
In the Concept and Design Phases, there are greater opportunities to apply elimination and substitution controls, as these phases allow for strategic decisions that can avoid or minimize hazards altogether. For instance, hazard identification studies (HAZID) help assess risks and drive decisions that prioritize safety in the design and location of the facility.
Engineering controls are also embedded into the design to mitigate risks from the outset, making it more cost-effective than retrofitting safety features once the platform is operational.
Operational Phase
During the operational phase, engineering controls, such as automatic shutdown systems and gas detection systems, play a central role in preventing hazards. Administrative controls also become critical, as comprehensive safety protocols and training ensure that workers are prepared to handle both routine and emergency situations effectively.
PPE remains essential but is treated as a last resort, used in conjunction with other controls to minimize the effects of hazards on individual workers.
Conclusion
The offshore oil and gas industry operates in some of the most hazardous environments, making effective safety management essential. By applying the Hierarchy of Controls throughout the facility lifecycle, operators can manage risks more effectively, optimize resource use, and ensure compliance with safety regulations. Early risk elimination and substitution during the Concept and Design Phases help prevent hazards before they develop, while engineering and administrative controls mitigate risks during construction and operations. Prioritizing these control measures at every phase ensures safer, more efficient, and cost-effective offshore operations in the long term.
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