CDB 1012 :

Health, Safety, and Environment

PROGRAMME : PG400D:PETROLEUM GEOSCIENCE
NAME

GROUP: GPG6
STUDENT ID

MUHAMMAD FAIZ BIN ZAHARI

20688

MUHAMMAD FIRDAUS BIN ABD. RAHMAN

20866

MUHAMMAD HAZIM BIN HALIM

21415

MUHAMMAD HAZIQ BIN YUSSOF

21398

MUHAMMAD NAQIB BIN NORMAN

21496

MUHAMMAD NUR ADIB BIN YAHAYA

20625

MUHAMMAD SYAHEED BIN AHMAD ZAKI

20672

NARESHA KAUR CHHABRA

20634

NUR AKMAL SYAZWANI BINTI KHIR

20785

NUR AMALINA BINTI OTHMAN

21282

Physical hazards Risk Assessment Using

Failure Mode and Effect Analysis (FMEA) And
Human Error Analysis (HEA) Method and
Preventive Measures in Oil and Gas Industry
Faiz Zahari, Firdaus Abd. Rahman, Hazim Halim, Haziq Yussof, Naqib
Norman, Adib Yahaya, Syaheed Zaki, Naresha Chhabra, Syazwani Khir &
Amalina Othman
Department of Geoscience, Universiti Teknologi PETRONAS,
Bandar Seri Iskandar, Perak 32610, Malaysia
Submitted on 16 August 2015

Abstract - In oil and gas industry, risk assessment tool is used

where it will help users in recognizing hazard and assessing danger
included in each distinguished risk. This tool will recognize
conceivable risk included in every undertaking in offices. When the
hazard has been distinguished, dangers included will be evaluated
and sorted. On the off chance that the evaluated hazard falls in a
classification, which is higher than the low risk classification, then
conceivable control measures will be suggested. In the meantime,
the user can include new work plan, undertaking, and control
measures into the framework to overhaul existing data framework.
Keywords- Physical hazards, Hazard Risk, Risk
Assessment, and Identification.

I. INTRODUCTION
Hazard is any source of potential damage, harm or
adverse health effects on something. Hazard is
classified into three modes which are dormant, armed
and active. There are many ways to identify hazards by
category which are ergonomic, biological, chemical,
physical, safety and psychosocial. One key concept for
identifying hazard is presence and amount of stored
energy that release can cause damage[1]. Stored energy
occur
in
many
forms
which are thermal, electrical, mechanical and chemical.
Another key concept is involves the presence of
hazardous situations. For example, the situation

involves are oxygen-depleted

repetitive motions.

A)

atmospheres

and

HAZARD

Hazard Identification Risk Assessment (HIRA) is a

procedure of characterizing so as to char and depicting
dangers their likelihood, recurrence and seriousness
and assessing unfavorable outcomes, including
potential loses and wounds. A danger evaluation that
gives the authentic premise to exercises proposed in the
method to diminish misfortunes from distinguished
risks. Nearby hazard appraisals must give adequate
data to empower the purview to distinguish and
organize fitting alleviation activities to decrease
misfortunes from recognized dangers[1].
B) FAILURE MODE AND EFFECTS ANALYSIS
Failure mode and effects (FMEA) is a system used in
order to evaluate processes or potential product,
determine remedial actions to avoid identified
problems and observe the possibility of failure. A
FMEA process includes failure modes, the causes of
failures, possible consequences and their close
examination of processes. An FMEA report aims to
reducing accompanying risks and turn away failures.
FMEAs are particularly important as the introduction
towards new manufacturing process and techniques. It
should be closely linked to an affect the design process
and technique in order to correct possible failure
modes[2]. The FMEA also identify corrective actions
required to prevent failures from reaching someone,
thereby assuring the possibility of highest reliability,

quality and durability in a product and service. The

good FMEA are consist of provides for problem
follow-up and corrective action, identify the causes and
effects of each failure mode and also known about
potential failure modes. Besides, prioritizes the identify
failure modes according to risk priority number is the
example of good FMEA. There are only two
weaknesses about this tools which are not account for
component interfaces and no human error factor.
C) HUMAN ERROR ANALYSIS
Human Error Analysis (HEA) is a tool in designing
new products and systems by predicting human error
before accidents occur. It can also be used in risk
assessment in which resolve critical system state that is
vital. HEA techniques involve observing employees at
noting hazard and work, and also get a first-hand feel
for hazard by performing job tasks given by
company[2]. HEA report is aim to assist in analyzing
the dependability and reliability of systems with a
human component. Human error is a significant factor
in the success of take-up of any system and it is
particularly of concern where activities are safety
clinical. It is the best perform HEA together with either
FMEA or HAZOP. This will enhance the effectiveness
and output of all process. When this HEA and FMEA
combine together, the weaknesses can be reduce and
the quality of new product will be high rate and
customer first choice.

II. PHYSICAL HAZARDS IN

TRANSPORTATION
According to a record by the Bureau of Labour
Statistics in the years of 2005 to 2009, the fatality rate
in the oil and gas industry was 7 times higher than in
the general industry and 2.5 times higher than the
construction industry. These fatalities were mostly due
to highway crashes and being hit by an object. Most of
the traffic fatalities were associated with the lack of
seatbelt use among drivers [3].

Process/
Function

Transportation

Potential
Failure
Mode

Potential
Effects of
Failure(s)

Tanker
running
aground

Oil spill.
Endangering
marine life.
Company
losses.
Loss of
lives.

Derailing
of train

Explosion
and fire.
Company
losses.
Loss of
lives.

Collision
with
other
vehicles/
vessels.

Loss of
lives.
Fire and
explosions.
Company
losses.

Severity

Potential
Causes of
Failures(s)

10

Hitting a
rock that
was
undetected.
Bad weather.
Failure of
rudder.

Failure of
brakes and
tracks.

Dangerous
roads.
Brake
failure.

Occ
.

Current
Process
Controls

Advance radar
system.

Ensure
backup brakes
installed.
Regular
inspections

Inspection of
roads.
Inspection of
vehicles
before
transportation.

Detectio
n

Risk
Priorit
y
number

Recc. Actions

150

Come up
with new
technology to
detect unseen
hazards at sea
with an alarm
system.

30

Ensure the
track and
train
machinery
are frequently
serviced.

80

Drivers have
to undergo
professional
training and
equipped
with
knowledge
on actions to
be taken
during an
emergency.

TABLE 1
THE FMEA OF TRANSPORTATION SYSTEM

In the United States of America, commercial truck

accidents account for approximately 5000 fatalities
every year. However, depending on the type of cargo
bring transported in the truck, the severity of the
catastrophes may differ from each cases. One of the
common danger of cargo truck accidents are firerelated which involves the transportation of
flammable liquid such as petroleum or gasoline.
Most of the commercial truck accidents are caused
by the human errors, either the person handling the

truck, or the people from the surroundings. Based on

our research, we have identified few causes of
accidents using the Human Error Analysis (HEA)
method.

TABLE 2
HUMAN ERROR ANALYSIS OF
TRANSPORTATION

Error type
Checking error

Likelihood
Error
Frequent
Tyre maintenance
Probable
omitted
Occasional
Over speedingRemote
Overloading Improbabl
e

Violation of
transportation
regulations
Communication error

Information not
obtained

TABLE 3
RISK ASSESSMENT MATRIX OF
TRANSPORTATION

III.

RISK ASSESSMENT MATRIX

Severity
Catastrophic Critical Margined

PHYSICAL HAZARD OF PIPELINE

SYSTEM

Negligible

Transporting petroleum fluids with pipeline is a

continuous and reliable. Due to their superior
flexibility to the alternatives with minor exceptions,
most refineries are served by one or more pipelines
[4]. However, there are several failures and human
errors that can occur which may affect the project,
employers, organisation as well as the environment.
According to Gas and Oil Pipeline Standards (GOST)
of Nigeria, the standard lifetime of a pipeline is 33
years, but a research has found out that 42% of its
failures are mechanically incited, 18% by erosion,
outsider movement contributed 24%, 10% through
operational mistake and 6% by normal perils[5].

Pipeline is a structure which is commonly used to

transport hydrocarbon (oil and gas) products.
TABLE 4
Process

Potential
Failure
Mode

Pipe
corrosion

Pipeline
Free
Span

Potential
Effects of
Failure(s)

Sev
erit
y

Potential Causes
of Failures(s)

Occ
.

Chemical
reaction of
seawater and
metal

Internal and
external wall
of the pipe
corroded
7
Pipe leaking
(contaminated
water & danger
to marine life)
Bending of the
pipe can cause
the pipe to
break
4
Will cost a lot
of money to
replace new
pipe.

Presence of sand
in oil and gas
transported from
offshore

Excessive
yielding and
fatigue[4]

Current
Process
Controls

Dete
ction

Risk
Priority
number

Use noncorrosive metal

for pipeline
8

Inspection
and
maintenance
(pigging)[6]

Using
flexible pipe
in pipeline
system

280

Explosio
n of gas
line.

Corrosion
8

9
Poor
maintenance of
pipeline [6]

Inspection of
pipeline
system

THE FMEA OF PIPELINE SYSTEM

Apply filter to
avoid unwanted
particle inside
the pipe

192

Make an
inspection focus
on the soil
beneath the pipe
to observe the
soil reaction

504

Inspection of the
pipeline need to
be conducted by
latest technology
and an expert
operator

Metal fatigue
Loss of lives.
Fire and
explosions.
Company
losses.

Recc Actions

For the Human Error Analysis, there are

several accidents happened due to the errors
made by human.
1.

2.

3.

Likelihood
Frequent
Probable
Occasional
Remote
Improbabl
e

Natural gas transmission pipeline

rupture and fire in Cleburne, Texas on
7th June 2010 occurred because of
human error. The contractor was
wrongly
puncturing
the
unmarked,
underground natural gas pipeline with a
power auger. It is because the pipeline
locator could not find the exact location on
the pipeline before the installation of the
utility pole on it. Hence, the presence of
visual cues in making a decision is very
important [7].

Natural gas transmission pipeline rupture

and fire in Palm City, Florida on 4th May
2009 also occurred because of the human
error. The integrity management program
could not detect the cracking under a
disbanded polyethylene coating. This show
that the officers are lacking in term of
checking or detecting any flaws of the
pipeline [7].
Natural gas transmission pipeline rupture
and fire in Marshall, Michigan in 25 th July
2010 also due to the human error.
Inadequate training of control centre
personnel which allowed the rupture to
remain undetected for 17 hour and through
two start-ups of the pipeline [7].

Therefore some analysis has been made about

human error and being listed below:
1.

The workers do not have in adequate

training in controlling and checking any
defects of the pipeline. Hence they cannot
make a correct decision and are unable to
detect any failure on it.

2.

The workers might not be in the most fitted

condition when they are working. Some
maybe have physical problems and some
maybe have emotional problem. Hence they
tend to make careless mistakes.

3.

The conditions at the workplace affected the

performance of the workers. They do not
have an ergonomic condition that could
make them perform even better than before.

RISK ASSESSMENT MATRIX

Severity
Catastrophic Critical Margined

Negligible

TABLE 5
HUMAN ERROR ANALYSIS OF PIPEPLINE
Error Type
Checking error
Ergonomics problems

TABLE 6
RISK ASSESSMENT MATRIX OF PIPELINE
SYSTEM

IV.

PHYSICAL HAZARD OF PIPELINE

SYSTEM

A drilling rig is a machine that makes holes in the

soil of the earth crust. Drilling apparatuses can be
monstrous structures lodging hardware used to bore
oil wells, regular gas or water wells, or they can be
sufficiently little to be moved physically by one
individual and are called "auger". The Failure Mode
and Effect Analysis (FMEA) table above shows the
potential failure mode, effect of failure, causes of
failure, process controls and its recommended action
of a drilling rig.
One of the potential failure modes for a drilling rig
is loss of circulation. This failure mode occurs
because of the excessive downhole pressure and
setting intermediate. It usually occurs in the transition
part. The failure mode will cause the mud continually
flowing to the surface. To overcome this problem, we
should set casing to be kept safety from the upper
weaker part formation. We also should maintain
proper mud weight to avoid this failure happen.
Secondly, the potential failure mode for a drilling
rig is drill pipe failure. This failure mode occurs
because of the induced shearing stress caused by high
torque. The failure mode will cause twist off or
collapse and burst of the drill pipe. Furthermore, we
should minimize the induced cyclic stresses to
prevent this problem. We also should insure a noncorrosive environment during drilling operation.

Could not
makes care
tend to be s

Lastly, the potential failure modes for a drilling rig

is hole deviation. This failure mode occurs because of
the improper hole cleaning. The failure mode will
leads to higher costs and lease boundary legal
problems. To overcome this problem, we should not
use weight on the bits because it tends to bring the
hole towards vertical. We also should use stabilizer as
an addition to control this process.

TABLE 7
THE FMEA OF DRILLING SYSTEM
Process/
Function

Drilling
Rig

Potential
Failure
Mode

Potential
Effects of
Failure(s)

Loss of
Circulation

Mud
continues
to flow to
the surface
with some
loss to the
formation.

Drillpipe
Failure

Twist off.
Collapse
and burst

Hole
deviation

Leads to
higher
costs and
leaseboundary
legal
problems

Severity

Potential
Causes of
Failures(s)

10

Excessive
down hole
pressure and
setting
intermediate.
Especially in
the transition
part.[8]

Induced
shearing stress
caused by high
torque.

Improper hole
cleaning. [8]

For the Human Error Analysis, there are several

accidents happened due to the errors made by human.
1.

Two apparatus managers kept on penetrating

at an CD Resources site close Nashville, in
2010, even though the air loaded with
combustible methane gas. After then blasted,
harming seven people and softening the
apparatus. Some ethane gas originated from
a deserted coal mine the West Drilling Inc.
group has effectively punctured once when
penetrating a neighboring admirably. The

Occ.

Current
Process
Controls

Maintaining
proper mud
weight

Insuring a
noncorrosive
environment
during drilling
operation.

Use stabilizer

Detection

Risk
Priority
number

Recc.
Actions

150

Setting
casing to
protect
upper
weaker
formations
within a
transition

96

Minimizing
induced
cyclic
stresses

70

Use no
weight on
the bits
because it
tends to
bring the
hole
towards
vertical.

people were utilizing a procedure named

"penetrating on air" which is especially
hazardous when a boring tool hits
petroleum[9].
2.

A blast executed an organization worker, the

wellbeing supervisor of Weatherfold,
advised specialists for the place she was still
new to the job and did not have any formal
preparing in security. Agents trust the
representative, Timmy Paxtone, 55, and four

RISK ASSESSMENT MATRIX

Severity
Catastrophic Critical Margined

Likelihood
Negligible liable to happen and reason real issues will be
Frequent
viewed later
Probable
ACKNOWLEDGEMENT
Occasional
Remote
We would like to express our special thanks of
Improbabl
gratitude
to our committee chair, Dr Asna Binti
e
Mohd
Zain,
who has the attitude and the substance
other men were remaining in a combustible
of
a
genius
She continually and convincingly
vapor cloud at the Anterot Resources site
close East Union., in 2014 when a flash set
conveyed a spirit of adventure regarding on how to
off some blast. Johnson Mean, 37, a
finishing and researching the paper and an excitement
representative of Habors Completions, was
in regard to teaching.
without her guidance and
additionally killed and four others were
persistent in helping our paper and report, this
harmed. [9].
dissertation would not have been completed. Lastly, we
are pleased to thank everyone who is indirectly or
directly involved in completing this paper
since the day we started.
TABLE 8
HUMAN ERROR ANALYSIS OF DRILLING
REFERENCES
SYSTEM
Error Type
Action error
Checking error
Information retrieval error

Information communication error

Selection error
Planning error
Violation

TABLE 9
RISK ASSESSMENT MATRIX OF DRILLING
SYSTEM

V. CONCLUSION
The primary step for emergency readiness and
keeping up a safe work environment is characterizing
and dissecting hazards. Albeit all risks ought to be
addressed to, resource restrictions as a rule don't
permit this to happen at one time. So in this paper, we
will perform Hazard identification and risk
assessment procedure to survey all risks and will
build up needs so that the most unsafe circumstances
will be addressed first and those to the least extent

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