Oil & Gas Safety Manual

What Should an Oil & Gas Safety Manual Include?

The contents of an Oil & Gas Safety Manual should reflect the work actually performed.

Depending on company operations, the manual may address:

• Oilfield safety responsibilities.
• Hazard assessments.
• Job Safety Analysis (JSA/JHA).
• Safety inspections.
• Stop-work authority.
• Contractor safety.
• Vehicle and transportation safety.
• Site preparation.
• Rigging up and rigging down.
• Drilling operations.
• Well completion.
• Well servicing and workover.
• Production operations.
• Struck-by and caught-between hazards.
• High-pressure equipment.
• Well control.
• Hydrogen Sulfide (H2S).
• Hydrocarbon gases and vapors.
• Fire and explosion prevention.
• Hot work.
• Lockout/Tagout.
• Machine guarding.
• Electrical safety.
• Confined spaces.
• Fall Protection.
• Rigging and material handling.
• Cranes and hoisting.
• Hazard Communication.
• Respiratory Protection.
• Silica Exposure Control.
• Noise and Hearing Conservation.
• Personal Protective Equipment.
• Heat and Cold Stress.
• Fatigue Management.
• Emergency Response.

Programs should be selected according to actual oilfield operations and employee exposures.

Oil & Gas Safety Program

An effective Oil & Gas Safety Program establishes responsibilities and procedures for identifying hazards, controlling employee exposures, preventing injuries and illnesses, and coordinating work at drilling, servicing, production, and other oilfield locations.

Management should provide the equipment, engineering controls, PPE, training, supervision, communication systems, and other resources necessary for employees to perform assigned work safely.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate workplace hazards.
• Maintain applicable written safety programs.
• Conduct workplace inspections.
• Coordinate safety requirements with operators and contractors.
• Provide appropriate equipment and PPE.
• Maintain equipment in safe operating condition.
• Investigate occupational incidents.
• Correct identified hazards.
• Provide employee training.
• Monitor changing site conditions.
• Maintain applicable records.

Employees should follow established procedures, participate in JSAs and pre-job planning, inspect equipment, use required PPE, and promptly report unsafe conditions, equipment defects, injuries, exposures, spills, releases, and other hazards.

Operator and Contractor Safety Requirements

Oil and gas worksites frequently involve multiple employers performing specialized operations at the same location.

Before work begins, employers should determine:

• Who controls the worksite.
• What hazards are present.
• What work will be performed.
• What safety procedures apply.
• How simultaneous operations will be coordinated.
• How emergencies will be communicated.
• What operator or client requirements apply.

Employees should receive information necessary to understand hazards created by other operations that may affect their work.

Job Safety Analysis (JSA/JHA)

Job Safety Analysis is particularly important in oil and gas operations because hazards can change according to the activity, equipment, well condition, weather, contractors, and simultaneous operations.

A JSA/JHA should identify:

• Job steps.
• Hazards associated with each step.
• Required controls.
• PPE.
• Equipment.
• Employee responsibilities.
• Emergency considerations.

Employees performing the work should participate in the JSA process when appropriate.

Pre-Job Safety Meetings

Before higher-risk or non-routine operations begin, affected employees should review:

• Work scope.
• JSA/JHA.
• Site hazards.
• Employee assignments.
• Simultaneous operations.
• Required PPE.
• Communication.
• Emergency procedures.
• Stop-work expectations.

The plan should be revised when conditions change significantly.

Stop-Work Authority

Employees should understand their authority and responsibility to stop or suspend work when they identify an imminent danger, uncontrolled hazard, unexpected condition, or significant deviation from the work plan.

Work should not resume until the condition has been evaluated and appropriate controls have been established.

Employees should not be discouraged from exercising legitimate stop-work authority.

Oilfield Safety Inspections

Inspections should reflect the equipment and activities present at the worksite.

Potential inspection areas include:

• Rig floors.
• Derricks and masts.
• Wellheads.
• Pumps.
• Compressors.
• Tanks.
• Pressure lines.
• Mud systems.
• Engines.
• Generators.
• Electrical equipment.
• Cranes and hoists.
• Mobile equipment.
• Ladders and platforms.
• Walking-working surfaces.
• Emergency equipment.

Deficiencies should be documented and corrected.

Site Preparation

Oil and gas wellsite preparation may involve construction activities such as:

• Lease-road construction.
• Excavation.
• Grading.
• Pad preparation.
• Equipment access.
• Utility work.
• Material delivery.

Employees performing site-preparation activities should follow applicable construction-safety requirements.

Transportation and Vehicle Safety

Vehicle incidents are a major oilfield hazard because employees frequently travel long distances between remote worksites.

Vehicle-safety procedures should address:

• Driver qualification.
• Seat belts.
• Distracted driving.
• Speed.
• Fatigue.
• Journey planning.
• Weather.
• Road conditions.
• Remote travel.
• Vehicle inspection.
• Load securement.

Drivers should operate vehicles according to conditions rather than treating posted speed limits as safe under every circumstance.

Journey Management

Companies whose employees routinely travel to remote oilfield locations should consider journey-management procedures appropriate to their operations.

Planning may include:

• Destination.
• Route.
• Weather.
• Road conditions.
• Driver fitness.
• Expected arrival.
• Communication.
• Emergency contacts.

Employees should avoid unnecessary travel during dangerous conditions.

Fatigue and Driving

Long shifts, night work, extended travel, and remote locations can increase fatigue.

Employees should not operate vehicles or equipment when fatigue has impaired their ability to work safely.

Supervisors should consider travel time when scheduling extended shifts.

Vehicle Inspection

Vehicles should be inspected according to company procedures.

Employees should report conditions such as:

• Tire damage.
• Brake problems.
• Lighting defects.
• Steering problems.
• Fluid leaks.
• Damaged mirrors.
• Windshield damage.
• Other safety defects.

Defective vehicles should be removed from service when necessary.

Mobile Equipment

Oilfield operations may involve:

• Forklifts.
• Telehandlers.
• Loaders.
• Excavators.
• Skid steers.
• Cranes.
• Service trucks.
• Other mobile equipment.

Only trained and authorized employees should operate equipment requiring specialized qualification or authorization.

Spotters

Spotters should be used when necessary to control blind spots, backing, tight clearances, equipment positioning, or interaction between equipment and personnel.

Operators and spotters should agree on signals before movement begins.

The operator should stop if visual or reliable communication with the spotter is lost.

Struck-By and Caught-Between Hazards

Employees may be exposed to struck-by, caught-in, and caught-between hazards involving:

• Vehicles.
• Mobile equipment.
• Suspended loads.
• Tubulars.
• Rig equipment.
• Pressure lines.
• Moving machinery.
• Falling objects.
• Stored energy.

Employees should remain outside established danger zones unless their work requires entry and appropriate controls are in place.

Line-of-Fire Safety

Employees should recognize and avoid positions where they could be struck, crushed, pinned, sprayed, or otherwise injured if equipment moves or energy is unexpectedly released.

Line-of-fire hazards may include:

• Suspended loads.
• Tensioned lines.
• Pressure equipment.
• Moving vehicles.
• Rotating equipment.
• Tubulars.
• Stored mechanical energy.

Employees should continually evaluate their position as work progresses.

Red Zones and Restricted Areas

Where appropriate, the worksite should establish restricted areas around higher-hazard operations.

Access should be limited to employees whose duties require entry.

Restricted areas may be used around:

• Suspended loads.
• Pipe-handling operations.
• Pressure testing.
• Well-control activities.
• Crane operations.
• Moving equipment.

Drilling Operations

Drilling operations involve specialized equipment and changing hazards throughout the drilling process.

Potential activities include:

• Rigging up.
• Drilling ahead.
• Tripping pipe.
• Casing operations.
• Maintenance.
• Well control.
• Rigging down.

Employees should receive task-specific training appropriate to their duties.

Rigging Up and Rigging Down

Rigging up and rigging down may involve:

• Heavy equipment.
• Cranes.
• Suspended loads.
• Pinch points.
• Elevated work.
• Electrical hazards.
• Material handling.
• Vehicle movement.

Work should be planned and coordinated before major equipment movement begins.

Rig Floor Safety

Rig floors may contain:

• Moving equipment.
• Rotary equipment.
• Tubulars.
• Slippery surfaces.
• Tools.
• Hoses.
• Elevated work areas.
• Pressure equipment.

Good housekeeping, equipment guarding, communication, and controlled access are essential.

Drilling Ahead

Employees involved in active drilling should understand hazards associated with:

• Rotating equipment.
• Drilling fluids.
• Pressure.
• Tubulars.
• Well control.
• Machinery.
• Slips and falls.

Employees should remain clear of moving equipment unless their duties require otherwise.

Tripping Pipe

Removing and replacing drill pipe can expose employees to:

• Moving tubulars.
• Suspended loads.
• Pinch points.
• Tongs.
• Slips.
• Falls.
• Struck-by hazards.

Employees should follow established pipe-handling procedures and remain clear of line-of-fire hazards.

Casing Operations

Casing operations can involve large tubulars, lifting equipment, suspended loads, elevated work, and significant pinch-point hazards.

Procedures should address:

• Lifting.
• Rigging.
• Employee positioning.
• Communication.
• Suspended loads.
• Equipment inspection.

Well Control

Well-control procedures are critical for preventing uncontrolled releases of formation fluids.

Employees assigned well-control responsibilities should receive training appropriate to their duties.

Well-control procedures may address:

• Monitoring.
• Drilling-fluid conditions.
• Pressure indicators.
• Blowout prevention equipment.
• Communication.
• Emergency response.

Employees should not perform specialized well-control activities beyond their training and authorization.

Blowout Prevention Equipment

Blowout prevention equipment should be operated, inspected, tested, and maintained according to applicable procedures and equipment requirements.

Employees working around the equipment should understand:

• Pressure hazards.
• Stored energy.
• Restricted areas.
• Testing hazards.
• Emergency procedures.

Well Completion

After drilling reaches the planned depth, well-completion activities may involve casing, cementing, perforating, pressure equipment, service rigs, and installation of production equipment.

Completion operations should be evaluated for task-specific hazards before work begins.

Hydraulic Fracturing — When Applicable

Hydraulic fracturing operations may involve:

• High-pressure pumps.
• Pressure lines.
• Sand handling.
• Silica exposure.
• Chemicals.
• Mobile equipment.
• Noise.
• Large numbers of workers and contractors.

A site-specific JSA and coordination plan should address the hazards associated with the operation.

High-Pressure Fracturing Equipment

Employees should remain clear of high-pressure lines and equipment except when required for assigned work.

Pressure equipment should be:

• Properly installed.
• Inspected.
• Secured.
• Operated within appropriate limits.
• Depressurized before servicing.

Employees should never attempt to tighten, loosen, strike, or repair pressurized connections.

Silica Exposure During Hydraulic Fracturing

Handling large quantities of silica sand can generate respirable crystalline silica.

Where employees may be exposed, employers should evaluate exposure and implement appropriate controls.

Controls may include:

• Engineering controls.
• Dust collection.
• Enclosed systems.
• Work practices.
• Restricted access.
• Respiratory protection when required.

Flowback Operations — When Applicable

Flowback can involve high-pressure fluids, gases, hydrocarbons, chemicals, sand, and other materials returning from the well.

Procedures should address:

• Pressure.
• Ignition sources.
• Hydrocarbon gases and vapors.
• Employee positioning.
• Equipment integrity.
• Communication.
• Spill control.

Well Servicing and Workover

Well servicing and workover operations may involve specialized crews and equipment used to maintain, repair, restore, or increase production.

Potential activities include:

• Removing wellhead equipment.
• Pulling rods.
• Running rods.
• Pulling tubing.
• Running tubing.
• Pumping operations.
• Wireline operations.
• Other specialized services.

Task-specific procedures should reflect the equipment and operation being performed.

Pumping Units

Employees working around pumping units may be exposed to:

• Counterweights.
• Horseheads.
• Belts.
• Rotating equipment.
• Stored energy.
• Unexpected startup.

Equipment should be appropriately guarded and hazardous energy controlled during servicing.

Tubular Handling

Pipe, rods, casing, and tubing can create:

• Struck-by hazards.
• Pinch points.
• Crush hazards.
• Manual-handling injuries.
• Rolling hazards.

Mechanical handling equipment should be used when appropriate.

Employees should avoid placing hands or other body parts between tubulars and fixed objects.

High-Pressure Lines and Equipment

High-pressure lines and equipment can fail suddenly and release substantial energy.

Potential hazards include:

• Line rupture.
• Connection failure.
• Hose failure.
• Flying equipment.
• High-pressure fluid injection.
• Gas release.

Pressure systems should be installed, inspected, operated, and maintained according to applicable requirements and manufacturer specifications.

Pressure Testing

Pressure testing should be planned before pressurization begins.

Procedures should address:

• Test pressure.
• Equipment rating.
• Employee positioning.
• Restricted areas.
• Communication.
• Pressure release.
• Emergency response.

Nonessential personnel should remain outside established hazard areas.

Depressurization

Equipment should be verified as depressurized before employees disconnect, open, service, or repair components that could contain pressure.

Employees should consider trapped pressure and blocked sections of piping.

Hose and Connection Safety

Hoses, fittings, unions, and other pressure connections should be inspected before use.

Damaged or incompatible components should not be used.

Employees should remain clear of potential hose-whip and connection-failure paths.

Fire and Explosion Prevention

Oil and gas operations can release flammable gases and vapors from:

• Wells.
• Tanks.
• Trucks.
• Production equipment.
• Flowback equipment.
• Surface equipment.

Potential ignition sources include:

• Electrical equipment.
• Static electricity.
• Open flames.
• Hot work.
• Engines.
• Hot surfaces.
• Smoking.
• Lightning.
• Friction.

Ignition sources should be controlled according to the hazards present.

Hydrocarbon Gases and Vapors

Employees may encounter hydrocarbon gases and vapors during production, flowback, tank operations, fluid transfer, gauging, sampling, and other activities.

Potential hazards include:

• Fire.
• Explosion.
• Toxic exposure.
• Oxygen displacement.
• Loss of consciousness.

Employees should not rely on odor to determine whether an atmosphere is safe.

Tank Gauging and Sampling

Manual tank gauging, sampling, or opening tank hatches can expose employees to concentrated hydrocarbon gases and vapors.

Where these tasks are performed, procedures should address:

• Atmospheric hazards.
• Employee positioning.
• Ignition sources.
• Wind direction.
• Monitoring.
• Respiratory protection where required.
• Alternative measurement methods where feasible.

Employees should avoid placing their head or upper body directly over an open hatch.

Static Electricity

Operations involving movement of flammable liquids, gases, or materials may generate static electricity.

Bonding, grounding, equipment selection, and work practices should be used where required to control ignition hazards.

Hot Work

Welding, cutting, brazing, grinding, and other spark- or flame-producing work should be controlled around oil and gas operations.

Before hot work begins, employees should evaluate:

• Flammable gases.
• Vapors.
• Combustible materials.
• Tanks.
• Piping.
• Nearby operations.

Hot work authorization, atmospheric testing, fire watches, ventilation, and other controls should be used where appropriate.

Hydrogen Sulfide (H2S)

Oil and gas wells and production operations can release hydrogen sulfide.

H2S can present severe health hazards and may rapidly create life-threatening conditions.

The company’s H2S procedures should reflect the potential exposure at its worksites.

H2S Hazard Assessment

Before work begins in locations where H2S may be present, employers should evaluate:

• Well conditions.
• Process information.
• Previous monitoring.
• Nearby operations.
• Wind direction.
• Potential release points.
• Employee duties.

Controls should reflect the potential concentration and exposure.

H2S Monitoring

Appropriate atmospheric monitoring should be used where H2S hazards may exist.

Depending on conditions, monitoring may include:

• Fixed monitors.
• Portable instruments.
• Personal monitors.

Monitoring equipment should be inspected, maintained, calibrated, and used according to appropriate procedures.

H2S Alarms

Employees should understand:

• Alarm types.
• Alarm set points.
• Required response.
• Evacuation routes.
• Muster areas.
• Wind direction.
• Emergency communication.

Employees should respond immediately to alarms according to site procedures.

Wind Direction

Windsocks, streamers, flags, or other methods may be used where appropriate to help employees determine wind direction during a release.

Employees should know how wind direction affects evacuation.

H2S Respiratory Protection

When respiratory protection is required for H2S, respirators should be selected and used under the company’s Respiratory Protection Program.

Employees should not enter an unknown or immediately dangerous atmosphere unless appropriately trained, equipped, and authorized.

H2S Emergency Response

Emergency procedures should address:

• Alarm.
• Evacuation.
• Muster.
• Communication.
• Rescue.
• Medical response.

Employees should not attempt an unprotected rescue in an H2S atmosphere.

Confined Spaces

Oil and gas operations may contain confined spaces such as:

• Tanks.
• Vessels.
• Certain pits.
• Process equipment.
• Other enclosed spaces.

Spaces should be evaluated according to their actual configuration and hazards.

Where permit-required confined spaces exist, applicable entry procedures should be followed.

Atmospheric Testing

Confined-space atmospheric testing may evaluate:

• Oxygen.
• Flammable gases and vapors.
• H2S.
• Other toxic contaminants.

Testing equipment should be appropriate to the expected hazards.

Confined Space Entry

Where permit entry is required, procedures should address:

• Entry authorization.
• Atmospheric testing.
• Ventilation.
• Isolation.
• Attendants.
• Communication.
• Rescue.
• PPE.

Confined Space Rescue

Rescue procedures should be established before entry begins.

Employees should not enter a hazardous confined space to perform rescue unless they are appropriately trained, equipped, and authorized.

Lockout/Tagout

Oilfield equipment can contain electrical, mechanical, hydraulic, pneumatic, pressure, thermal, and other hazardous energy.

Applicable energy-control procedures should be followed during servicing and maintenance.

Equipment Shutdown

Before servicing begins, employees should:

• Identify energy sources.
• Shut down equipment.
• Isolate energy.
• Apply required locks or tags.
• Control stored energy.
• Verify isolation.

Equipment should not be returned to service until appropriate release procedures have been completed.

Stored Energy

Employees should consider stored energy in:

• Pressure systems.
• Hydraulic systems.
• Pneumatic systems.
• Springs.
• Counterweights.
• Elevated components.
• Rotating equipment.

Stored energy should be relieved, restrained, blocked, or otherwise controlled.

Machine Guarding

Oilfield employees may work around:

• Drawworks.
• Pumps.
• Compressors.
• Engines.
• Belts.
• Chains.
• Sprockets.
• Conveyors.
• Rotating shafts.
• Pumping units.

Required guards should remain in place during operation.

Employees should not bypass or remove guards except under controlled maintenance procedures.

Electrical Safety

Oilfield electrical systems may involve generators, motors, temporary power, electrical distribution equipment, and portable tools.

Employees should:

• Inspect equipment.
• Report defects.
• Protect cords.
• Maintain appropriate clearances.
• Follow hazardous-energy procedures.
• Use equipment suitable for the environment.

Only appropriately qualified employees should perform specialized electrical work.

Overhead Power Lines

Cranes, derricks, masts, trucks, and other equipment can contact overhead electrical lines.

Work should be planned to maintain applicable clearances and prevent equipment or loads from entering hazardous areas.

Fall Protection

Oilfield employees may work on:

• Derricks.
• Masts.
• Platforms.
• Tanks.
• Ladders.
• Elevated equipment.
• Other walking-working surfaces.

Appropriate fall-protection systems should be provided where required.

Working at Heights

Before elevated work begins, employees should evaluate:

• Access.
• Fall exposure.
• Anchor points.
• Equipment.
• Weather.
• Dropped-object hazards.
• Rescue considerations.

Dropped Objects

Tools, equipment, and materials can fall from elevated work areas.

Controls may include:

• Restricted areas.
• Tool retention.
• Proper storage.
• Toe boards.
• Barricades.
• Hard hats.

Employees should avoid standing beneath elevated work whenever possible.

Ladders

Ladders should be selected, inspected, and used according to applicable requirements.

Employees should:

• Maintain secure footing.
• Face the ladder while climbing.
• Maintain appropriate contact.
• Avoid carrying loads that prevent safe climbing.
• Remove defective ladders from service.

Rigging and Hoisting

Oilfield operations frequently involve lifting:

• Tubulars.
• Equipment.
• Pumps.
• Wellhead components.
• Tools.
• Other heavy materials.

Rigging equipment should be selected according to the load and inspected before use.

Suspended Loads

Employees should not stand or work beneath suspended loads.

Only personnel necessary for the operation should enter controlled lifting areas.

Rigging Inspection

Slings, hooks, shackles, wire rope, and other rigging components should be inspected according to applicable procedures.

Damaged equipment should be removed from service.

Crane Operations

Crane operations should be planned according to:

• Load.
• Capacity.
• Ground conditions.
• Radius.
• Rigging.
• Overhead hazards.
• Power lines.
• Employee positioning.

Operators, riggers, and signal persons should meet applicable training or qualification requirements.

Hand and Power Tools

Employees should inspect tools before use.

Damaged tools should be removed from service.

Tools should be appropriate for the task and used according to manufacturer instructions.

Hazard Communication

Oil and gas operations may use or produce hazardous chemicals.

The Hazard Communication Program should address:

• Chemical inventories.
• Safety Data Sheets.
• Labels.
• Employee training.
• Non-routine tasks.
• Contractor communication.

Employees should know the hazards of chemicals before using them.

Chemical Handling

Employees handling acids, caustics, solvents, treatment chemicals, drilling additives, or other hazardous products should use appropriate:

• Engineering controls.
• Work practices.
• PPE.
• Storage.
• Transfer methods.

Chemical Transfer

Chemical-transfer procedures should address:

• Hose condition.
• Connections.
• Compatibility.
• Spill containment.
• PPE.
• Communication.
• Emergency shutdown.

Employees should verify connections before transfer begins.

Spill Prevention and Response

Oilfield operations should maintain procedures appropriate to foreseeable releases of:

• Fuels.
• Crude oil.
• Produced fluids.
• Chemicals.
• Hydraulic fluids.
• Other materials.

Employees should know:

• How to stop work.
• How to report a spill.
• How to isolate the area.
• What PPE is required.
• When specialized response personnel are necessary.

Silica Exposure

Employees may encounter respirable crystalline silica during hydraulic fracturing, sand handling, certain construction activities, and other operations involving silica-containing materials.

Exposure should be evaluated and controlled according to applicable requirements.

Noise Exposure

Oilfield noise sources may include:

• Engines.
• Pumps.
• Compressors.
• Drilling equipment.
• Fracturing equipment.
• Generators.
• Machinery.

Employee exposure should be evaluated where hazardous noise may be present.

Hearing Conservation

Where employee noise exposure reaches applicable thresholds, the company should implement required Hearing Conservation measures.

These may include:

• Exposure monitoring.
• Audiometric testing.
• Hearing protection.
• Training.
• Recordkeeping.

Personal Protective Equipment

PPE should be selected according to the hazards present.

Depending on operations, PPE may include:

• Hard hats.
• Safety glasses.
• Goggles.
• Face shields.
• Gloves.
• Protective footwear.
• Flame-resistant clothing.
• Hearing protection.
• Respiratory protection.
• Fall-protection equipment.

Employees should receive training in required PPE use and limitations.

Flame-Resistant Clothing — When Required

Where employees are exposed to flash-fire hazards, appropriate flame-resistant clothing should be selected according to the hazard assessment and applicable requirements.

Employees should understand proper use, care, and limitations.

Respiratory Protection

When respirators are required, the company should maintain an appropriate Respiratory Protection Program.

Applicable elements may include:

• Hazard evaluation.
• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Maintenance.
• Program evaluation.

Heat Stress

Oilfield employees may perform physically demanding work outdoors in high temperatures.

Heat-illness prevention procedures should consider:

• Water.
• Rest.
• Shade or cooling.
• Acclimatization.
• Workload.
• PPE.
• Environmental conditions.

Employees should understand signs and symptoms of heat illness.

Cold Stress

Employees working in cold, wet, or windy conditions should receive appropriate protection.

Procedures should consider:

• Clothing.
• Work duration.
• Warming areas.
• Weather.
• Employee monitoring.

Fatigue Management

Oil and gas operations may involve:

• Extended shifts.
• Night work.
• Remote worksites.
• Long travel.
• Emergency operations.
• Physically demanding tasks.

Work schedules and travel should be evaluated to reduce fatigue-related risks.

Employees should report when fatigue may prevent them from safely performing assigned work.

Naturally Occurring Radioactive Material — When Applicable

Some oil and gas production operations may encounter Naturally Occurring Radioactive Material (NORM).

Where NORM is present or reasonably anticipated, the company should evaluate:

• Employee exposure.
• Contaminated equipment.
• Scale.
• Sludge.
• Work practices.
• PPE.
• Waste handling.

Specialized procedures should be developed when necessary.

Naturally Occurring Radioactive Material During Maintenance

Employees opening, cleaning, cutting, or repairing contaminated production equipment may encounter deposits containing NORM.

Affected equipment should be evaluated before work begins when NORM contamination is reasonably anticipated.

Housekeeping

Oil, mud, hoses, tools, pipe, cables, and debris can create significant walking-working-surface hazards.

Work areas should be maintained to reduce:

• Slips.
• Trips.
• Falls.
• Blocked access.
• Emergency-egress problems.

Spills should be corrected or controlled promptly.

Emergency Response

Oil and gas emergency planning should reflect the hazards of the specific worksite.

Potential emergencies may include:

• Fire.
• Explosion.
• H2S release.
• Well-control incident.
• Chemical release.
• Pressure-equipment failure.
• Severe weather.
• Medical emergency.
• Vehicle incident.

Employees should understand alarms, communication methods, evacuation routes, muster points, and assigned responsibilities.

Muster Areas

Muster locations should be selected according to site hazards and emergency scenarios.

Where atmospheric releases are possible, employees should understand how wind direction may affect the appropriate muster location.

Emergency Communication

Remote oilfield operations should maintain reliable methods for summoning emergency assistance.

Employees should know:

• Site location.
• Emergency numbers.
• Communication methods.
• Access routes.
• Information responders may need.

Medical Response

Oilfield locations may be remote from emergency medical services.

Emergency planning should consider:

• Communication.
• First-aid capability.
• Travel time.
• Site access.
• Employee location.
• Specialized rescue needs.

First Aid

Appropriate first-aid resources should be available according to workplace conditions and applicable requirements.

Employees should know how to obtain medical assistance.

Severe Weather

Oilfield operations may be affected by:

• Lightning.
• High winds.
• Tornadoes.
• Severe thunderstorms.
• Flooding.
• Extreme heat.
• Extreme cold.

Procedures should establish when operations should be suspended and where employees should seek shelter.

Incident Reporting and Investigation

Employees should promptly report occupational incidents, including:

• Injuries.
• Illnesses.
• Near misses.
• Fires.
• Explosions.
• Pressure releases.
• Chemical exposures.
• H2S alarms or exposures.
• Equipment failures.
• Vehicle incidents.
• Spills.

Significant incidents should be investigated to identify contributing factors and corrective actions.

Root Cause Analysis

Investigations should look beyond the immediate employee action and evaluate potential underlying factors such as:

• Procedures.
• Training.
• Supervision.
• Equipment condition.
• Maintenance.
• Hazard identification.
• Job planning.
• Communication.
• Staffing.
• Scheduling.
• Contractor coordination.
• Management systems.

Corrective actions should address identified causes rather than merely restating the rule that was violated.

Oilfield Safety Training

Employee training should reflect assigned duties and actual hazards.

Depending on operations, training may address:

• Oilfield orientation.
• JSA/JHA.
• Stop-work authority.
• H2S.
• High-pressure equipment.
• Line-of-fire hazards.
• Fire and explosion prevention.
• Lockout/Tagout.
• Confined spaces.
• Fall Protection.
• Rigging.
• PPE.
• Hazard Communication.
• Respiratory Protection.
• Silica.
• Heat stress.
• Emergency response.

Task-specific training should be provided before employees independently perform higher-hazard work.

Short Service Employees — When Applicable

Companies using a Short Service Employee program may identify employees who are new to the company, industry, position, or task and require additional supervision or mentoring.

The program may address:

• Identification.
• Orientation.
• Mentoring.
• Work restrictions.
• Competency verification.
• Removal from short-service status.

Contractor Safety

Contractor safety is particularly important where multiple companies perform simultaneous operations.

Coordination should address:

• Site orientation.
• Hazard communication.
• JSAs.
• Emergency procedures.
• Simultaneous operations.
• Operator requirements.
• Contractor responsibilities.
• Incident reporting.

Contractors should understand the hazards that may affect their employees before work begins.

Simultaneous Operations

When multiple operations occur at the same time, employers should evaluate how one activity may affect another.

Potential conflicts may involve:

• Hot work.
• Pressure operations.
• Crane lifts.
• Vehicle movement.
• Chemical transfers.
• Well servicing.
• Production operations.

Work should be coordinated before incompatible or interacting operations begin.

Oilfield Safety Meetings

Regular safety meetings can reinforce safe work practices and address current site hazards.

Potential topics include:

• Line-of-fire hazards.
• H2S.
• Pressure equipment.
• Vehicle safety.
• Rigging.
• Hand safety.
• Housekeeping.
• PPE.
• Heat stress.
• Fatigue.
• Recent incidents and near misses.

Recordkeeping

Oil and gas employers should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Injury and illness records.
• Exposure monitoring.
• Respiratory Protection records.
• Hearing Conservation records.
• Equipment inspections.
• JSA/JHA records.
• Safety inspections.
• Incident investigations.

Medical and exposure records should be maintained according to applicable requirements.

Additional Safety Programs

Depending on oil and gas operations and employee exposures, additional programs may be necessary for:

• Job Safety Analysis (JSA/JHA).
• Stop-Work Authority.
• Short Service Employees.
• Contractor Safety.
• Driver Safety & Defensive Driving.
• Fleet Vehicles.
• Mobile Equipment.
• Heavy Equipment.
• Hydrogen Sulfide.
• Fire Prevention.
• Hot Work.
• High-Pressure Systems.
• Lockout/Tagout.
• Machine Guarding.
• Electrical Safety.
• Confined Space.
• Fall Protection.
• Ladder & Stairway Safety.
• Rigging & Material Handling.
• Crane Safety.
• Hand & Power Tools.
• Hazard Communication.
• Chemical Safety.
• Respiratory Protection.
• Silica Exposure Control.
• Hearing Conservation.
• Personal Protective Equipment.
• Heat Stress Prevention.
• Cold Stress.
• Fatigue Management.
• Naturally Occurring Radioactive Material.
• Spill Prevention & Response.
• Hazardous Waste Management.
• Emergency Action Plan.
• First Aid.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the company’s operations, equipment, chemicals, client requirements, and employee exposures make them applicable.

Building an Oil & Gas Safety Manual

A useful Oil & Gas Safety Manual should reflect the company’s actual position within the oil and gas industry.

A drilling contractor may require extensive procedures for rigging up, drilling, tripping pipe, casing, well control, derricks, and rig-floor operations.

A well-servicing company may place greater emphasis on workover rigs, rods, tubing, pressure equipment, pumping units, and specialized services.

A hydraulic-fracturing contractor may require extensive controls for silica, pressure pumping, chemical handling, mobile equipment, flowback, and simultaneous operations.

A production company may focus more heavily on wellheads, tanks, production equipment, H2S, hydrocarbon gases and vapors, gauging, sampling, maintenance, and contractor coordination.

The applicable programs should therefore be selected according to the work actually performed rather than automatically assigning every oilfield program to every company.

Customized Oil & Gas Safety Manuals

An Oil & Gas Safety Manual can be developed around the company’s drilling, well servicing, completion, production, hydraulic fracturing, equipment, chemicals, vehicles, contractors, client requirements, and other occupational hazards.

The finished manual may incorporate applicable programs for H2S, High-Pressure Systems, Fire Prevention, Lockout/Tagout, Confined Space, Fall Protection, Rigging, Mobile Equipment, Hazard Communication, Respiratory Protection, Silica, PPE, Heat Stress, Fatigue Management, Emergency Response, Contractor Safety, JSA/JHA, and other hazards present within the operation.

This provides drilling contractors, well-service companies, oilfield service companies, producers, and other oil and gas employers with a practical safety manual organized around the work their employees actually perform.