LECTURE NOTES 4

DESIGN
Emergency Eye or Body Wash Stations
Where the eyes or body of personnel may be exposed to injurious materials, eyewash and
shower equipment for emergency use shall be provided. For information on emergency
eyewash and shower equipment, see ANSI Z358.1.

Critical Equipment
Critical equipment is defined as equipment and other systems determined to be essential in
preventing the occurrence of, or mitigating the consequences of an uncontrolled event. Such
equipment may include pressure vessels, pressure relief devices, compressors, alarms,
interlocks, and emergency shutdown systems.
1. Critical equipment should be periodically inspected and tested as recommended by the
manufacturer or in accordance with recognized engineering practices.
2. When using nondestructive testing (NDT) methods, qualified persons should conduct
the tests in accordance with recognized methodology and acceptance criteria. Certified
NDT inspectors shall be trained per ASNT RP No. ASNT-TC-1A.
3. Other types of inspection should be conducted by qualified persons.
4. When critical equipment is removed from service, a program should be in place to
ensure equivalent protection is provided.
Changes to Critical Equipment
Procedures to manage changes (except for “replacements in kind”) to critical equipment should
be implemented, as appropriate. These procedures should address the following prior to making
the change:
1. The basis for the proposed change.
2. Impact of change on safety and health.
3. Modifications to operating procedures.
4. Authorization requirements for the proposed change.
Employees whose job tasks will be affected by the change in the critical equipment should be
informed of the change prior to start-up.

Fire Prevention
 1. Safe storage and location of combustible and flammable materials and the prevention
of accumulation of rubbish are important to fire prevention. Smoking shall be
prohibited at or in the vicinity of operations that constitute a fire hazard. Such locations
should be conspicuously posted with a sign, “NO SMOKING OR OPEN FLAME,” or
equivalent.
2. Smoking shall be permitted only in areas designated for smoking.
3. Change rooms and other buildings where smoking is permitted should be located in
areas designated safe for smoking.
4. No source of ignition should be permitted in an area where smoking has been
prohibited, unless it is first determined safe to do so by the supervisor in charge or his
designated representative.
5. Potential sources of ignition should be permitted only in designated areas located at a
safe distance from the wellhead or flammable liquid storage areas.
6. Equipment, cellars, ground areas around and adjacent to the facility should be kept free
from oil and gas accumulations that might create or aggravate fire hazards.
7. Combustible materials such as oily rags and waste should be stored in covered metal
containers and the covers kept in place.
8. Natural gas or liquefied petroleum gas shall not be used to operate spray guns or
pneumatic tools.
9. Material used for cleaning should have a flash point of not less than 100°F.
Fire Protection
1. Firefighting equipment shall not be tampered with and shall not be removed for other
than fire protection, firefighting purposes, and services. A firefighting water system
may be used for wash down and other utility purposes so long as its firefighting
capability is not compromised.
2. Fire extinguishers and other firefighting equipment should be suitably located, readily
accessible, and plainly labeled as to their type and method of operation.
3. Fire suppression equipment (extinguishers, fixed systems, etc.) should be periodically
inspected and maintained in operating condition at all times. A record of the most recent
equipment inspection should be maintained.
4. Portable fire extinguishers shall be tagged with a durable tag showing the date of the
last inspection, maintenance, or recharge or accomplished using other acceptable
recordkeeping media. Inspection and maintenance procedures should comply with
NFPA 10.
 5. Personnel should be familiar with the location of fire control and selected personnel
trained in the use of such equipment. Firefighting equipment shall be accessible and
free of obstructions.

Grounding & Bonding

Production facilities are subject to various forms of electrical hazards that must be protected
against. Static electricity can be generated by fluid movement in vessels, piping and tankage.
These results in static sparks being generated which can be an ignition source. Lightning strikes
to a facility are also an ignition source. Electrical equipment failure can occur exposing
personnel to shock hazards. For guidelines to address these potential risks, refer to industry
recommended practices such as API RP 2003 Protection against Ignition Arising out of Static,
Lightning, and Stray Currents and NFPA 77 Static Electricity.

Flammable Liquids
Containers
1. Hand portable containers for storing flammable liquids should be Underwriters
Laboratories (UL) listed or Factory Mutual (FM) approved, or equivalent.
2. Tanks, drums, and other containers containing flammable liquids should be properly
labeled to denote their contents and should be properly stored when not in use.
3. Metal or other conductive material containers should be used in handling, storing, or
transporting flammable liquids. The handling of flammable liquids in plastic containers
is potentially dangerous due to static charge buildup. Metal parts on any plastic
containers used in such service shall be bonded to the fill connection. If plastic
containers are used, the conductive fill connection or a grounded rod should be inserted
prior to filling the container with any flammable liquid. See NFPA 77 and API RP 2003.
Fuel and Oil Transfers and Refueling
1. Hydrocarbon-fueled engines should be shut down during refueling operations.
2. Fuel tanks should be monitored while they are being filled to prevent overfill and
spillage.
3. During refueling operations, the filling nozzle should be kept in contact with the intake
pipe to ensure bonding and prevent fuel spillage.
Liquefied Petroleum Gas (LPG) and Compressed Gas
1. Handling, connecting, and transfer operations involving liquefied petroleum gas (LPG)
shall conform to NFPA 58 Standard for the Storage and Handling of Liquefied
 Petroleum Gases, and NFPA 55 Compressed and Liquefied Gases in Portable
Cylinders.
2. Ignition Source Control. Ignition source controls shall be established in any area where
flammable or oxidizing compressed gases are stored or used.
3. Protective Caps. Where compressed gas cylinders are designed to accept valve
protective caps, the user should keep such caps on compressed gas cylinders at all times
except when being filled or connected for use.
4. Where gas-tight valve outlet caps or plugs are provided, the user should keep such
devices on the valve outlet at all times except when compressed gas cylinders are being
filled or connected for use.
5. Compressed or liquefied gas cylinders in use or in storage shall be secured to prevent
them from falling or being knocked over.
6. Compressed gas cylinders should be transported, stored and used in an upright position.
7. Compressed gas cylinders exposed to fire shall not be used until they are requalified in
accordance with the pressure vessel code under which they were manufactured.
8. Containers that show denting, bulging, gouging, or excessive corrosion should be
removed from service.
9. Repair or alteration of containers shall comply with the regulations, rules, or code under
which the container was fabricated.
10. Compressed gas cylinders should be marked or labeled in accordance with CGA C-7
Guide to the Preparation of Precautionary Labeling and Marking of Compressed Gas
Containers. Such markings or labels should not be removed.
11. Compressed gas cylinders shall not be placed where they could become a part of an
electrical circuit.
12. Compressed gas cylinders should not be exposed to temperatures exceeding 125°F.
Cylinders shall not be subjected to direct heating to increase vapor pressure.
13. Stoves and heaters used with LPG fuel should only be used in well-ventilated areas.
Personnel should ensure proper ventilation exists before lighting the heater/ stove. All
hoses and connections on LPG stove or heater systems should be checked frequently to
ensure they do not leak.
a. Only qualified personnel should be allowed to fill LPG bottles. Protective
gloves should be worn when refilling or replacing LPG bottles. There is a
possibility of freeze burns if propane comes in contact with skin.
Storage
1. Flammable liquids storage areas within any building or shed should:
a. Be adequately vented.
b. Have unobstructed exit(s) leading from the building.
c. Be maintained with due regard to fire potential with respect to housekeeping
and materials storage.
d. Be identified as a hazard and have appropriate warning signs posted.
e. Have a Class BC fire extinguisher (see NFPA 10) readily available.
f. Be properly classified for electrical installations in accordance with API RP 500
or API RP 505.
2. Paint and solvents should be stored in an adequately vented area safely away from heat
and ignition sources.
3. Flammable liquids should not be stored within 50 ft (15.2 m) of the wellbore, except
for fuel in the tanks of operating equipment. Where terrain and location configuration
do not permit maintaining this distance, equivalent safety measures should be taken.

Equipment
Generators, Motors, and Lighting
1. All electrical conductors and switch gear shall be sized in accordance with NFPA 70.
2. All generators should have an overload safety device that will provide protection from
shorting and burnout.
3. When adequate fixed illumination cannot be made available, temporary portable lights
approved for the electrical classification should be provided. Where possible,
floodlights in use should be placed in positions so as not to impair vision of persons in
the work area. Operations should not be performed using vehicle headlights as a
substitute for lighting.
4. All electrical extension cords shall be properly insulated and plugs and receptacles shall
be in good condition.
5. Light fixtures should be placed and maintained to provide illumination for work areas
in conformance with NECA/IESNA-502-99 Installing Industrial Lighting Systems
ANSI Approved.
6. Repairs to electrical equipment shall not be performed unless the power source has been
isolated and the control has been locked out/tagged out, and the person making the
repairs is authorized to do so.
 7. Electric motors, generators, and control panels shall be grounded.

Electrical Systems
Electrical Systems Equipment
1. Electrical equipment used in hazardous locations should be designed for such locations,
and listed or approved by a nationally recognized testing laboratory. All wiring
components and electrical equipment should be maintained in accordance with the
manufacturer’s recommendation.
2. Wiring should be replaced or properly repaired and sealed as necessary when insulation
damage is detected. Because of fire and other hazards, makeshift wiring components
and installations should not be used.

Classification of Areas
Classification of areas shall be in accordance with API RP 500 and RP 505.

Tanks, Separators and Heater Treaters

1. Tanks, separators and heater treaters should be installed and maintained in accordance
with accepted engineering practices or manufacturers recommendations. See API
RP12R1, Specs 12J, 12K, 12L, 12P and RP12N.
2. Walking directly on the roof of a tank is discouraged. However, if personnel are
required to access the roof of a tank, roof integrity shall be checked and appropriate
walking surfaces, guardrails or fall protection shall be provided.

Vapor Recovery Systems (Systems Designed to Minimize Vapor Releases to the

Environment)
1. This section describes the safety guidelines for vapor recovery systems, especially
thermal combustion systems and carbon absorption systems. See NFPA 30 for
additional information.
2. Vapor recovery systems should be considered potential sources of ignition; facility
design shall consider system location with respect to potential sources of hydrocarbon
vapors.
3. Procedures should be developed for switching carbon beds and changing out the
activated carbon in the absorbers.
4. Devices should be installed to prevent a flame from propagating from the vapor
recovery unit into the production equipment. See API RP12N.