Flash Fire Fatality: What Every Oil & Gas Worker Should Know About Hazard Zones

Flash Fire Fatality: What Every Oil & Gas Worker Should Know About Hazard Zones

What began as a standard repair job ended in tragedy.

Three workers were tasked with fixing a leaking crude oil flow line that connected a production well to its tank battery, which is a typical task in the oil and gas industry. They dug a trench, removed a section of the pipe, and began preparing the exposed line for threading. But in a matter of seconds, a spark from an electric pipe threader ignited flammable vapors, setting off a flash fire that engulfed the trench.

Two workers were hospitalized with severe burns. One of them didn’t survive.

This incident is a reminder of just how fast things can go wrong when hazards are both underestimated and overlooked. It highlights the importance of job hazard analysis (JHA), proper equipment selection, atmospheric monitoring, and continuous safety training.

Lessons

• Perform a job hazard analysis (JHA) prior to beginning work to determine potential hazards of the job and appropriate controls. For example: leaking flammable vapors from equipment that had previously contained hydrocarbons, control of ignition sources, working in excavations, and lockout/tagout.
  
  
• Do not use electrical tools and equipment that are not approved for the hazardous location where the work is to be performed, i.e., do not allow unapproved electrical tools and equipment to be an ignition source for flammable vapors. 
  
  
• Develop and implement a hot work permit program that includes atmospheric monitoring for concentrations of flammable vapors and provide ventilation to limit the concentration of flammable vapors to below 10% of their LEL. Provide and require the use of flame-resistant clothing (FRC) for workers who are exposed to flash-fire hazards.
  
  
• Provide worker training that emphasizes the following:
  Recognizing the hazards of working with piping and other equipment for locations where flammable vapors might be present. Using electrically approved tools and equipment for locations where flammable vapors might be present. Recognizing the hazards of working in trenches, e.g., engulfment hazards and fire/explosion hazards, due to the fact that flammable vapors accumulate and do not readily dissipate from trenches and low-lying areas.

Workers in the oil and gas industries face the constant risk of fire and explosion due to the ignition of flammable vapors or gases. Ignition sources can include static electricity, electrical tools, open flames, lightning, cigarettes, cutting and welding equipment, hot surfaces, and frictional heat. Take action now to prevent a tragic event like this from happening to your employees.

 For more jobsite safety tips, contact your local Risk Control Consultant. Click the button below to find an agent near you. 

For information purposes only. BITCO's blog content does not address all potential circumstances and is not a substitute for business, safety, or legal consultation.