A risk-based approach to safety mitigates offshore fire hazards
By Ariana Hurtado, Editor-in-chief
Hazards related to fire and explosion pose a threat to lives, assets and inventories in the offshore energy industry.
On May 20, a fire broke out on Chevron’s Benguela Belize Lobito Tomboco (BBLT) deepwater platform operated by gas consortium CABGOC (Cabinda Gulf Oil Co. Ltd.), an affiliate of Chevron. The fire occurred while the platform, located offshore Angola, was undergoing scheduled maintenance. Three workers died, and another 15-17 people were injured. As of May 30, an investigation into the cause of the fire was still underway.
In another example, two large oil tankers were on fire on July 19, 2024, after colliding near Singapore, the world's biggest refueling port. Two crew members were airlifted to the hospital and others were rescued from life rafts. The exact circumstances leading to the incident were reported as unknown.
Corrosion management and asset maintenance
Corrosion of steel structures and process equipment is a hazard that can lead to the equipment or structures being compromised, so safeguarding assets from fires is critical. Effective corrosion management of steel infrastructure not only reduces the risk of failure and damage, but also extends the lifespan of existing infrastructure, reduces the need for steel replacement and limits associated environmental impacts, according to Jotun.
Jotun, a Norway-based paint manufacturer and exterior protection specialist, recently conducted a survey to assess the perspectives of senior decision-makers and those who are responsible for maintenance at both onshore and offshore oil and gas assets. Working with Censuswide, the survey collected the views of 1,017 senior professionals in the onshore and offshore oil and gas industry across 10 countries, exploring maintenance management strategies and the near-term outlook.
The report showed that:
- 76% of professionals believe reducing risks of fire-related incidents is an important driver behind companies' maintenance strategies;
- 74% say protective coatings or paints play an important role in reducing these risks; and
- 56% of respondents say corrosion represents a high risk as a fire hazard.
Offshore recently spoke with Andy Czainski, Jotun's global category manager of fire protection, about fire reduction strategies, the challenges companies are facing when trying to implement those techniques and maintenance best practices.
Offshore: What are the most effective ways companies can reduce fire risks offshore?
Czainski: Offshore facilities have several safety challenges arising from their operational environment and function. The main safety challenges whilst handling volatile hydrocarbons, often at high pressure and temperature are fire and explosion hazards. Hydrocarbon fires pose a serious risk of reduced structural integrity, endangering the lives of operation personnel and fire responders alike. The presence of flammable hydrocarbons requires robust structural fire protection and suppression systems, as well as strict control of potential ignition sources.
Furthermore, the remoteness of offshore assets and the confined nature of operations add challenges for emergency response and evacuation. To address these challenges, a risk-based approach to fire prevention and structural protection is essential.
Identification of hazards and incorporating consequence modeling allows operators to estimate the potential impact of a fire or explosion on personnel and property. Such information can then be used in the design of both active and passive fire protection systems, which can prevent escalation and extend the period of integrity of the structure.
This combination of risk and consequence analysis, combined with implementation of appropriate passive and active fire protection mitigation, will contribute to substantially reducing hydrocarbon fire-related risks offshore.
Offshore: Jotun's report states awareness is increasing. What are the challenges or the causes for hesitancy that offshore companies face trying to implement fire protection strategies?
Czainski: Identification of hazards, consequence modeling and establishing suitable fire mitigation plans and specifications is well recognized as being safety critical by operators, and they are committed to compliance and operational safety of their assets. However, the process is often considered complex and requiries a high degree of specialized knowledge, preparing detailed documentation supporting compliance with relevant regulatory frameworks.
Operators, engineers and EPC contractors have access to only a limited and finite pool of industry specialists who have the necessary knowledge, experience and capability to support their new construction or maintenance projects.
The industry is currently committed to increasing awareness of the resources available to operators and other stakeholders.
Offshore: What can be done to spread more awareness around the importance of specifying suitable fire protection measures offshore?
Czainski: There is a wealth of knowledge and experience within the passive fire protection (PFP) industry.
PFPNet is an umbrella organization with the aim to improve awareness and standards, safety, competence and education across the hydrocarbon fire protection sector. A large and growing membership includes major operators, legislators, certification bodies, universities and representatives from the supply chain. PFPNet is becoming a key hub for technical information, safety-related design guides as well as publication covering many aspects of fire safety. PFPNet holds annual technical and other regional conferences, where offshore safety matters are presented as well as information on current work programs and resources are shared.
Other reference organizations include the Fire and Blast Information Group (FABIG), which publishes highly regarded technical notes covering offshore safety. FABIG holds regular meetings where safety professionals can get an in-depth understanding of the risks, consequences and solutions related to hydrocarbon fire hazards.
Offshore: What's the longevity of coatings and the maintenance best practices for fire protection coatings on offshore assets?
Czainski: Epoxy intumescent fire protection coatings have proven performance for more than 50 years in some of the most challenging offshore environments. Epoxy intumescent systems are available that have been tested to NORSOK M501:2020, considered the gold standard for performance testing of intumescent coatings in challenging offshore environments. Many operators insist on compliance with this standard as it provides confidence that materials will deliver the certified fire performance, even after many years of exposure in some of the world's harshest environments.
Aged and deteriorating PFP materials applied to offshore facilities represents an industry wide concern. The Energy Insititute has published several PFP related guidance documents including "Guidelines for In-service Management of Passive Fire Protection Coatings Systems" (2021). This can help operators understand how the integrity of their existing PFP systems can impact operational safety and what a sensible acceptance criterion is for damaged PFP.
Importantly, the guidance can help operators identify types of PFP anomalies or deterioration and how severe these may be. This can then facilitate a prioritized plan for remedial action using a risk-based approach. Once completed, PFP suppliers can assist with suitable remedial specification, ranging from repair through replacement.
PFPNet is also publishing guidelines, such as "Guidelines for Assessing Age and Damage Severity on all Types of PFP Systems," which incorporates the experience, input and best practice from contributing members.
