More than 150 oil refineries in the United States conduct day-to-day business operations from exploration and processing to refining and transporting dangerous materials. These operations increasingly pose myriad safety risks to employees and possibly local communities, making safety precautions at every level a crucial strategy for a refinery.
In response to stricter governmental and industry regulations, decision-makers continue to evaluate solutions designed to improve emergency preparedness strategies. Technology continues to evolve, awarding greater features and flexible options that provide critical alerting and information across multiple communication channels. The oil and gas industry has made great strides in maintaining an unwavering commitment to safety. However, some companies may unintentionally overlook new and updated technologies and best practices that should be central components in year-round, proactive safety planning.
Many oil and gas refineries are searching to find the right mix of solutions to achieve better overall compliance. For instance, OSHA recently sent letters in June 2009 to more than 100 oil refineries, providing data on compliance issues found under OSHA’s Refinery National Emphasis Program (NEP) and urging refiners to comply with their obligations under the process safety management (PSM) standard. This standard requires employers to develop and incorporate comprehensive, site-specific safety management systems to reduce the risks of fatal or catastrophic incidents.
In comparison, the NEP issued nearly 350 PSM citations to 14 refineries in 2007 – the program’s first year – demonstrating today’s amplified focus on compliance. This enforced the strong awareness companies needed to ensure facilities meet or exceed safety standards.
To maximize the effectiveness of an integrated emergency planning and communication program, facilities should clearly define objectives at the earliest stages of system development. Because each oil and gas refinery is different, each facility presents unique requirements in the areas of emergency preparedness and mass notification. In general, recommended guidelines include the following considerations: assessing potential risks; outlining anticipated emergency scenarios; previewing possible contingencies; developing and documenting emergency procedures; deploying sufficient system resources based on best practices; and implementing management and employee training.
Thoroughly defined objectives that reflect the requirements of a particular plant facility will invariably result in a unique set of priorities. In one case, these priorities may stress “when” and “who” needs to be notified.
In another instance, the focus may be on determining the most effective method to ensure that everyone – employees, management, visitors, contractors, etc. – in the facility are alerted during different types and levels of emergencies. And still another facility may emphasize the need for real-time bi-lingual emergency alerts, or multiple network support, or ad hoc and system-automated alert notifications.
Beyond supporting emergency response, today’s mass notification systems can be a valuable asset for everyday, non-emergency, intra- and inter-facility communications. This has become particularly evident in the deployment of interoperable, multi-device communications technology that not only enhances overall plant communications, but provides a host of useful software-based management and administrative tools. Additionally, many of the more traditional approaches to mass notification (e.g., public address and intercom systems, e-mail, and voice and text messaging) provide everyday functionality for communications and process control that represents attractive potential for return on investment.
A Unique Facility’s Solution
A close look at one of world’s most challenging work environments can help illustrate these points. Qatargas is one of the world’s largest liquefied natural gas (LNG) facilities based on production volume. However, being a dominant player with a world-class facility brings its own set of distinct challenges when integrating mass notification solutions.
Qatargas specified a need for a public address/general alarm (PA/GA) system designed to achieve total integration with the facility’s fire and gas warning systems. The best solution for Qatargas was to install a PA/GA system using a fiber optics based network to provide a redundant system with addressable speakers, user-friendly touch screen control panels and automated testing and diagnostics that simplified both operation and maintenance requirements while assuring the highest degree of reliability.
The facility implemented a strategic emergency plan, limiting the number of warnings/alerts. They chose a single alert tone for all emergency situations. Though the system is capable of providing hundreds of tones, relying on a single tone eliminates the need for employees to memorize, interpret and react to multiple tones. The single tone is followed by automated voice instructions. Qatargas’ employees consist of 38 different nationalities, so management conducts a weekly routine automated test allowing personnel to familiarize themselves with the ALARM/ALL CLEAR signals.
Qatargas now incorporates more than 3,000 individual loudspeakers, which ranks as one of the world’s largest systems. The system integrated seamlessly with Qatargas’ existing warning systems, which is something facilities should pay close attention to in order to avoid unnecessary costs.
Evaluating Notification Systems
In developing a mass notification site strategy, it is critical to evaluate systems for their ability to notify employees of emergency situations at determined locations. In some areas of a facility, such as high-noise locations, audible alarms may not be sufficient. Devices such as horns, sirens, public address systems, intercoms, flashing lights, etc., can be used for site notification depending upon the size of the site and the variety of potential emergencies. Notification systems may vary from single-signal units to multifunctional/code series systems. If a code system is employed, all employees need to be aware of the various codes and what they represent.
Another component of mass notification/alarm system planning centers is the ability to notify community officials, emergency response agencies (fire, police and emergency medical personnel), neighboring facilities and the community at large. These types of alarms will vary depending on the geography of the community, and the pre-established intent of the alarm system. Telecommunications or special radios can be used to notify these groups, while nearby facilities can be alerted by audible alarms. In almost all cases — both internal and external — consideration should be given to the need for auxiliary power supplies.
Safety Preparation Never Stops
Those responsible for a facility’s safety preparation understand that safety is a continuous process that requires constant vigilance and an ongoing investment.
However, these commitments are minor when compared to the substantial, and potentially devastating, risks to human life and lasting reputational damage a major accident or other safety breach can cause. Facility managers are recommended to strengthen cooperative relationships with suppliers to share a commitment to apply real-world best practices and proven technologies that form the backbone of today’s best-prepared safety programs.
Ray White is director of integrated systems for Federal Signal, Federal Signal Safety and Security Industrial Division. White can be reached at This e-mail address is being protected from spambots. You need JavaScript enabled to view it or 708-534-3400.
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