Hazards of Fluid Transfer in Oil and Gas

The transfer of fluids is a critical step in the oil and gas supply chain. Fluids transferred can include process fluids, produced water, flowback fluids, condensate, and crude oil. However, there are several health hazards associated with fluid transfers in oil and gas. In these activities, there is a risk of spills, fires and explosions, health hazards due to exposure to chemicals, and environmental concerns. The CDC has reported that from 2016-2020 at least 12 oil and gas worker fatalities occurred during the transfer of process fluids in the US. Incidents involving transfer fluids are also cited in WorkSafe BC’s annual report delivered to the Oil and Gas Industry in Ft St John.

Fluid transfer often involves a truck driver who needs to transfer fluids by themselves. This lone-worker situation elevates the risk of the activity and makes it difficult to get timely help, particularly in remote and isolated areas. Incidents involving fluid transfer activities have included cardiac events, combustion-related explosions, being struck by a vehicle, exposure to hydrogen sulfide, and heat stroke. To prevent accidents, it is important to implement proper training and safety protocols, proper maintenance of equipment, and effective hazard communication.

Key Takeaways

Fluid transfer hazards are known and preventable. The main risks are hydrocarbon gases and vapours, hydrogen sulfide, oxygen-deficient air, fires and explosions, and spills.
Lone work raises the stakes. Truck drivers often transfer fluids alone at remote sites, so a small incident can become serious before help arrives.
Assess every transfer before it starts. A chemical risk assessment identifies the hazards of each fluid and the controls each activity needs.
Equipment and communication do the rest. Inspected hoses, valves and monitors, plus clear hazard communication and emergency procedures, prevent most incidents.

How to improve safety in Fluid Transfers

1. Hazard awareness and assessment

All staff involved in fluid transfer work activities should undergo appropriate training to recognize potential hazards and to understand the protocols established to prevent accidents. Hazards during fluid transfers are known, understood and preventable. These hazards include the inhalation of chemicals such as hydrocarbons and hydrogen sulfide, the creation of oxygen-deficient atmospheres, and the potential for fires and explosions. Chemical risk assessments will determine the appropriate controls for each activity.

2. Controls and equipment inspection and maintenance

Equipment used for fluid transfers such as piping, hoses and valves, control systems and monitors need to be properly maintained and inspected regularly.

3. Communication protocols

Establish a hazard communication and training program to make workers aware of the location of potential hazards, and what emergency procedures are in place in case an accident does occur. To avoid devastating consequences, policies and procedures must be strictly adhered to.

Fluid transfer hazards and controls: a quick reference

Hazard	How it happens during fluid transfer	Example controls
Hydrocarbon gases and vapours	Vapours released when opening hatches, connecting hoses or venting tanks	Closed-loop transfer, standing upwind, personal gas monitors
Hydrogen sulfide (H2S)	Sour fluids, produced water and flowback can release H2S	H2S monitors, site-specific H2S procedures, respiratory protection where required
Oxygen-deficient atmospheres	Gases and vapours displace oxygen around tanks and low-lying areas	Atmospheric testing before work, avoiding enclosed and low-lying spaces
Fires and explosions	Flammable vapours meet an ignition source, including static electricity	Bonding and grounding, controlling ignition sources, flame-resistant clothing
Spills and releases	Hose, valve or fitting failure, or overfilling a tank or truck	Regular equipment inspection and maintenance, spill response kits
Lone work in remote areas	Drivers transfer fluids alone, far from help	Check-in procedures, emergency response planning, reliable communication
Vehicles, heat and fatigue	Moving trucks on site, hot weather and long shifts	Traffic control, rest and hydration breaks, heat stress awareness

Frequently Asked Questions

What are the main hazards of fluid transfer in oil and gas?

The main hazards are inhaling hydrocarbon gases and vapours or hydrogen sulfide, oxygen-deficient atmospheres, fires and explosions, and spills. Workers have also been hurt by vehicles, heat stroke and cardiac events during fluid transfers.

Why is lone work a concern during fluid transfers?

A truck driver often transfers fluids alone, sometimes at remote and isolated sites. If something goes wrong, such as a gas exposure or a medical event, it can be hard to get timely help. Check-in procedures and emergency plans reduce that risk.

How can workers be protected from hydrogen sulfide during fluid transfers?

Know which fluids can carry hydrogen sulfide, wear a personal H2S monitor, and follow the site’s H2S procedures. Hydrogen sulfide can deaden the sense of smell at higher concentrations, so workers should never rely on odour to detect it.

What controls reduce the risk of fluid transfer incidents?

Work through the hierarchy of controls: remove the need for workers to be exposed where possible, then use engineering controls such as closed-loop systems and bonding and grounding, then safe work procedures and training, and finally personal protective equipment. A chemical risk assessment shows which controls each activity needs.

What training do workers involved in fluid transfers need?

Workers need to recognize the hazards of the fluids they handle, understand the safe work procedures and controls in place, and know the emergency procedures if an incident occurs. A hazard communication and training program keeps that knowledge current.

Watch the latest industry training video on safe fluid transfer

Collaboration within the oil and gas industry and sharing of best practices are essential in preventing incidents and to continuously improve the industry’s safety record. To learn more, we recommend watching Understanding Hazards, Risks, and Controls for Safer Fluid Transfers in Oil and Gas Extraction. This 8-minute video provides recommendations for controlling hazards in fluid transfer based on the hierarchy of controls.

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