The oil and gas industry is one of the most hazardous sectors in the world. According to data from the U.S. Bureau of Labor Statistics, workers in oil and gas extraction are more than six times as likely to die on the job compared to the average across all industries. These elevated risks stem from exposure to dangerous chemicals, high-pressure equipment, extreme temperatures, and physically demanding work in remote environments.
The Occupational Safety and Health Administration (OSHA) frequently cites violations in oil and gas operations under General Industry Standards (29 CFR 1910) and Construction Standards (29 CFR 1926). These standards are in place to control exposure to serious health and safety hazards that continue to affect workers across drilling, servicing, and production activities.
Common health hazards include diesel engine particulate matter, fatigue caused by long shifts and remote work locations, and exposure to hazardous chemicals such as benzene and toluene. Hydrocarbon gases and vapors (HGVs) can create low-oxygen environments, and hydrogen sulfide (H₂S), a highly toxic gas, can be fatal even in small amounts.
This blog breaks down the most common safety issues in oil and gas, examines their causes, and explores practical solutions for building safer, more resilient work environments and protecting your workforce.
Why is Safety a Critical Concern in Oil and Gas?
Oil and gas operations occur in high-risk settings, such as isolated areas exposed to rough sea conditions that are difficult to evacuate quickly in emergencies. Drilling rigs involve heavy equipment, rotating machinery, and flammable materials. Refineries and processing plants handle high-temperature and high-pressure processes, where even a small failure can escalate quickly.
Each environment presents unique safety challenges that demand specific procedures and constant monitoring. Workers are regularly exposed to flammable gases and liquids like natural gas, crude oil, and vapors that can ignite easily. High-pressure systems that, if they fail, can cause explosions or equipment blowouts. Toxic chemicals such as hydrogen sulfide (H₂S) and benzene can lead to serious health effects with prolonged exposure.
Proper containment, detection, and handling procedures are essential to minimize risks. Remote locations often mean limited access to emergency medical care and longer response times during incidents. Extreme weather conditions, from intense heat to freezing temperatures, can affect equipment and worker performance. Long shifts and irregular hours are standard, contributing to fatigue, which increases the likelihood of human error.
Common Safety Issues and Hazards in Oil and Gas Operations
Here are some of the most common safety issues associated with oil and gas extraction and servicing operations.
Vehicle Collisions
Transportation is a significant part of oil and gas operations, mainly since healthy sites are often located in remote or rural areas. Workers and equipment are routinely moved over long distances, often on poorly maintained roads or in challenging weather conditions.
Vehicle collisions are the leading cause of death in the oil and gas industry, with roughly 40% of worker fatalities resulting from highway crashes. Fatigue from long shifts, driver distraction, and mechanical issues with vehicles are essential factors contributing to these incidents. Additionally, oilfield traffic can be heavy and unpredictable, increasing the risk of accidents on or near work sites.
Struck-By, Caught-In, and Caught-Between Hazards
Another major source of fatal injuries on oil and gas sites involves workers being struck by equipment or caught in moving machinery. This includes being hit by swinging loads from cranes, falling tools, or being pinned between heavy vehicles and structures. Rotating equipment such as catheads, pumps, or hoist blocks pose high risks if not properly guarded.
These types of incidents account for a large percentage of fatalities and injuries in the industry and often occur during rig-up, drilling, maintenance, or dismantling operations. Many of these events happen quickly and without warning, leaving little room for reaction.
Explosions and Fires
Flammable gases and liquids make oil and gas sites vulnerable to fires and explosions. Methane, hydrogen sulfide, and petroleum vapors can be released during drilling, servicing, or production activities.
When these gases accumulate in the presence of an ignition source, such as static electricity, welding equipment, or running engines, the result can be a flash fire or explosion. These events can cause severe injuries or mass casualties and often lead to extensive damage to equipment and infrastructure. Ignition sources are usually challenging to detect or control, particularly in unpredictable field environments.
Falls and Elevated Work Risks
Working at heights is common in oil and gas operations. Workers may need to access platforms, masts, tanks, or scaffolding, all of which present serious fall hazards. Tasks like rig inspection, maintenance, or installation often involve climbing and working on elevated structures where a misstep can lead to a fatal fall.
Many worksites are exposed to environmental factors like wind, rain, or ice, which increase the risk of slips and falls. These incidents endanger individuals, disrupt operations, and lead to significant delays.
Confined Spaces
Confined spaces like storage tanks, mud pits, sand containers, and reserve pits present unique risks. These areas are often poorly ventilated and may contain toxic gases or low oxygen levels. Workers entering confined spaces may be exposed to chemical vapors, the risk of fire or explosion, or asphyxiation.
Access and egress are often limited, making rescue operations difficult in an emergency. Confined space entry can quickly become life-threatening without proper atmospheric monitoring and procedural controls.
Ergonomic Hazards
Oil and gas work is physically demanding and often requires lifting heavy loads, operating tools in awkward postures, or performing repetitive motions. Tasks such as handling drill pipes, connecting equipment, or moving materials expose workers to the risk of musculoskeletal injuries.
Over time, these repetitive physical demands can lead to strains, sprains, and chronic injuries. These risks are often overlooked compared to immediate hazards like fire or explosions, but they contribute significantly to long-term worker health issues and lost productivity.
High-Pressure Lines and Equipment
Operations frequently involve the use of high-pressure lines for fluid and gas transfer. If these systems fail, they can pose serious dangers. Internal erosion, poor connections, or faulty components can lead to sudden line bursts or leaks.
Workers in the vicinity of a failed line can be struck by released energy or high-velocity fluids, which can cause severe trauma or fatal injuries. These incidents can occur without warning signs, making awareness and routine equipment inspection critical.
Electrical and Other Hazardous Energy
Oil and gas operations require electrical systems to power equipment and tools. Workers may be exposed to electrical hazards if systems are improperly installed or maintained. In addition to electrical energy, other sources such as hydraulic, pneumatic, or mechanical energy can also be dangerous if not properly isolated.
The accidental startup of machinery during maintenance or failure to follow lockout/tagout procedures can lead to severe injuries. These hazards are hazardous because they can affect workers not directly involved with the equipment at the time.
Equipment and Machinery Hazards
Drilling and production sites are filled with large, powerful machines that pose constant risks. Workers may come into contact with unguarded rotating parts, conveyors, or pressurized systems. Equipment such as drawworks, pumps, compressors, and belt wheels can cause serious injuries if safeguards are not in place.
Many of these machines operate continuously, and in some cases, workers are required to work near them. Lack of training, poor communication, or lapses in safety protocols can easily result in serious or fatal accidents.
Root Causes of Safety Failures
Many safety breakdowns can be traced back to a few common factors that compromise the effectiveness of risk management systems.
Lack of Training
Many incidents involve workers who were not properly trained for their tasks. This is especially true for new hires, temporary workers, or contractors who may not receive the same level of instruction as permanent staff. Without a clear understanding of hazards, equipment operation, or emergency procedures, workers will likely make mistakes that lead to injuries.
Complacency
Over time, routine can lead to complacency. Workers who have performed the same tasks repeatedly may begin to take shortcuts or overlook safety steps. This false confidence can result in skipped checks, ignored warning signs, or reduced attention to changing site conditions. Complacency often develops when safety practices are viewed as routine rather than critical.
Poor Safety Culture
In some organizations, safety is treated as a checklist item rather than a core value. This can result in a weak safety culture where concerns are ignored, incident reporting is discouraged, and accountability is unclear. When leadership doesn’t actively support safety or fails to respond to risks, workers may stop taking safety seriously.
Cost-Cutting Measures
Budget pressures can also lead to safety failures. Companies may reduce maintenance spending, delay equipment upgrades, or cut back on safety personnel to save costs.
These decisions increase the likelihood of equipment failures, overlooked hazards, and slow response times during emergencies. In the long run, cost-cutting often results in higher costs due to accidents, downtime, and liability.
Effective Safety Measures for Oil and Gas Workplaces
Below are essential areas where focused efforts can significantly reduce risks and improve safety outcomes.
1. Strengthen On-Site Communication
Oil and gas sites are complex and active environments where workers operate simultaneously in different zones. Effective communication is critical to coordinating tasks, preventing misunderstandings, and responding quickly during emergencies.
Workers must clearly understand communication protocols and emergency signals through radios, hand signals, or verbal instructions. Regular equipment checks, such as testing radios and communication devices at the start of a shift, should be standard practice.
2. Ensure Familiarity with Work Environments
Workers unfamiliar with their job site will likely make mistakes or overlook hazards. Every worker should receive a site-specific orientation that covers the layout, safety equipment locations, emergency exits, and known risks. This orientation should be enforced through pre-job briefings and walkthroughs when conditions change or new equipment is introduced.
3. Maintain Equipment Consistently
Machinery and tools used in oil and gas operations must be in reliable condition to operate safely.
Regular inspections, servicing, and timely repairs prevent malfunctions that could lead to serious incidents. Companies should establish clear maintenance schedules and encourage workers to report any irregularities. Properly maintained machines reduce safety risks and boost productivity by minimizing unplanned downtime.
4. Build a Collaborative Safety Culture
Building a strong safety culture means involving workers in discussions about risks, procedures, and improvements. When workers take ownership of safety and feel heard, they’re more likely to follow protocols and speak up about concerns.
Safety committees that include workers from different roles can help guide policy, track performance, and promote shared accountability.
5. Invest in Comprehensive Safety Training
Workers must understand the risks they face and know how to respond appropriately in various situations. Practical training includes multiple components.
Hazard awareness training educates workers on the dangers associated with their roles, from exposure to toxic substances to equipment-related risks. Skills-specific training focuses on correctly using machinery and personal protective equipment (PPE), helping workers carry out tasks safely and efficiently. Emergency response training prepares teams to act quickly during fires, chemical spills, or other emergencies. Finally, regulatory compliance training ensures workers are familiar with industry standards and legal requirements, such as OSHA and EPA regulations, to meet safety expectations consistently.
Collaborating with Gallagher Bassett, Safe T Professionals is essential in enhancing workplace safety through expert training and staffing solutions. Their onsite, in-person, and hybrid training courses, led by certified professionals, provide workers with hands-on knowledge and real-world applications for hazard prevention. This partnership strengthens businesses’ ability to implement the hierarchy of controls effectively and ensures that employees are well-prepared to handle workplace hazards.
6. Implement Effective EHS Management
A structured Environmental, Health, and Safety (EHS) management system is essential for overseeing safety performance. These systems help companies track incidents, conduct inspections, and manage compliance with safety standards.
Essential components of a robust EHS program include incident reporting, regular safety audits, and real-time tracking of safety metrics such as the Total Recordable Incident Rate (TRIR) and Days Away, Restricted, or Transferred (DART) rate. Additional tools like behavior-based safety analysis and safety data sheet (SDS) management also play a critical role. When appropriately integrated, EHS systems ensure that safety is not reactive but proactively managed and continuously improved.
Improve Workplace Safety & Compliance with Safe T Professionals
At Safe T Professionals, we are dedicated to elevating safety standards through our expert consulting and staffing services. By proactively addressing and preventing safety issues and equipping your workforce with the necessary knowledge and tools, we help create a safer work environment.
Partner with Safe T Professionals to enhance your company’s safety protocols and ensure compliance with industry standards. Whether you are looking to fill safety-specific roles or need expert consultation to mitigate workplace hazards, we are here to help.
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