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Every year, hundreds of people have died and thousands have been injured because of insufficient management of well control at oil and gas drilling and production sites. Major causes which have been reported in previous studies included uncontrollable blowouts and failure of blowout preventers because of insufficient safety practices. These onshore and offshore blowout disasters not only harm the work force but also critically affect the environment and marine life. In this research paper, a detailed quantitative survey and qualitative risk assessments (RA) have been carried out for assessing the potentially hazardous activities associated with well control along with their appropriate controls and risk reduction factors and mitigating measures in Middle East and south East Asian countries.

The sequential explanatory research design has been adopted in this study. Whereas, descriptive statistical approach has been used for the quantitative data analysis of this study. While, in-depth interview approach has been used for qualitative data collection. Similarly, what-if analysis method has been adopted in this study for the identification of effective safety and health risk mitigating factors because it provides in-depth information from health and safety environment experts.

The cumulative quantitative results based on the response from Saudi Arabian drilling industry have indicated that the well control operation is highly hazardous then Malaysian and Pakistani oil and gas industries. Likewise, findings from what-if analysis approach demonstrate that the drilling crewmembers have repetitively faced life threatening hazards which occur (safety and chemical) during well control onshore and offshore operation because of oil base mud, confined space at site, pinch points and falling during working on blow out preventers. According to the overall result, respondents have highly recommended engineering and administrative hazard controlling factors as most suitable for the elimination of safety and chemical hazards during well control activities.

Besides, the developed methodological framework for the identification of suitable hazard controls can also be effectively used for potential hazards reorganization and identification of suitable hazard controls for other drilling and production industries and regions for accident prevention and safety and health management.

This is a first comparative research study which has been carried out in Malaysian, Saudi Arabian and Pakistani onshore and offshore oil and gas industries for well control health and safety management and reorganization of most effective hazards mitigating factors at drilling sites.

Annually, hundreds of drilling crew suffer from major injuries during performing oil and gas drilling operation because of the deficiency of an adequate hazard safety management system for real-time decision-making in hazardous conditions. According to previous studies, there is a sheer industrial need for an effective industrial safety management decision support system for accident prevention at oil and gas drilling sites at both drilling domains. Therefore, this paper aims to focus on the design and development of knowledge base decision support system (KBDSS) for the prevention of hazardous activities at Middle Eastern and South Asian origins’ onshore and offshore oil and gas industries during drilling operations.

In this study, data were gathered from safety and health professionals from targeted oil and gas industries in Malaysia, Saudi Arabia and Pakistan through quantitative and qualitative approaches. Based on identified data, KBDSSs (HAZFO Expert 1.0) were systematically developed and designed by adopting Database Development Life Cycle and Waterfall Software Development Life Cycle models. MySQL and Visual Studio 2015 software were used for developing and designing knowledge base and graphical user interface of the system.

KBDSS (HAZFO Expert 1.0) for accident prevention at onshore and offshore oil and gas drilling industries based on identified potential hazards and their suitable controlling measures aligned with international safety standards and regulations. HAZFO Expert 1.0 is a novel KBDSS that covers all onshore and offshore drilling operations with three and nine outputs, respectively, to achieve the current trend of Industry Revolution 4.0 and Industrial IoTs for workforce safety.

This industrial safety management system (HAZFO Expert 1.0) will be efficiently used for the identification and elimination of potential hazards associated with drilling activities at onshore and offshore drilling sites with an appropriate hazard controlling strategy.

Moreover, the developed KBDS system is unique in terms of its architecture and is dynamic in nature because it provides HAZFO Expert 1.0 data management and insertion application for authorized users. This is the first KBDSS which covers both drilling domains in Malaysian, Saudi Arabian and Pakistani industries.