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Condensate Safety Awareness
02/11/2015PIOGA Safety Committee
Wayne Vanderhoof CSP
“Working Safe, Preventing Injuries, Protecting Prof its”
RJR Safety Inc.
Incidents
• Jan. 11, 2014
• Cabot Oil & Gas– “vapors in the
headspace of a wastewater tank ignited”
– “worker checking the level…using his cellphone as a flashlight”
– Unknown on injuries
• July 7, 2013
• Antero Resources– “build-up of gas from
tanks used to store flow-back water”
– “were not measuring for flammable gas levels in the area”
– Ignition source unknown
– 2 workers killed2
Incidents
• Oct. 27, 2013
• Antero Resources– “condensate was
released…vapors were ignited by a nearby heater”
– “workers installing floats on…production tanks”
– 2 workers injured
3
Incidents
• March 31, 2010
• Atlas Resources– “spark ignited
condensate vapors in a pit” and flames spread into water tanks of flow-back water
– “Malfunction ignited the flames”
– At least 1 worker injured
• During the investigation– “other well sites…had
condensate storage…with vapors escaping…”
4
Objective
• Make you aware of the presence of Natural Gas Liquids and Condensate
• Give you enough information to:– Develop a healthy respect for Natural Gas
Liquids and Condensate• Knowing & understanding the hazards
– Gain an AWARENESS of Condensate & the hazards
– Better able to protect workers from the hazards
5
Agenda
• Describe Natural Gas Liquids & Condensate
• Identify the Hazards• Discuss methods to eliminate & control
the hazards• Review PPE to protect workers• List Procedures that are necessary
6
Natural Gas Liquids (NGL)
• Components of natural gas that are liquid…
• Includes Ethane (some), Propane, Butane, & Pentane(some)
– Not methane and ethane – need refrigeration to be liquefied.
• (Schlumberger Oilfield Glossary at http://www.glossary.oilfield.slb.com)
7
Wet Gas NGL Condensate
8
ComponentsCarbon Molecules
Methane C1
Ethane C2
Propane C3
Butane C4
Pentane C5
Hexane C6
Heptane C7
Octane C8
Other Hydrocarbon Molecules
C9-C12
• Non-energy Components– Nitrogen– Carbon Dioxide– Hydrogen Sulfide*– Helium– Toluene– Benzene
Condensate (light)
9
Specific Gravity API Gravity
Condensates, Natural Gas Liquids
(NGL),& Natural Gas
0.30 to 0.70 340 to 71 Degrees
Crude Oil 0.76 to 1.03 55 to 6 Degrees
Water 1 10 Degrees
10
Natural Gas Liquids (NGL) & Condensate
Water:• Clear -produced• Dirty – Frac flow back• Creamy – flow back• Combination
Many Names
• Natural gas liquids (NGL)
• Natural gas condensate
• Hydrocarbon condensate
• Y- grade
• Lease Condensate
• Gas condensate
• Drip gas
• Field condensate
• Pipeline liquids• Natural Gasoline
11
Mistaken Identity
• Condensates are not:– Liquefied natural gas (LNG)
– Liquefied Petroleum Gas (LPG) (Propane mix)
12
Where does it come from?• Natural gas or crude oil reservoirs
– Wet gas• Less than 85% Methane, rest is Condensate• Dry gas – pure methane - little to no condensate or
liquids
– Lighter C2 through C5 hydrocarbons• Ethane, Propane, Butane, Pentane
• Gas cools as it comes up the wellbore forming liquid called condensate– Reduction in pressure and temperature
13
Where does it come from?• Pipelines
– As the pipe cools, the gas cools and condensate forms in the pipeline• More condensate in the winter months
14
Common Hazards
15
Highly Flammable
• Condensate is Flammable (extremely)– Flash fire hazard
– Flashpoint (FP) range of -211o F to -100o F• Gasoline has FP of -45o F
16
Lighter than Water• Condensate floats on top of water
– Specific Gravity of less than 1• Lighter than water
17
Solubility & Evaporation
• Not water-soluble– Does not mix easily with the water
• Unless stirred with agitator continuously• Stirring stops and separation will begin
• Evaporates Easily– The higher the vapor pressure the greater the
tendency for the liquid to evaporate• Turns from liquid to vapor• Vapors become airborne easily• Accumulates quickly to LEL (potential)
18
Heavier than Air
• NGL has Vapor Density slightly greater than 1– Gathers in low places (heavier than air)
• Condensate floats on top of water and the vapors stay close to the top of the condensate– Does not rise easily
– Depends on the heat inside the tank• Hotter air will make it rise more easily
– Makes it “lighter” than air 19
Health Hazards
• Flammable gases– Asphyxiant (Suffocation)
• Reduces the amount of oxygen available
• Carcinogen– Benzene only
• Mostly present in crude oil• Small amounts (less than 1%) in natural gas
liquids• OSHA PEL 1ppm
– 29CFR1910.1028 Benzene standard20
Controlling Hazards
21
Hazard Control Order
• Eliminate the hazards– Cannot be eliminated to 100%
• Control the hazards• Protect the workers
22
Hazard: Highly Flammable
• Ignition sources– Static electricity– Electricity
• Eliminate arcs
• Electrically-rated equipment
– Heat• Hot surfaces
• Flames
• Hot work
• Control methods– Bonding & grounding– Proper equipment
• Non-arcing equipment
• Explosion-proof
• Intrinsically safe
– Eliminate/Control heat sources
• Hot Work Permit
• Cell phones
• Digital cameras
• Flashlights
– Fire Extinguishing Equipment23
Static Electricity
24
Static Electricity• Created by friction and the movement of
materials in tanks & flow in pipe
• Controlling static electricity• Provide a path (Bonding & Grounding)• Eliminate the spark!
25Ground
++++++
Zero chargeStatic Charge
++++++
Bonding
• Connects two or more conductive objects using a conductor such as a copper wire.– Equalizes the
potential charge so there is no voltage difference between them. 26
Ground
+++ +++
Bond Wire
Equally static charged
Equalizes –does not eliminate static charge
Grounding
• Grounding connects one or more conductive objects directly to the earth. Unlike bonding, proper grounding does drain static charges.
27
Ground
+++ +++
Bond Wire
Eliminates static charge
++++++
Bonding & Grounding
28
Bonding & Grounding
29
Grounding
30
9 ft. long, 8ft. deep
5/8” or 1/2” dia.
Frac Tank Incident
31
Incident in late 2005 & early 2006 - Tanks (epoxy-lined) are in a row and only one tank had damage from exploding condensate vapors caused by static electricity.
Frac Tank Protection
32
Compliments:Lightning Master® in-tank static drain (ITSD)
Static DissipatorSystem
Frac Tank Protection
33
GroundingBonding
Frac Tank Protection
• Are these tanks bonded together through the Manifolds?
34
They could be with conductive hoses; no specific bonding wires are seen. It is doubtful!
Water Tank Grounding
35Grounding
Other Equipment to be Grounded
36
• Portable Equipment– Heaters
– Combustion engine-driven equipment
– Pumps
Follow Manufacturer’s instructions!
Exception: Other Equipment to be Grounded
37
• Portable Equipment– Light plants*
– Generators*• “…supplies only equipment mounted on the
generator…or cord & plug connected equipment through receptacles on the generator…” AND
• “…non-current carrying metal parts…(fuel tank, engine, housing)… are bonded to the generator frame…
Reference: OSHA Fact Sheet “Grounding Requirements for Portable Generators” and LOI dated 11/5/1991
Truck Transferring
38Conductive Hose
Eliminate Heat Sources• Smoking in designated areas• Restrict running or parked vehicles
– Within 100 ft. of Wellbore or Production Tank• API RP 54 “Occupational Safety for Oil and Gas Well Drilling and
Servicing Operations”, Chapter 6 “Operations” Section 6.1.15
• Hot Work Permit• Use correct electrically-rated tools
– Intrinsically safe• Not capable of releasing sufficient electrical or
thermal energy under normal or abnormal conditions to cause ignition
• Flashlights, cameras, portable radios, cell phones 39
Hazard: Lighter than WaterHazard: Evaporates EasilyHazard: Heavier than Air
• NGL and Condensate floats on top of water– Lighter than water; Not water-soluble
• Turns from liquid to vapor & becomes airborne easily
• Vapors stay close to the top of the water– In the tank headspace
– Escape upon opening of hatch 40
Hazards Control• Assume other than fresh water tanks have
condensate in/on them• Unless tested & proven otherwise
– Need to best determine testing methods
• Use LEL meter or 4-gas monitor• Personal and/or Area monitoring• When opening the hatch
• Follow tank gauging procedures• Leave 1 to 2 feet (+) of water in the tank• Fire extinguishing equipment
41
Field Testing Methods
• Color Cut Test• Multi-gas monitor• Manual sample
42
Testing Method
• Color Cut Test (Kolor Kut)
– Place a thin layer of paste on a clean measuring tape
– Lower the measuring tape to the bottom of the water tank
– Paste is a light pink paste which turns to a contrasting bright red upon contact with petroleum product such as gasoline
43
Bef
ore
gaug
ing
Condensate
Afte
r ga
ugin
g
Testing Methods
• Multi-meter– Oxygen level
• Less than 19.5%– Asphyiation/suffocation
– Lower Explosive Limit (LEL)• Any % indicates a
flammable is present!
44
Testing Methods• Manual Sample
– Obtain a sample
– Shake it up, let stand
– Approximate percent of total sample
– Hazards include taking the sample• Reaching into tank
– Potential flammable atmosphere 45
Locations & Tasks
With potential hazards!
46
Wet Gas Areas
47
How does it get there?• Flow-back water from a well
– Residual amounts stay in the flow-back water
– Flow-back water stored in “frac” tanks
– Flow-back water re-used for next hydraulic fracturing operation
• Produced water being used for hydraulic fracturing
• Water is transferred using vacuum trucks– Transfer between sites, locations
• Varies in quantity of condensate 48
“Frac” Water Tanks & Tasks
49
• Gauging tanks• Visual level
check• Prep for
transport• Cleaning Containing
flow-backwater
Production Tank& Tasks
50
Gauging tanks, Checking visual levels,Tank cleaning or maintenance
What is wrong with the picture?• FRC sleeves up• Wristwatch
Produced Water Tanks & Tasks
51
• Gauging tanks
• Check visual levels
• Water transfer by truck
Water Trucks & Tasks
52
Checking visual levels,Tank cleaning
Loading/Unloading operations
Pits – Flowback & Tasks
53
• Sampling• Check
levels• Water
transfer by truck
Other Locations & Tasks• Maintenance
– Piping• Production, gathering, transmission, and
distribution• Pipeline pigging operations
– Compressor stations
– Processing equipment
54
Potential Hazards & ControlsPotential Hazards
• Highly flammable• Lighter than water• Evaporates easily• Heavier than air
Control Measures• Bonding & grounding
– Bare hand grounding
• Proper equipment use
• Eliminate/Control heat sources
• Assume other than fresh water tanks have condensate in/on them
• Use LEL meter or 4-gas monitor
• Follow tank gauging
procedures
• Do not empty tanks
• Fire extinguishing equipment
55
• Address hazards on JSA• Discuss during pre-shift
meetings• Define emergency
response actions
Basic PPE
56
Protect the Worker
57
Hazards Control Methods
Flash Fire FRC
Asphyxiant/Suffocation Respiratory Protection
Carcinogenic Respiratory Protection
Vapors- Evaporates easily- Collects at the top of the
tank in the headspace
Follow Procedures
Flame-Resistant Clothing
• Flash Fire PPE• Why place a worker in
an environment with a known or potential flash fire hazard?– How much potential?– Eliminate the hazard?
– Engineer out the hazard?
• LAST RESORT!
• Must be worn correctly
• Maintained correctly
58
Respiratory Protection
• Vapors may cause:– Asphyxiation/suffocation– Cancer (Benzene)
• Asphyxiation/suffocation & Carcinogen– Full-face, supplied –air
respirator
• Respiratory protection program– Medical evaluation– Fit testing– Training
• 1910.1028 Benzene– Follow standard if concentration
equals or exceeds exposure limits (1 ppm)
59
Procedures
60
Now that we know about a hazard…
• Identify areas, process, equipment, tasks, operations for potential NGL/condensate
• Develop S.O.P.s• Update/develop Safety Procedures• Train the workers• Coach & enforce the SOPs & procedures
61
Programs & Procedures• Safety
– HAZCOM• Understand NGL &
Condensate hazards
– Hot Work• Ignition Source Control
• Permit
• Bonding & Grounding
• Designated smoking areas
– Electrical Safety– LEL Monitoring– PPE
• FRC
• Respiratory Protection
• Work Procedures– Transferring
• Loading/unloading procedures
– Engineering/Design• Bonding & Grounding
• Ignition Source Control
• Vapor control/recovery– Closed systems
• Proper equipment design & placement
– Standard Operating Procedures (SOP)
62
If No Procedures…
• Exercise Stop Work Authority• Get your Supervisor involved• Do not proceed with Operations until
hazards have been eliminated and/or controlled and workers are protected.
63
Summary
• Discussed Natural Gas Liquids and Condensate
• Identified common hazards• Discussed methods to eliminate & control the
hazards• Reviewed PPE to protect workers• Listed some Procedures that are necessary
More information & training is needed! 64
ReferencesDocument Title
API 2003 Protection against Ignitions Arising out of Static, Lightning, and Stray Currents
API 2015 Cleaning Petroleum Storage TanksAPI 2027 Ignition Hazards in Abrasive Blasting of
Atmospheric Hydrocarbon Tanks in Service
API 2219 Safe Operation of Vacuum Trucks in Petroleum Service
NFPA 30 Flammable and Combustible Liquids Code
NFPA 70 National Electrical CodeNFPA 77 Static Electricity
65 66
Questions or Comments?
Thank you!
Wayne Vanderhoof CSP
“Working Safe, Preventing Injuries, Protecting Prof its”Email: wayne@rjrsafety.com Cell 724-809-4234
RJR Safety Inc
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