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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

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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…”

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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

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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

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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)

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Wet Gas NGL Condensate

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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)

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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

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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

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Mistaken Identity

• Condensates are not:– Liquefied natural gas (LNG)

– Liquefied Petroleum Gas (LPG) (Propane mix)

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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

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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

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Common Hazards

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Highly Flammable

• Condensate is Flammable (extremely)– Flash fire hazard

– Flashpoint (FP) range of -211o F to -100o F• Gasoline has FP of -45o F

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Lighter than Water• Condensate floats on top of water

– Specific Gravity of less than 1• Lighter than water

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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)

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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

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Hazard Control Order

• Eliminate the hazards– Cannot be eliminated to 100%

• Control the hazards• Protect the workers

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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

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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.

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Ground

+++ +++

Bond Wire

Eliminates static charge

++++++

Bonding & Grounding

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Bonding & Grounding

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Grounding

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9 ft. long, 8ft. deep

5/8” or 1/2” dia.

Frac Tank Incident

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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

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Compliments:Lightning Master® in-tank static drain (ITSD)

Static DissipatorSystem

Frac Tank Protection

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GroundingBonding

Frac Tank Protection

• Are these tanks bonded together through the Manifolds?

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They could be with conductive hoses; no specific bonding wires are seen. It is doubtful!

Water Tank Grounding

35Grounding

Other Equipment to be Grounded

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• Portable Equipment– Heaters

– Combustion engine-driven equipment

– Pumps

Follow Manufacturer’s instructions!

Exception: Other Equipment to be Grounded

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• 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

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Field Testing Methods

• Color Cut Test• Multi-gas monitor• Manual sample

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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

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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!

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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!

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Wet Gas Areas

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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

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• Gauging tanks• Visual level

check• Prep for

transport• Cleaning Containing

flow-backwater

Production Tank& Tasks

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Gauging tanks, Checking visual levels,Tank cleaning or maintenance

What is wrong with the picture?• FRC sleeves up• Wristwatch

Produced Water Tanks & Tasks

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• Gauging tanks

• Check visual levels

• Water transfer by truck

Water Trucks & Tasks

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Checking visual levels,Tank cleaning

Loading/Unloading operations

Pits – Flowback & Tasks

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• Sampling• Check

levels• Water

transfer by truck

Other Locations & Tasks• Maintenance

– Piping• Production, gathering, transmission, and

distribution• Pipeline pigging operations

– Compressor stations

– Processing equipment

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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

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• Address hazards on JSA• Discuss during pre-shift

meetings• Define emergency

response actions

Basic PPE

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Protect the Worker

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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

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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)

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Procedures

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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

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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)

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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.

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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

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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