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Condensate Safety Awareness

02/25/2015PIOGA Winter Meeting

Wayne Vanderhoof CSP

“Working Safe, Preventing Injuries, Protecting Profi ts”

RJR Safety Inc.

Incidents

• Jan. 11, 2014• Cabot Oil & Gas• Susquehanna County

– “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• New Milton, WV

– “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 killed 2

Incidents

• Nov. 12, 2014• Blue Racer (midstream)

– Noble County OH– Explosion when

working on a pump that moves condensate

– Would have been testing & calibrating electrical components on the pump

– 1 person killed

• Oct. 28, 2014• Blue Racer (midstream)

– Monroe County, OH– Pipeline ruptured &

caught fire– Carrying natural gas-

condensate to processing plant in WV

– No injuries, evacuations, & brush fires 3

Incidents

• Oct. 27, 2013• Antero Resources

Doddridge County WV– “condensate was

released…vapors were ignited by a nearby heater”

– “workers installing floats on…production tanks”

– 2 workers injured

• Between 2012 to 2014– Specific date unknown

• Injection Well in OH– Fire in the sump– Minor damage except

for multitude of fire extinguishers

– Condensate on top of the water in the sump/drain area at the rear of the truck 4

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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Why Discuss Now?

• Number of incidents increasing– Deaths, injuries, & property damage,

environmental incidents

• NGL production increases so goes condensate production

• Unconventional well condensate hazards are very different from conventional wells– Appears not a realization or consideration

• Hazard is recognized now has to be eliminated or otherwise controlled

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Objective• Make you aware of the hazards of

Condensate• Begin the process of developing

methods to control the hazards• Better able to protect workers from the

hazards

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• Agenda– Describe Condensate– Identify the Hazards– Discuss methods to control the hazards

Locations

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Wet Gas Areas

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How does it get there?• Gas cools as it comes up the wellbore

forming liquid called condensate• Flow-back water from a well

– Stored in “frac” tanks/Re-used for next “frac”

• Produced water used for hydraulic fracturing

• Water is transferred using vacuum trucks– Transfer between sites, locations

• Varies in quantity of condensate

• Pipelines– More in the winter due to cooling

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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 (Light liquids)

C9-C10

Crude oil (Heavy liquids)(Parafins, Naphthenes, Aromatics, Asphaltics)

C11 to C20

• 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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• Condensates are not:– Liquefied natural gas (LNG)– Liquefied Petroleum Gas (LPG) (Propane mix)

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 (expand) 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• Created by friction and the movement of

materials in tanks & flow in pipe

• Controlling static electricity• Provide a path (Bonding & Grounding)• Eliminate the spark!

24Ground

++++++

Zero chargeStatic 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

++++++

Grounding

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9 ft. long, 8ft. deep

5/8” or 1/2” dia.

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

Water Tank Grounding

29Grounding

Truck Transferring

30Conductive 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 31

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 32

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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Field Testing Methods

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Bef

ore

gaug

ing

Condensate

Afte

r ga

ugin

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

• Oxygen level– Less than 19.5%

» Asphyiation/suffocation

• Lower Explosive Limit (LEL)

• Any % indicates a flammable is present!

Tasks

With potential hazards!

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“Frac” Water Tanks & Tasks

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• Gauging tanks• Visual level

check• Prep for

transport• Cleaning Containing

flow-backwater

Production & Produced Water Tanks & Tasks

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Gauging tanks, Checking visual levels,Tank cleaning or maintenance, water transfer by truck

Water Trucks & Tasks

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Checking visual levels,Tank cleaning

Loading/Unloading operations

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

Engineering/Design

• Standardized facility designs• Remote monitoring• Bonding & Grounding• Ignition Source Control• Vapor control/recovery

– Closed systems

• Proper equipment design & placement– Correct per area electrical rating

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Engineering/Design

• Condensate creates a Flash Fire hazard• 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?

• API RP 99 – Flash Fire Risk Assessment for the Upstream Oil & Gas Industry– April 2014 release

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Standard Operating Procedures (SOP)• Operating Equipment• Performing tasks

– Transferring/Loading/Unloading procedures• Frac tanks/Water tanks/impoundments/Prod.

Tanks

– Gauging tanks– Cleaning tanks

• Maintenance/Repair tasks– Tanks/pumps/valves/gauges– Pigging operations– Electrical equipment 44

Safety Procedures• HAZCOM

– Understand NGL & Condensate hazards

• Hot Work– Permit/Ignition Source Control– Designated smoking areas

• Electrical Safety– Bonding & Grounding

• LEL Monitoring• PPE• Emergency Action & Response Plans

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PPE

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Hazards Control Methods

Flash Fire Flame-resistant Clothing

Asphyxiant/Suffocation Respiratory Protection

Carcinogenic Respiratory Protection

Now that we know about a hazard…

We are required to do something!• Analysis/Audit

– 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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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• Incidents involve potential for injuries, property

damage, environmental incidents• So long as wet gas is drilled for, we will have

Condensate & associated hazards• Discussed methods to control the hazards &

protect workers– Engineering & Design– SOPs & Safety Procedures– PPE – last resort

More information & training is needed!49

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 Profi ts”Email: wayne@rjrsafety.com Cell 724-809-4234

RJR Safety Inc

Bakken Oil in N.D.

• Crude oil & natural gas & natural gas liquids coming from same wellbore– Previously separated then flared the natural

gas• Leaving the natural gas liquids (NGL)

• NGL makes the mixture more unstable– More flammable than just crude oil– Vapor pressure is higher than just crude oil

• Vapor (flammable) more easily created

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Hydrocarbons in Crude Oil

• Four main types:– Carbon– Paraffins (15-60%)

• waxy substance

– Naphthenes (30-60%)– Aromatics (3-30%)

• Benzene, toluene

– Asphaltics (remainder)• Asphalt

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