Occupational Hygiene in the
Oil & Gas Industry
Day 4 – Section 17
Design & Review
1.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Summary
• Design Review
• Design Issues For Upstream &
Downstream Sites
– Noise
– Ventilation
– Ergonomics
– Sample points
2.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Hierarchy of Control
1.
2.
3.
4.
5.
3.
Elimination - Best
Substitution
Engineering Controls
Administrative Controls
Personal Protective Equipment (PPE) –
Least effective
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Design Information P&I
• Current detailed description of the project.
• Flow diagrams of the process (including
material balance information)
– Chemical components to be used.
– Volumes of feed stock, raw materials, catalysts,
additives,
– Production rates, by-products and intermediates
• Complete inventory of ‘chemicals/materials’
– Materials used and produced (including products,
intermediate streams, feed stocks, catalysts,
process additives, etc.)
4.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Design Information – Operations-1
• Information regarding process
– Sampling and process control requirements,
– Frequency of catalyst regeneration/skims/changeouts;
– Process stream sample points should be easily
accessed. Closed loop sampling methods should
be considered for materials which are particularly
toxic (Benzene), or high vapour pressure
(e.g. liquefied gases).
– Enclosed sample points for corrosive materials
• Some of this information can be obtained from the
P&I (Process and Instrumentation) diagram.
5.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Open bottle sampling
6.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Closed Loop sampling (heavy gasoline)
7.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Design Information – Operations-2
• Information on equipment.
– Chemicals are often added to the process through
mixing drums or hoppers.
– When? How? Who?
– These may require local exhaust ventilation,
depending on hazardous properties of material to
be added, likelihood that the operator will be
exposed to the material, and the frequency and
duration of the task
• Review Standard Operating Procedures
• Noise levels (manufacturer’s data)
8.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Noise reduction – large heater
9.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Design Information – Operations-3
• Wastes and sludge generated,
– Storage, Sampling
– Removal methods.
– Potential releases to air and water should be
identified.
– Releases to atmosphere from safety relief valves,
vents and stacks should be at a safe location.
– Vent and safety valve releases are often most
effectively controlled when directed to a flare
system
10.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Design Information – Operations-4
• Environmental Controls
– Reviewed against new and proposed regulations,
and changes incorporated.
– For example, a new environmental regulation
regarding fugitive emissions from valves will
impact on the project design; more stringent water
quality standards may require additional water
treatment processes.
11.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Design Information – Operations-5
• Safety Equipment in the field
– Need for deluge showers/eye wash stations
– Breathing Apparatus (SCBA) stations
– Amenities, change rooms, shower and
decontamination facilities
– Continuous monitoring systems
– Personal monitors – e.g. H2S
• Other sources of information.
– Regulatory impact statements often required by
legislators prior to project approval.
12.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Review
•
•
•
•
Understand the project
Understand the process
Understand the reactions
What are the people (operators,
maintenance, contractors) doing?
• What are the wastes, emissions?
• What are the environmental controls?
13.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Basics
Understanding the process
• Carbon Numbers
• Some Process Reactions
14.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Carbon Numbers
15.
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= number of carbon atoms in the molecule
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
16.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Dehydrocyclization
CAT = Catalyst
R+0 = Research Octane Number (RON) with no lead
17.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Hydrogenation – Sulphur Removal
18.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Naphthene Dehydrogenation
19.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Review – Isom Unit
• Understand the project – Isom unit is to
be added to existing refinery operations
• Understand the process – Isom Process
• Understand the reactions – Isom reaction
• What are the people (operators,
maintenance) doing?
• What are the chemicals used?
20.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
21.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Isomerization Process
Desulfurized Feed
Organic Chloride
Make-up Gas
HCl Recovery
HCl Stripper
Hydrogenation
Neutralizer Product
22.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Issues to consider
•
•
•
•
•
Hydrogen Gas – wide flammability range
Organic Chloride
Hydrogen chloride – potential release
Neutralising solution - & waste handling
Flammability and potential exposure to light
hydrocarbons
• Insulation materials used in the heater
• Noise - heater, compressor, pumps etc.
• Sample points for feed, intermediates, product
23.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Review - Gas Plant
• Understand the project – Gas plant to separate
refinery ‘light ends’ C1 to C6
• Understand the process – P&I
– Volumes
– Composition
• Understand the reactions – Fractionation
• What are the people doing? (operators,
maintenance, contractors)
• What are the chemicals used?
24.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Part of the Gas Plant
Feed
3. Light Naphtha
Stabilizer Gas
2. Gas from Crude
& Syn Tower
6. Sovaformer Liquid
1. Syn Tower Accum
25.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
26.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Process
• Gas from three streams #2, #3, #6 are combined,
compressed, (water removed) into stream #7
• Stream #1 & #7 are feed for the ‘Reboiled Absorber’
(fractionator) which produces streams #8 (gas) which
is further separated gas streams #10 & #12 (for fuel
gas), and liquid #14 which is further fractionated in
the Stabilizer to stream #16 (gas) (Overheads) for the
Alkylation unit feed.
• The bottoms from the Stabilizer #15 is Stabilized
Gasoline which will add to gasoline blend stocks
27.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Feed Streams to the Gas Plant
Part of Gas Plant P&I shows the feed to the gas plant
comprises the following identified by numbers
#3. Light Naphtha Stabilizer Gas from the reformers
#2. Gas from Crude & Synthetic Tower (Vac tower)
#6. Sovaformer Liquid
#1. Syn Tower Accumulator
This combination of hydrocarbon streams (gases &
liquid) need to be separated
28.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Feed Streams to the Gas Plant
Moles/hr
Stream
Composition
Hydrogen
Methane C1H4
Ethylene C2H4
Ethane C2H6
Hydrogen Sulphide
Propylene C3H6
Propane C3H8
Isobutane C4H10
Butenes C4H8
n-Butane C4H10
Isopentane C5H12
n-Pentane C5H12
Hexanes & greater, C6+
Water
Total
Mole %
1
Synthetic Tower
Accumulator Liquid
0.3
0.4
0.9
0.6
5.6
4.6
17.3
17.7
6.5
53.0
31.9
391.1
529.9
Pounds/Hour
60,600
Kgm/Hour
27,487
Molecular Weight
114.2
MSCF/day
Cu.M/day
Bbls/day
5,860
© 2013 Petroch Services Pty Ltd
29.
MLitres/ day
932
Moles/hr
Mole % Moles/hr
2
ST Accumulator
Vapour
2
CT Accumulator
Vapour
0.1%
0.1%
0.2%
0.1%
1.1%
0.9%
3.3%
3.3%
1.2%
10.0%
6.0%
73.8%
50.0
121.7
43.9
69.0
36.3
151.2
104.2
157.1
137.1
43.2
145.8
68.0
90.6
3.9%
9.4%
3.4%
5.3%
2.8%
11.7%
8.0%
12.1%
10.6%
3.3%
11.2%
5.2%
7.0%
100%
78.0
1296.1
6.0%
100%
65,500
29,710
50.5
11,800
333,940
-
Mole % Moles/hr
Mole % Moles/hr
3
Light Naphtha
Stabilizer Gas
Mole %
6
Sovaformer
Liquid
0.0
13.9
10.5%
2.6
2.2%
44.7
5.1
33.7%
3.8%
40.9
9.4
34.1%
7.8%
13.6
17.3
16.0%
20.4%
35.1
8.4
10.0
8.8
26.5%
6.3%
7.5%
6.6%
45.5
7.1
7.7
6.8
37.9%
5.9%
6.4%
5.7%
41.8
6.1
6.1
49.2%
7.2%
7.2%
6.7
132.7
5.0%
100%
120.0
100%
84.9
100%
7,020
6,800
4,900
3,184
3,084
2,223
53
56.7
57.7
1,200
1,090
33,960
30,847
578
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
92
What do we know of the feed?
• Synthetic Tower Accumulator Liquid #1
– 42% of feed to Gas Plant , Hydrogen Sulphide 0.05%
Mostly iC5 9%, nC5 5% & C6+ 80%
• ST Accumulator Vapour #2
– 45% of feed to Gas Plant , Hydrogen Sulphide 2.8%
Wide range Hydrogen to C6+
30.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
What do we know?
• CT Accumulator Vapour #2
– 5% of feed to Gas Plant , C3 (28%), C4s (33%), C5s
(20%), C6+ (10%)
• Light Naphtha Stabilizer Gas #3
– 5% of feed to Gas Plant , similar to CT Accumulator
Vapour
• Sovaformer Liquid #6
– <2% of feed to Gas Plant , C3 (16.0%), C4s (70%)
31.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
What are potential problems?
• Hydrogen Sulphide 2.8% ST Accumulator
Vapour stream
• Probably No Benzene
• Wide range of hydrocarbons from hydrogen
to C6+
32.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
What do we know of the products?
• Fuel Gas
– Dry Gas #10, Fuel Gas #12
• Stabilized Gasoline
– Gasoline blend stock #15
• Feed for Alkylation Unit
– #16 comprising C3, and importantly Isobutane ,
Propylene
33.
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BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Reboiled Absorber
Separates the lighter
gases into fuel gas
and heavier
hydrocarbons which
provide feed for the
next unit
34.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Feed & Products - Reboiled Absorber
Moles/hr
Stream
Composition
Mole %
Moles/hr
1
Mole % Moles/hr
8
Synthetic Tower
Accumulator Liquid
10
Wet Gas
Hydrogen
Mole % Moles/hr
Mole %
12
Dry Gas
Gas to Fuel Gas
50.0
9.5%
49.9
10.8%
0.1
0.5%
Methane C1H4
0.3
0.1%
122.0
23.1%
120.8
26.1%
1.1
5.7%
Ethylene C2H4
0.4
0.1%
44.1
8.3%
42.4
9.2%
1.3
6.7%
Ethane C2H6
0.9
0.2%
84.9
16.1%
80.5
17.4%
3.2
16.6%
Hydrogen Sulphide
0.6
0.1%
33.2
6.3%
30.9
6.7%
1.6
8.3%
Propylene C3H6
5.6
1.1%
73.8
14.0%
63.6
13.7%
5.1
26.4%
Propane C3H8
4.6
0.9%
68.9
13.0%
57.5
12.4%
5.3
27.5%
Isobutane C4H10
17.3
3.3%
12.3
2.3%
7.6
1.6%
0.6
3.1%
Butenes C4H8
17.7
3.3%
9.9
1.9%
5.6
1.2%
1.0
5.2%
n-Butane C4H10
6.5
1.2%
3.7
0.7%
2.0
0.4%
Isopentane C5H12
53.0
10.0%
11.0
2.1%
1.9
0.4%
n-Pentane C5H12
31.9
6.0%
5.2
1.0%
0.6
0.1%
Hexanes & greater, C6+
391.1
73.8%
9.4
1.8%
Total
529.9
100%
528.4
100%
463.3
100%
19.3
100%
Pounds/Hour
60,600
17,000
12,950
740
Kgm/Hour
27,487
7,711
5,874
336
Molecular Weight
114.2
32.3
28
38.3
-
4,800
4,200
176
135,840
118,860
4,981
Water
MSCF/day
Cu.M/day
Bbls/day
MLitres/ day
35.
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5,860
932
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Stabiliser
Separates
hydrocarbons which
provide feed for
Alkylation Unit and
stabilised gasoline for
the gasoline pool
36.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
Feed & Products - Stabiliser
Moles/hr
Stream
Mole %
14
Moles/hr
Mole %
15
Feed to Stabilizer
0.2
1.5
3.7
83.0
139.1
0.0%
0.3%
0.7%
15.7%
26.3%
Isobutane C4H10
Butenes C4H8
n-Butane C4H10
Isopentane C5H12
n-Pentane C5H12
193.9
144.9
168.4
209.4
118.5
36.6%
27.3%
31.8%
39.5%
22.4%
0.8
8.2
6.6
203.6
118.0
0.2%
1.6%
1.2%
38.5%
22.3%
Hexanes & greater, C6+
Water
Total
487.9
92.1%
487.9
92.3%
1550.5
293%
825.1
156%
Pounds/Hour
Kgm/Hour
Molecular Weight
Bbls/day
MLitres/ day
126,300
57,287
81.6
13,300
2,115
37.
© 2013 Petroch Services Pty Ltd
Mole %
16
Composition
Hydrogen
Methane C1H4
Ethylene C2H4
Ethane C2H6
Hydrogen Sulphide
Propylene C3H6
Propane C3H8
Stabilized Gasoline
87,800
39,825
106
8,610
1,369
Moles/hr
Feed to Alkylation
0.2
1.5
3.7
83.0
139.1
0.0%
0.3%
0.8%
17.9%
30.0%
193.1
136.7
161.8
5.8
0.5
41.7%
29.5%
34.9%
1.3%
0.1%
725.4
157%
38,500
17,463
53
4,720
750
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry
End of Section 17
Design & Review
38.
© 2013 Petroch Services Pty Ltd
BP Version J11002– Occupational Hygiene in the Oil & Gas Industry