1. 1. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Occupational Hygiene in the Oil & Gas Industry Day 1 – Section 7 Production Processes Gas Plants & Crude Stabilisation

2. 2. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Overview of Production Processes – Gas Plants Gas processing plant separates gas from its contaminants into marketable product by separation and treatment. Gas plants - nearly always land based, fixed installations, close to shipping, connected by pipelines. Four main processes to remove the impurities: Oil and Condensate Removal Acid Gas (Sulphur and Carbon Dioxide) Removal Mercury, Water, Nitrogen, Helium Removal Separation of Natural Gas Liquids Fractions

3. 3. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Raw natural gas - Composition Methane (CH4), Ethane (C2H6), Propane (C3H8), Butanes, Pentanes Acid gases: carbon dioxide (CO2), hydrogen sulphide (H2S), mercaptans (CH3SH) & (C2H5SH) Mercury Other gases present are Nitrogen (N2), Helium (He), water vapour & liquid Liquid hydrocarbons (natural gas condensate, gasoline, crude oil) Water, sand, debris, etc.

4. 4. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Gas Plant Process Flare

5. 5. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Typical gas plant

6. 6. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Gas Plant Processes Condensate and water removal Acid Gas Removal Dehydration (removal of water)

7. 7. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Slug Catcher Fractionation towersStorage tank areaFlare system Gas plant

8. 8. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Ancillary units/ operations Slug Catcher Gas Flare Utilities –Boilers –Power Generation –Waste Water Treatment Maintenance

9. 9. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry ComponentMole% Dry basis HeHelium0.05 N2N2 Nitrogen5.60 H2SH2SHydrogen Sulphide2.40 CO 2 Carbon Dioxide3.85 C1C1 Methane77.71 C2C2 Ethane4.73 C3C3 Propane1.68 C4 Butanes 0.91 C5 Pentanes 0.50 C6 Hexanes 0.41 Benzene 0.06 C7+ C7-C20 Hydrocarbons 2.06 Mercaptans Mercaptans (C1-C5) 0.05 Total 100.00

10. 10. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues For Gas Processing Plants a) Hazardous Substances b) Thermal Environment c) Noise d) Asbestos and Other Fibres e) Ergonomic f) Radiation g) Maintenance & Turnaround Hazards h)Other Hazards i) Environmental hazards

11. 11. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (a) Hazardous Substances Process streams and contaminants – crude oil, natural gas, (condensate), Mercury, Radon, Hydrogen sulphide and sulphur compounds Purchased chemicals and products – catalysts, treatment chemicals (amines, caustic) - this requires a chemical inventory and MSDS information Generated hazardous substances e.g. welding fume Generated waste and waste disposal

12. 12. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (b) Thermal Environment General environment & location Gas plants are usually located on land relatively close to the crude/gas field where there is access to shipping and/or pipelines. This can be in cold or hot climates.

13. 13. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (c) Noise Noise from process units, utilities and maintenance activities High noise sources are compressors and generators (typically >105 dBA) however with modern designs and improved engineering the new gas plants may be able to achieve noise levels < 85 dBA

14. 14. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (d) Asbestos and Other Fibres Removal of asbestos insulation

15. 15. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (e) Ergonomic Ergonomic hazards associated with any facility Opening/closing valves – poor posture

16. 16. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (f) Radiation Ionizing – Radiation – level measurement, radiography Naturally Occurring Radioactive Material (NORM) Non-Ionizing Radiation- Visible – Lighting UV radiation (sun, welding)

17. 17. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (g) Maintenance & Turnarounds Planned and unplanned shutdowns Potential release of product Inspection of process equipment both external and internal – confined space entry Turnarounds – Increased workforce – trained & untrained –Untrained and unskilled workforce need training on O&G hazards

18. 18. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (h) Other Hazards Location hazards – on land, predatory animals, insects, disease (Cholera, Malaria, HIV) Civil Unrest- stability of government Security of site.

19. 19. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry OH Issues (i) Environmental Hazards Environmental hazards – earthquakes, hurricanes, flood, and fire

20. 20. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry Typical gas plant located near offshore oil/gas field

21. 21. © 2013 Petroch Services Pty Ltd BP Version J11002– Occupational Hygiene in the Oil & Gas Industry End of Section 7 Natural Gas Plant