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Oil refineries, processing plants, pipelines, storage farms, LPG/LNG plants, and offshore platforms all utilize or produce a wide range of hazardous combustible and toxic gases. In addition, the processes involved in each can produce non-toxic gases which, when accumulated in high concentrations, depletes oxygen causing a hazardous condition to personnel who occupy the area without proper protection.
Where hazardous conditions are the greatest, it is essential to have monitoring system that constantly monitor a facility's
conditions even if personnel are not present. Hand-held/personal monitors don't have the ability to detect concentrations
of combustible gases in unoccupied areas that are hazardous to equipment, personnel, and the facilities themselves. Depletion of
oxygen is hazardous to individuals entering any unoccupied areas, whereas any amount of toxic gases can have serious health implications (even death) for any personnel entering an unoccupied area where they are present.
Monitoring for hazardous gases in the Oil and Gas Industry can be broken down into the following categories:
 1.
LPG/LNG FACILITIES
2.
HVAC'S
3.
TURBINES
4.
COMPRESSORS AND PUMPS
5. ONSHORE
i. Wells and Remote Wells
ii. Pipelines
iii. Refineries
iv. Processing Plants
v. Storage Farms
vi. Loading Stations
6. OFFSHORE
i. Offshore Oil Rigs
ii. Floating Production Storage and Off-loading (FPSO)
All of the facilities/processes in these categories contain unique monitoring needs, select an application and the content will appear below.
LPG/LNG FACILITIES
Liquefied Natural Gas (LNG) with its major component methane is drilled from the ocean bed in various parts of the world (especially the North Sea) using either fixed exploration platforms or Floating Production Storage and Offloading (FPSO) vessels. The natural gas is transported via pipelines and tankers to the onshore facilities where it is stored in special tank farms before it is distributed to the various users.
Beside this natural resource, the petrochemical industry has developed various distillation and cracking processes that produce light hydrocarbon gases like methane, ethane, propane, butane and their derivates ethylene, propylene, butylene, etc. These refined gases, are compressed and liquefied for storage purposes and known commercially as Liquefied Petroleum Gases (LPG).
One of the major concerns associated with the LNG/LPG facilities is the fugitive emissions and liquid spills that evaporate very fast when exposed to the atmospheric pressure. The light methane gas migrates very fast over large areas hence the need for reliable, fast methane monitoring, over large areas of pipelines and storage facilities. The LPG, which contains light hydrocarbon mixtures (C1-C4), is heavier than air and tends to accumulate in low areas thus posing a fire/explosion hazard in the congested production and pipelines manifolds areas.
In addition to gas monitoring systems, Optical Flame Detectors and advanced CCTV Flame Detectors provide enhanced coverage of the LPG/LNG facilities.
HVAC'S
Monitoring the air quality in heating, ventilation, and air conditioning shafts (HVAC) is crucial, especially in the oil and gas industry where all the processes involve toxic or combustible materials. Every area of the industry comes into contact with these hazards, whether in the ventilation ducts of living quarters on offshore rigs, or in air conditioning shafts of refineries, these combustible and toxic gases that are the product or byproduct of the industry can result in the loss of millions of dollars in capital investment and hundreds of priceless lives if not continuously monitored.
TURBINES
Onshore and Offshore installations contain dedicated turbine and power generation areas that produce energy to run the various processes. The turbine enclosures and generator rooms are high risk areas due to the combination of high temperatures, moving parts, fuel, and lubricants. Combining these factors means that a fire or explosion hazard is always present. In order to limit this hazard, flame and gas monitors should be installed in these areas.
COMPRESSORS AND PUMPS
Facilities with compressors, pumps, and valves also require continuous gas and flame monitoring. These areas are prone to spills and fugitive emissions that, if undetected, can cause extensive damage to the entire facility.
The combination of heat, pressure, and vibration in compressor decks can create leakage. This, along with broken seals and gaskets in valves or pumps, provide the fuel that can come into contact with heated parts and an ignition source to develop into a fire.
Flame and gas monitors minimize theses risks, and even provide a system to monitor for the maintenance needs of equipment. The monitors should be installed in areas overlooking compressors and pumps.
| Application |
Source |
Product Solution |
| Hydrocarbon gases (Methane (CH4), ethane, propane, butane, ethylene, propylene, butylene, etc.) (Combustible) |
Turbines, compressors, pumps, drilling sites, pipelines, refineries, processing plants, storage farms, loading stations |
MLP-SC1100 (Catalytic Bead),
MLP-SIR100 (Infrared) |
| Hydrogen Sulphide (H2S) (Toxic) |
Drilling sites, pipelines, refineries, processing plants, HVAC's |
MLP-ST1200 (Electrochemical),
Gas Shield Junior or Senior |
| Fire |
Hydrocarbons |
Phoenix IR3 (multi-spectral infrared) detector,
Smart UV/IR detector,
Smart UVS detector |
WELLS & REMOTE WELLS
Hydrogen Sulphide (H2S) is a major hazard encountered at drilling sites. Leaks in drilling applications can see large quantities of H2S released, which becomes extremely hazardous to well-site personnel. Areas that are susceptible to leaks include the drillers stand, blow-out preventer, shale shaker, and mud tank.
Combustible gases can also accumulate at drilling sites, whether in primary oil recovery, where methane (CH4) is usually present; secondary oil recovery, where methane is sometimes reinjected into reservoirs; or tertiary oil recover that uses fuel to power the turbines of cogeneration plants. As a result, combustible gas monitoring is a requirement, with flame detection equipment used as a backup to safeguard equipment and personnel.
Remote well sites pose an extra challenge in the monitoring of toxic and combustible gases. As most remote sites are without a source of uninterruptible, low-cost power, a reliable and cost-effective source of power is required for these monitoring needs. Fortunately, the solution can be found in the form of stand-alone, multi-channel solar powered units.
PIPELINES
Pipelines carrying combustible hydrocarbons like oil, gasoline, and LNG/LPG (Liquefied Natural/Petroleum Gas). Liquid spills or fugitive gaseous emissions may go undetected and create hazardous concentrations of combustible and toxic gases, putting equipment, facilities, and personnel at risk. Monitoring of pipelines should occur at compressor stations for LNG/LPG, at pump stations for oil, and at metering stations for both.
| Application |
Source |
Product Solution |
| Hydrogen Sulphide (H2S) (Toxic) |
Leaks at pump stations |
MLP-ST1200 (Electrochemical),
Gas Shield Junior or Senior |
| Hydrocarbons (LNG/LPG, oil, gas) (Combustible) |
Leaks at compressor stations, pump stations, metering stations |
MLP-SC1100 (Catalytic Bead),
MLP-SIR100 (Infrared) |
| Fire |
Ignition of highly combustible hydrocarbons at compressor, pump, and metering stations |
Phoenix IR3 (multi-spectral infrared) detector,
Smart UV/IR detector,
Smart UVS detector |
REFINERIES
Continuous combustible and toxic gas monitoring is a critical facet of refineries. There are many processes and special production units in a refinery that pose specific safety hazards. These include:
Crude Desalting - The potential exists for a fire due to a leak or release of crude from heaters in the crude desalting unit. Low boiling point components of crude may also be released if a leak exists. These are closed processes, however, heaters and exchangers in the atmospheric and vacuum distillation units could provide a source of ignition, and the potential for a fire exists should a leak occur.
Thermal cracking, coking, and catalytic cracking - These are some other closed process with the potential for fire coming from the leakage of liquids, gases, or vapors that come into contact with an ignition source.
Catalytic dust - Explosive concentrations of catalyst dust can accumulate during its recharge or disposal. The handling of coked catalyst creates the possibility for iron sulfide fires, which can occur when iron sulfide ignites spontaneously in air.
Hydrogen generation - Hydrogen generation is required to provide for a continuous supply. This creates a hazard in the event of a leak or release of product or hydrogen gas.
Hydrogen Sulfide (H2S) - The hydrogen sulfide content of the feedstock must be continuously monitored to prevent personnel exposure to toxic concentrations, reduce corrosion, and prevent environmental pollution.
Isomerization - Isomerization processes convert n-butane, n-pentane and n-hexane into their respective isoparaffins of substantially higher octane number. This is another closed process with hazardous implications in the form of leaks coming into contact with an ignition source.
Sweetening - Air or oxygen is used in sweetening processes. If too much oxygen enters these processes, it is possible for a fire to ignite in the settler due to the generation of static electricity.
| Application |
Source |
Product Solution |
| Hydrogen Sulphide (H2S) (Toxic) |
Leaks from feedstock |
MLP-ST1200 (Electrochemical),
Gas Shield Junior or Senior |
| Combustibles |
Leaks from crude desalting, thermal cracking, coking, catalytic cracking, hydrogen generation, isomerization, and sweetening. Catalytic dust |
MLP-SC1100 (Catalytic Bead),
MLP-SIR100 (Infrared) |
| Fire |
Combustible leaks coming into contact with ignition sources |
Phoenix IR3 (multi-spectral infrared) detector,
Smart UV/IR detector,
Smart UVS detector |
PROCESSING PLANTS
Combustible and toxic materials found at processing plants are extremely hazardous to the facility and its personnel, especially in highly congested production areas that contain reactors, turbines, valves, and high pressure distribution pipelines.
Some of these materials include:
- Hydrogen feedstock fuel
- LNG and LPG - used as feedstock, or as energy sources for various distillation processes
- Organic monomers and polymers produced in the Plastics industry (Ethylene and Polyethylene, PFE- Perfluoroethylene, PVC - Poly Vinyl Chloride, Urethane and Polyurethane
STORAGE FARMS
Continuous monitoring of storage-tanks for leaks and fugitive emissions is a must for the safety of equipment and personnel, and is mandatory in most countries.
Petrochemical storage farms require the monitoring of Hydrogen Sulphide (H2S) close to pipes and valves around leakage points, and also require monitoring of heavy combustible hydrocarbon gas leaks that stay close to the ground.
LOADING STATIONS
Whether used as refined fuels, raw materials for processing, or feedstock for other industries, petrochemicals have to be shipped from
a processing plant or storage farm. They have to be offloaded at loading stations in either gas, liquid or compressed form - all of which are highly combustible and a major hazard to any equipment or people working in or living close to these areas.
Railway loading platforms and Truck filling stations require combustible gas and flame monitoring capable of detecting fugitive emissions and alerting in case of explosive concentrations or the incidence of fires.
OFFSHORE OIL RIGS
Drilling vessels are used for the exploration of new, and the expansion of existing, oil and gas fields. There are a number of common types of offshore structures in use, depending on the depth of the water, the water state, and field potential. The most common structures used are steel jacket and gravity based concrete platforms, as well as tethered platforms and spar structures. The typical offshore oil rig is composed of several modules, including the well- bay, personnel quarters, process areas, power, and drilling areas.
The closeness of the modules on offshore rigs calls for the continuous monitoring of fugitive emissions while
their concentrations are small and for highly reliable flame monitoring. Areas requiring protection from combustible
and toxic gas hazards include oil de-watering plants, gas compressors, accommodation blocks (HVACs), turbine / power
skids, well heads temporary refuges (TRs), cranes, shale shakers, battery rooms, bottled gas stores, and water
treatment areas. In any case, the monitoring solutions' signals need to be accurate and rapid to allow the crew to perform emergency and preventive measures that can save their lives and reduce damage to the oil rig.
The highly corrosive nature of marine environments requires that the monitoring solutions used on offshore oil rigs should be made of the most anticorrosive materials available.
| Application |
Source |
Product Solution |
| Hydrogen Sulphide (H2S) (Toxic) |
Accumulations at well-head, process, drilling areas, H2S refuge, temporary refuge (TR), shale shakers, HVACs, accommodation module |
MLP-ST1200-SS (Stainless Steel Electrochemical),
Gas Shield Junior or Senior |
| Carbon Monoxide (CO) (Toxic) |
Accumulations in Temporary Refuge (TR), and Air Intakes |
MLP-ST1200-SS (Stainless Steel Electrochemical),
Gas Shield Junior or Senior |
| Hydrocarbons (Combustible) |
Accumulations at well-head, process, battery rooms, compressor packages, cranes, shale shakers, HVACs, control room, accommodation module, and temporary refuge (TR) |
MLP-SC1100-SS (Stainless Steel Catalytic Bead),
MLP-SIR100-SS (Stainless Steel Infrared) |
| Fire |
Ignition of combustible gas accumulations |
Phoenix IR3 Stainless Steel(multi-spectral infrared) detector,
Smart UV/IR Stainless Steel detector,
Smart UVS Stainless Steel detector |
FLOATING PRODUCTION STORAGE AND OFF-LOADING (FPSO) VESSELS
FPSOs are new build or converted super tankers that provide flexible means by which oil ad gas may be extracted, processed, stored, and off-loaded easily. Continuous flame and gas monitoring solutions are required to protect high-cost FPSOs and minimize the risk to personnel that operate and live on them.
Various facilities on the vessel are used for processing the production fluids and gases, and therefore susceptible to leaks and extremely hazardous concentrations of combustible and toxic gases. These include the turret, moon pool, and topsides (pipework, pump, compressors, separators). These process facilities are commonly located above the main vessel deck in order to achieve safe separation from storage tanks. The utility systems, such as power-generation, separate the process area from the temporary refuge (TR), to provide enhanced protection to personnel.
The process and production areas are not the only sections that require continuous monitoring. Due to the compact design of FPSOs, monitoring for fugitive combustible and toxic gas emissions should be done throughout the vessel, including accommodation and control rooms. Also, being located in highly corrosive marine environments, monitoring solutions used on FPSOs should be made of the most anticorrosive materials available.
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