Petroleum Development Oman L.L.C.

Unrestricted
November 2004

Document ID: SP-1190

Filing Key:

DesignforSourServiceSpecification

Keywords: H2S, Sour Gas, Design, Specification, Layout, Classification

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of
this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any
form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written
consent of the owner.

Authorised for Issue:

Signed:
Anton Sluijterman, UEP
CFDH Process Engineering

The following is a brief summary of the most recent revisions to this document.
Version No.
1.0
2.0

Date
September
2000
November
2004

Author
A.C. Sluijterman
UEP/1
A.C. Sluijterman
UEP

Scope/Remarks
PDO-ERD-08-04 rewritten to new format.
Definitions clarified.
Revalidated and updated references.

Content
1.0
1.1
1.2
1.3
2.0
2.1
2.2
3.0
3.1
3.2
3.3
4.0
4.1
4.2
4.3
4.4
4.5
5.0
5.1
5.2
5.3
5.4
5.5

INTRODUCTION.................................................................................................................................4
BACKGROUND....................................................................................................................................4
PURPOSE AND SCOPE..........................................................................................................................4
COMPLIANCE WITH THIS SPECIFICATION............................................................................................4
GENERAL GUIDELINES..................................................................................................................5
EXPOSURE EFFECTS AND CHARACTERISTICS......................................................................................5
DESIGN PHILOSOPHY FOR SOUR SERVICE..........................................................................................5
SOUR SERVICE FACILITY CLASSIFICATION............................................................................6
GENERAL............................................................................................................................................6
FACILITY CLASSIFICATION..................................................................................................................6
CLASSIFICATION PROCEDURE.............................................................................................................6
DESIGN REQUIREMENTS TO PREVENT H2S RELEASE........................................................7
PIPING................................................................................................................................................7
SAMPLING SYSTEM.............................................................................................................................7
VENTS AND DRAINS...........................................................................................................................7
ROTATING EQUIPMENT.......................................................................................................................8
INSTRUMENTS.....................................................................................................................................9
DESIGN TO MINIMISE EFFECT OF H2S RELEASE.................................................................10
WELL ORIENTATION.........................................................................................................................10
LAYOUT............................................................................................................................................10
H2S DETECTION................................................................................................................................11
CONTROL ROOMS.............................................................................................................................13
DISPOSAL OF SOUR GAS...................................................................................................................13

6.0

PYROPHORIC MATERIALS..........................................................................................................13

7.0

RELATED BUSINESS CONTROL DOCUMENTS.....................................................................14

APPENDIX A: GLOSSARY OF TERMS, DEFINITIONS & ABBREVIATIONS..................................15

Design for Sour Service Specification

1.0

Introduction

1.1

Background

Version 2.0

In a significant number of cases, produced hydrocarbons contain hydrogen sulphide in sufficient

concentration to pose a potential hazard to personnel and equipment. The production,
transportation and treatment of these hydrocarbons require special care in the design of the
equipment and the facilities. The operation, maintenance and surveillance shall be such as to
prevent a potentially hazardous situation from developing. Should such a situation nevertheless
occur, the practices should assure the early detection and rectification of the potentially hazardous
situation.
The Shell HSE manual on H 2S in Operations (EP 95-0317) provides a good overview of the sour
service hazards considerations.
1.2

Purpose and scope

This document specifies the design requirements for facilities designated as Sour Service. The
scope includes:
Characteristics and hazards of H2S
Facilities classification
Design requirements to prevent H2S release
Design to minimise H2S release
Pyrophoric materials
The classification requirements of this specification shall be applied retroactively. The specification
does not cover the requirements for material selection or materials testing techniques.

1.3

Compliance with this specification

The user shall obtain written approval from the Corporate Function Discipline Head (CFDH)
Process Engineering for any deviation from this specification.

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Design for Sour Service Specification

2.0

General guidelines

2.1

Exposure effects and characteristics

Version 2.0

The exposure effects and characteristics of hydrogen sulphide are described in the HSE Manual
EP-95-0317. The key effects are summarised below:
Concentration
in air
1 ppm
10 ppm
200 ppm
500 ppm

Effect
Odour or rotten eggs can be clearly detected
Unpleasant odour. Possible eye irritation. This is the long term exposure
limit.
The sense of smell will be lost rapidly and it will irritate the eyes and throat.
Prolonged exposure (20 to 30 minutes) may cause irreversible pulmonary
oedema, i.e. accumulation of fluid in the lungs.
Unconsciousness after short exposure, breathing will stop if not treated
quickly. Dizziness, loss of sense of reasoning and balance. Victims need
prompt artificial ventilation and/or cardiopulmonary resuscitation
techniques.

H2S is highly soluble in both water and oil which enables it to be carried in solution for
considerable distances from a place of origin to escape in unexpected areas.
2.2

Design philosophy for Sour Service

The Hazard and Effects Management Process (HEMP) should be applied to the consideration of
H2S throughout the design process and facility life. The process consists of four basic steps:
(1) Identification.
(2) Assessment.
(3) Control.
(4) Recovery.
The HEMP approach, and tools to assist its implementation, are described fully in EP 95-0300. In
relation to H2S, the principal aspects to be considered are :
(1) Minimising process stream H 2S levels. At concept and front end design stages, process
selection should seek to minimise H 2S levels, and avoid generation of process streams with
very high levels of H2S.
(2) Ensuring that risks associated with H2S are quantified and recorded. The process of facility
classification is discussed further in section 3.
(3) Minimising exposure of operational and maintenance personnel to H 2S risk, e.g. by designing
for unattended plant operation and minimum maintenance requirements.
(4) Ensuring that detailed design minimises the risk of H2S release.
(5) Ensuring that adequate personnel protection is provided. This includes consideration of
training, access control, gas detection, personal protective equipment and escape.

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Design for Sour Service Specification

Version 2.0

3.0

Sour service facility classification

3.1

General
A risk assessment methodology has been developed for use in determining the H 2S Classification
of all PDO Production facilities (ref. Report TR/001/94 H2S Risk Assessment Methodology and
Classification of PDO Production Facilities, Sept 1994). This methodology has been adopted by
this specification and shall be applied during the design and operational phase.
The re-assessment requirements during the operational phase are covered by the Hydrogen
Sulphide Management procedure, PR-1078.

3.2

Facility classification
The production facilities shall be assigned to one of three categories, depending on the
concentration of H2S in the gas phase, resulting from reducing the process fluid or process gas to
atmospheric pressure:
0 to 49 ppm
Sweet facility
50 to 499 ppm
Low Risk Sour facility
500+ ppm
requires further assessment
Facilities shall be classified as High Risk Sour if both:
the concentration of H2S in the gas phase, resulting from reducing the process liquid to
atmospheric pressure, exceeds 500 ppm and
an 1 inch diameter release can cause a 200 ppm or higher H 2S in air concentration at a 2m
distance from the point of release, with a wind velocity of 1 m/s.
For gas release only, an empirical relationship between process stream pressure and H 2S
concentration has been established which enables the determination of whether a 200 ppm H 2S
concentration exists at 2m distance without individual gas dispersion calculations, as follows:
P * C > 1,000,000
where:
P = concentration of H2S in the gas phase, resulting from reducing the process fluid to
atmospheric pressure
C = process stream pressure (kPa (g) ).
For liquid or mixed phase release, individual dispersion calculations shall be performed.

3.3

Classification procedure
During the design phase, the process engineer shall quantify H2S concentrations and identify the
points on the facility where highest concentrations are anticipated to occur. If concentrations
greater than 500 ppm are predicted then points where the product of pressure and concentration are
expected to be highest shall be identified. These points shall be agreed with Operations and
included in the Area HSE Case and the Plant Design Manual (ERD-00-12).
Sampling facilities shall be included in the detailed design to enable monitoring of the identified
points during the operational phase of the facility.
Where modifications are made to the facility during the operational phase, the Project Engineer
shall be responsible for reviewing the impact of the modification on H 2S classification and
initiating any required change.

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Design for Sour Service Specification

4.0

Version 2.0

Design requirements to prevent H2S release

The following guidelines shall be followed where a facility is classified as High Risk Sour or Low
Risk Sour, to minimise the probability of H2S release.
All design considerations should consider the potential for the increase of H 2S concentration in
process streams over the life of the plant and the probability that the classification may change
from Low Risk to High Risk Sour over the production life cycle.

4.1

Piping
To minimise corrosion, piping should be designed and installed in such a way that dead ends and
areas of intermittent flow are eliminated.
Double block and bleed isolation shall be provided for High Risk Sour facilities.
Screwed fittings shall not be used in Sour Service. Flanges on piping in Sour Service should be
minimised wherever practical, to reduce the number of potential leak sources. Material selection
for sour service is addressed separately in ERD-08-02.

4.2

Sampling system
The location of sampling points necessary for future monitoring of facility classification, as per
section 3, shall be determined in consultation with Operations during design. Samples should be
taken from the areas of process plant expected to contain the highest concentrations of H 2S.
Typically 3 sample points would be expected to cover high, low and atmospheric pressure levels.
Where posible these sample points have to be combined with sample points for other purposes.
Details of sample points shall be determined in consultation and agreement with Production
Chemistry Department, to ensure compatibility with local sample handling facilities. Closed
system bomb sampling systems shall be used in High Risk Sour service. The use of bomb sampling
in Low Risk Sour service should also be considered where there is a high Gas Oil Ratio. Sample
return lines should be routed back into a lower pressure process stream. Where this cannot be
achieved the sample return line shall be flared or vented.

4.3

Vents and drains

Depressurising of equipment and process lines in Sour Service should be to a flare system. Where
this is not possible, venting may be allowed but shall be designed such that personnel cannot be
exposed to H2S concentrations above 10 ppm. Special attention should be paid to the vents from
Glycol Regenerator vapour outlets, which may contain very high levels of H2S.
All liquid in sour service shall be piped into a closed drains system, which shall be in accordance
with specification SP-1126. Vents and drains, which are for hydrotesting shall have their outlets
blocked-off by blind flanges.

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Design for Sour Service Specification

4.4

Version 2.0

Rotating equipment
This section provides a checklist for rotating equipment in Sour Service. A PDO rotating
equipment specialist shall be consulted for all rotating equipment specifications.

4.4.1

CENTRIFUGAL COMPRESSORS
The design shall be in accordance with DEP 31.29.40.30-Gen and DEP 31.29.60.32-Gen.
Shaft seals
The following mechanical seal types shall be considered:
(a)
Dry gas seals (most preferred) for design pressure below 120 bar
(b)
Conventional oil film seals for design pressure above 120 bar
(c)
Mechanical seals (restricted by speed/pressure) used typically in refrigeration systems and
small machines.
Dry gas seals shall be provided with a sweet buffer gas (e.g. nitrogen).
Lubricating and seal oil system for above 120 bar system.
A combined lubricating and seal oil system may be used unless the process gas contain levels of
H2S greater than 6 mole %, which cannot be adequately removed by a sour seal oil reclaimer. If the
H2S concentration is greater than 6%, then separate lubrication and seal oil systems shall be
provided. Seal oil collected in the contaminated seal oil trap shall not be recycled. Such oil shall be
reclaimed (vacuum degassing or air stripping) before re-circulating or be discarded.
Seal vent
A seal leak detection system shall be installed. Seal vent gas shall be directed to AP flare. If an AP
flare system does not exist, then local venting may be allowed.
Reciprocating compressors seal leak detection system shall be installed. Blanket gas shall be used
for distance piece venting. Vent gas shall be discharged to AP flare. If an AP flare system does not
exist, then local venting may be allowed. Distance piece venting and draining shall be in
accordance with DEP 31.29.40.31-Gen.
The compressor vendor shall provide (as part of the documentation package) process engineering
flow schemes of lubricating and seal oil systems, seal gas and flare and drain connections which
clearly shows how the above sour service requirements have been incorporated into the design.

4.4.2

Gas turbines and gas engines

Sour gas should not be used as fuel gas wherever possible. If sour gas is used then:
(a)
Turbine engine materials and pipework shall be compatible with the sour fuel.
(b)
Duplex filters shall be installed on the fuel gas inlet to ensure removal of ferrous sulphide
(fine black dust). These filters shall have water-flushing connections to avoid auto-ignition
of pyrophoric iron when they are opened.
(c)
Fuel supply shall be superheated to vendor specification.
(d)
Turbine enclosures shall be ventilated to ensure a safe working atmosphere.
(e)
Stack height shall be determined based on dispersion of exhaust gas to ensure that ground
level concentrations of SO2 do not exceed 5 ppm.

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Design for Sour Service Specification

4.4.3

Version 2.0

Centrifugal and positive displacement pumps

If High Risk Sour gas can be released in the event of a seal leakage, a seal leakage detection device
should be installed. If Low Risk Sour gas can be released in the event of a seal leakage,
consideration should be given to installation of a seal leakage detection device. This device may be
a seal pot with a level switch or pressure transmitter with switch, vented to an AP flare. The double
seal requirement for the centrifugal pump shall be governed by DEP 31.29.02.30-Gen.

4.5

Instruments
Sour gas shall not be used as instrument gas. Pneumatic instruments in Sour Service shall use
instrument air or sweet gas.

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Design for Sour Service Specification

5.0

Version 2.0

Design to minimise effect of H2S release

The following guidelines shall be followed to minimise the effect of an H2S release.

5.1

Well orientation
Well site access roads should, where possible, be located upwind of prevailing winds to minimise
exposure risk to personnel approaching them.

5.2

Layout
In selecting a facility site, consideration should be given to taking advantage of the prevailing wind
direction, climatic conditions, terrain, transportation routes, and the proximity of populated or
public areas. Clear entrance and exit routes should be maintained and confined areas within the
facilities should be avoided. Location, spacing, and height of flares or vent stacks should be
determined based on acceptable gas dispersion calculations.

5.2.1

Plant layout and spacing

For plant layout and spacing refer to PDO SP-1127. In addition to this specification the following
design criteria shall be followed.
Gas containing H2S may be heavier or lighter than air, and so can accumulate in low or high places.
Areas of restricted ventilation (both high and low), therefore, should be avoided, so as to allow
sour gas releases to disperse. Equipment handling sour fluid shall not be placed inside a totally
enclosed area.
The seals of rotating and reciprocating equipment which are a potential cause of High Risk Sour
releases shall be given special consideration in plant layout and spacing to avoid trapping high
concentrations of H2S and to take fullest advantage of the natural atmospheric dispersal effects. All
working locations should be equipped with at least two escape routes in separate directions. These
shall be located as far apart as possible.
Locations where operators make routine inspections for H 2S release should be easily accessible
when wearing a compressed air breathing apparatus. Elevated platforms shall use stairs only so that
there is no hindrance when carrying breather sets or rescuing H2S affected personnel.

5.2.2

Fences
Fences referred to in this document are all to stop personnel accidentally entering H 2S areas. The
H2S concentration at the station fence during normal operation shall not exceed 10 ppm. Dispersion
calculations shall be performed for all normal or operational vents.
High Risk and Low Risk Sour wellheads located in predominantly sweet fields shall be fenced.
Pipelines and flowlines in sour service do not need to be fenced.

5.2.3

Emergency escape exits

Emergency escape exits in Low Risk Sour and High Risk Sour facilities shall be provided such that
escape is possible upwind of (or at worse, perpendicular to) the prevailing wind direction. As a
minimum, escape gates shall be provided on opposite sides of the facility.

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Design for Sour Service Specification

5.2.4

Version 2.0

Warning signs
Each facility designated as being in Sour Service shall have a warning sign (in both English and
Arabic language) indicating whether it is classified as High Risk Sour or Low Risk Sour in
accordance with ERD-89-01. The following signs (as detailed in ERD-89-01) are applicable:

5.2.5

F 1003A:

Low Risk Sour Service Facility Sign

F 1003B:

High Risk Sour Service Facility Sign

WS 004:

H2S Hazard Warning Sign

Windsocks
Each Sour Service designated facility shall have sufficient windsocks located so that they may
easily be observed from any position within the station.

5.2.6

Assembly points
The preparation of a comprehensive Evacuation Plan, including consideration of requirements for
assembly points, shall be incorporated in the design of all High Risk and Low Risk Sour facilities.
Assembly points shall be located such that the local H2S concentration during the worse credible
accidental hydrocarbon release does not exceed 10 ppm. Where this would result in an assembly
point location at an excessive distance from the facility (which might create additional problems of
access and communication), a relaxation to a local concentration no greater than 50 ppm at the
assembly point may be allowed provided that Operations agreement is obtained.
Where the possibility exists for an H 2S concentration greater than 10 ppm at an assembly point,
local Emergency Procedures shall highlight that Personal H 2S Gas Detectors may continue to alarm
at the assembly point.
Dispersion calculations shall be performed for all Sour Service facilities to verify that assembly
points are suitably located. Maps showing worst case H 2S concentrations contours shall be
included in the Facility HSE Case and be displayed in the facility Control Room. The maps should
include 50 ppm and 10 ppm contours.

5.3

H2S Detection
The primary objective of fixed H 2S detection is to provide a warning to prevent entry of personnel
into a known hazardous area. A fixed system does not in itself provide personnel protection and
shall not be considered a substitute for entry precautions, personal H 2S detection or personnel
protective equipment.
A Fixed Detection system should be provided around all process plant facilities classified as High
Risk Sour. Consideration should be given to installation on Low Risk facilities as part of the
overall facility safeguarding philosophy.
Refer to HSE Manual EP-95-0317 Section 4.1 for further guidance on the selection and design of
H2S detection systems.

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Design for Sour Service Specification

5.3.1

Version 2.0

Fixed detectors in open air

There are two approaches that can be applied to fixed H2S detection in open areas:
1) H2S Leak Detection. A sensor is installed to detect leakage from a single source where the H 2S
concentration in the fluid is relatively high and /or there is a relatively high probability of a leak.
This may be applied on equipment for which an alternative design measure to minimise the
probability and/or quantity of a release, or to direct it to a safe location, is not readily available.
2) H2S Area Monitoring. Sensors are installed to detect H 2S dispersed into the plant area from any
source, and thus also cover less likely sources of release. This system may be applied in areas
where the installation of individual detectors for each potential source cannot be justified.
All fixed detectors shall have a range of 0 - 20 ppm, and shall alarm at 10 ppm.

5.3.2

Fixed detectors in enclosed areas

Buildings and enclosures where personnel can enter during normal operations (except well cellars),
located adjacent to or in High Risk Sour or Low Risk Sour designated facilities, shall contain fixed
H2S detectors set to activate alarms at 10 ppm.
For control rooms and other buildings with central air conditioning systems, which duct the chilled
air throughout the building, one fixed H 2S detector shall be installed in the air conditioning inlet.
The air conditioning unit shall be shutdown on H 2S detection. For High Risk Sour facilities, gas
tight dampers should be installed on the inlet to the air conditioning unit, to close on detection of
H2S.
For buildings where the air conditioning system does not duct air throughout the building (such as
standard gathering station control rooms), fixed H 2S detectors shall be installed; one inside the
main entrance and others in the principal rooms (e.g. the control room and the rest room).

5.3.3

Alarms
Fixed H2S detectors shall alarm audibly and visually at the:
(1)
Station control room panel.
(2)
Main entrance to the station.
(3)
H2S detector location.
(4)
Remote monitoring centre, if telemetry is installed.
The alarm shall also be audible throughout the facility under all normal operating conditions. These
detectors should be designated for H2S alarm only, and should not normally be connected to the
plant shutdown, due to the risk of spurious shutdown. Consideration may be given to a shutdown
action on H2S detection for High Risk Sour facilities, as part of an overall Safeguarding
Philosophy.
The alarm accept button shall be on the station control room panel. This alarm shall be
distinguishable from the station fire alarm. On acceptance of alarm at control room, only the
audible alarm in the control room should silence; the visual indication should remain on. At other
locations both audio and visual alarms shall remain on till H 2S level comes down below the
acceptance level. Portable H2S detectors both electronic and manual devices (with small hand
pump) are used for H2S detection.

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Design for Sour Service Specification

5.4

Version 2.0

Control rooms
Control rooms shall be designed in accordance with PDO-ERD-30-04. For Sour Service designated
facilities the additional requirements are :(1)
An oxygen resuscitator and spare O2 bottle shall be retained in each control room.
(2)
At least three wall mounted self-contained breathing apparatus sets for emergency use
shall be installed in each control room. These shall be of at least 30 minutes duration.
The above resuscitator, spare O2 bottle, breathing apparatus sets and portable H 2S detector, shall be
supplied as part of the control room project.

5.5

Disposal of sour gas

Sour gas that is to be disposed of in normal operation shall be flared. Flare systems shall be
designed in accordance with DEP 80.45.10.10-Gen.. The elevation of the flare stack and the
fencing at the base shall fulfil the following criteria:
(1)
50 ppm or less H2S at the stack base.
(2)
10 ppm or less H2S at the fence.
(3)
5 ppm or less SO2 at the fence.
Dispersion calculations shall be done to determine the stack height and fence location assuming
that flare is not ignited for H 2S and is ignited for SO 2. Attempts shall be made in design to
minimise sour gas release to environment. If no other solution is available, small volumes of sour
gas may be allowed to be vented locally to atmosphere, e.g.:
(1)
By pump seal pots which vent above the sun roof.
(2)
By level instrument vents (not the liquid drains).
(3)
By drain vessels on small facilities such as remote manifolds which do not have a flare
system.
(4)
By sour oil tank breather.

6.0

Pyrophoric materials
Pyrophoric iron sulphide can be formed on the internal surfaces of carbon steel equipment
containing H2S. Iron oxide present on the internal surfaces will react with the H 2S and form
pyrophoric iron sulphide. Pyrophoric iron sulphide can form even at very low H 2S concentration (<
0.1 ppm) as long as the partial pressure of H 2S exceeds the partial pressure of oxygen in the
environment.
Various engineering options may be considered to tackle the iron-sulphide problem, for example,
use of coated pipe to avoid iron-sulphide formation, use of filters or cyclone separators at the
station inlet to remove iron-sulphide fines, frequent pigging to keep the pipe line clean of ironoxide, etc. Any one of these options may be incorporated into the design.
While specifying the filter specification the particle size to be removed should be specified
depending on the service requirement. If a filter or cyclone separator is used to remove ironsulphides, water-flushing connection shall be provided to avoid auto ignition while removing the
pyrophoric debris.
HSE manual EP 95-0317 shall be consulted to determine the procedure for handling pyrophoric
iron sulphide.

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Design for Sour Service Specification

7.0

Version 2.0

Related Business Control Documents

PDO Business Control Documents

Number

Preparation Plant Design Manual

ERD-00-12

Materials Selection for Sour Service

ERD-08-02

Signs and Signboards

ERD-89-01

Hydrogen Sulphide Management

PR-1078

Isolation of Process Equipment Specification

SP-1125

Drain Systems Specification

SP-1126

Plant Equipment Layout Specification

SP-1127

Identification of On-Plot Pipework Specification

SP-1166

Shell Standards and Manual

Centrifugal Pumps

Number
DEP 31.29.02.30-Gen.

Centrifugal Compressors

DEP 31.29.40.30-Gen.

Reciprocating Compressors

DEP 31.29.40.31-Gen.

Rotary Type Compressors

DEP 31.29.60.32-Gen.

Piping Classes - Basis of Design

DEP 31.38.01.10-Gen.

Piping General Requirements

DEP 31.38.01.11-Gen.

Design of Pipeline Pig Trap Systems

DEP 31.40.10.13-Gen.

Pressure Relief and Flare System

DEP 80.45.10.10-Gen.

HSE Manual, Overview

EP 95-0300

HSE Manual, Hydrogen Sulphide (H2S) in

Operations

EP 95-0317

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Design for Sour Service Specification

Version 2.0

Appendix A: Glossary of Terms, Definitions & Abbreviations

AP
CFDH
DEP
ERD
HEMP
H2S
HSE
PDO
Ppm
SO2

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Atmospheric Pressure
Corporate Function Discipline Head
Design and Engineering Practice
Engineering Reference Document
Hazard and Effect Management Process
Hydrogen Sulphide
Health, Safety and Environment
Petroleum Development Oman LLC.
Parts per million
Sulphur Dioxide

15

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