Gas Detection For Offshore Application
Gas Detection For Offshore Application
Gas Detection For Offshore Application
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Abstract: Release of hazardous and flammable gas is a significant contributor to risk in the offshore oil
and gas industry and various types of automatic systems for rapid detection of gas are therefore installed
to accentuate the elimination or reduction of the dangerous releases. There are different types of gases
which may be released and gas may be released in different environments and under different conditions.
Several principles for detecting gas are therefore applied and a variety of types of gas detectors are in
use. However, a significant percentage of gas releases remain undetected by the dedicated detectors and
hence unaccounted for and uncontrolled.
The objectives of this paper are: (1) to present a state-of-the art overview of gas detection in relation to
offshore applications, (2) to present an overview of requirements for gas detection in the Norwegian off-
shore industry, and (3) to do a comparative study of performance standards for gas detection worldwide.
The paper builds on a review of literature, standards and guidelines in relation to gas detection offshore.
1. INTRODUCTION
In the offshore industry, dangerous gases are naturally occurring or man-made in petroleum operations.
Release of hazardous and flammable gas is a significant contributor to risk in the oil and gas industry. The
ignition of flammable gas clouds or vapors can lead to major fire and explosion with highly devastating
consequences as was the case in the Piper Alpha disaster [7]. Similarly, toxic gas release can lead to
multiple fatalities over a wide area as was the case in the Bhopal gas tragedy [7], although this happened
in an onshore location.
Gas detection is a crucial topic in the process industries, e.g. the Norwegian offshore industry where
focus has been on safety barriers supported by the policy of reporting hydrocarbon leaks [20]. The
process industry learns from related incidents/accidents in addition to being proactive to predict what
can go wrong and how to control it. Various types of automatic systems for rapid detection of gas are
therefore installed to control the risk. In fact, the safety of the offshore industry depends on the efficiency
and effectiveness of the gas detection systems.
Gas detection has, however, experienced mixed results in the industry. Although it has achieved more
success than failure, the failure statistics is significant. According to the report of a research conducted
by [19], about 44% of all gas releases, or 38% of major gas releases were undetected by the gas detectors
deployed. The offshore environment is being characterized by a complex mix of open and enclosed
areas, low and high areas, diversity of hazardous gases and conditions for release, potential gas traps,
and varieties of operational and environmental conditions that may influence the unreliability of gas
detection. Besides, offshore installations have different challenging gas detection needs that require
specific solutions; e.g. some facilities require that detectors identify gases at the lowest possible level (in
ppm or LEL range), whereas other facilities are exposed to compounds or other gases that can undermine
the detectability of the target gases (i.e. a problem of cross-sensitivity or non-specificity). Furthermore,
complexities in ventilation patterns and in the size and composition of modules often make it extremely
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
difficult to site gas detectors; this implies that availability of detectors is no guarantee for detection [19].
Other gas detection related problems include incorrect selection of gas detectors, deficiencies in design,
installation, calibration and maintenance of gas detectors as well as users’ lack of knowledge of the
limitations of a given detection principle.
Several authors and companies have made or are making efforts to improve gas detection technologies.
Work on enhancing the effectiveness of single technology has been carried out by several authors, e.g.
[18] and [8] etc. The optimal placement of sensors under uncertainty has been studied by [12]. Fur-
thermore, the development of versatile single technology or integrated technologies for multiple gas
detection has been or is being explored by several others, e.g. [16], [5, 6] and [11].
The main objective of this paper is to present a state-of-the art overview on gas detection in relation to
offshore applications. The rest of the paper is structured as follows. First, the types of releases that may
occur and the conditions under which they may occur are described. This is followed by a description of
relevant principles for detecting gas, and relevant Norwegian regulatory requirements and standard. A
comparative study of gas detection standards worldwide is then presented, followed by conclusion and
recommendations.
The different types of gases which may be released in the offshore petroleum industry are described in
the following:
• Hydrocarbon (HC) gas release: This is a flammable release that may occur at atmospheric condi-
tions or under pressure from containment systems [13]. Such releases can occur in containment
systems subject to the following failure mechanisms: corrosion, erosion, wear, manufacturing de-
fects, operational loading, well pressure etc. Other possible causes include human factors in the
form of normal operational releases, operators error and third party damage [13]. The release can
occur at the topside where the process equipment are located or subsea in the form of blowouts
from wells and leaks from subsea pipelines and isolation valves etc. Specific areas where releases
are likely such as the rig floor, the vicinity of the test separator and the choke manifold require
permanent rather than portable gas detection system [9]. It is also common to release methane
(CH4 ), a lower hydrocarbon, from combustion to generate electricity and to power compressors
and pumps as well as from flaring of excess gas for safety and during well testing [15].
• Hydrogen Sulphide (H2 S ) release: This is an extremely toxic release that usually occurs as a con-
taminant in produced gases. It occurs naturally together with natural gases from wells. During
well testing, it is advisable to monitor the area to check the presence of Hydrogen Sulphide (H2 S )
concentrations and that it is safe for working, since even in relatively low concentrations this re-
lease can readily lead to fatality [9]. The first significant presence of H2 S is readily noticeable
from samples taken downstream of the choke manifold and at the gas outlet from the separator
[9]. Furthermore, H2 S usually collect at the lowest points on rigs such as the cellar deck area
(offshore) and on land rigs since it is heavier than air [9].
• Carbon Dioxide (CO2 ) release: This is a release that becomes dangerous usually in relatively high
levels in confined spaces. The release usually results from combustion of fossil fuels to generate
electricity and to power compressors and pumps, as well as from flaring of excess gas for safety
and during well testing [15].
• Carbon Monoxide (CO) release: This is a highly toxic release. It usually results from combustion
of fossil fuel to generate electricity and to power compressors and pumps, as well as from flaring
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
of excess gas for safety [15].
Offshore gas detection system is necessary to warn about the presence of hazardous and flammable gases
in unacceptable concentrations within a given ambiance in order to prevent major accidents. Several
principles for detecting gas exist to cover the different types of gases which may be released under
different environments and conditions.
The types of gas detection technologies applicable to the offshore petroleum industry, a brief description
of their principles of operation as well as their safety-related applications are shown in Table 1.
Table 1: Operational principles and safety-related applications of gas detectors [1, 3, 10]
The coverage of gas detection is a crucial factor to consider in addition to the vulnerabilities of the
detection technology that can be exploited by certain operational and environmental conditions. To this
end, the various principles for gas detection are classified based on coverage and each of the detection
principles was described further by its application area, strengths and weaknesses as shown in Table 2.
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
Table 2: Further gas detection characteristics [10, 11, 14]
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
Area detection Ultrasonic (or General process areas, Very high detection rate of pressurized gas leaks, versatility (de- Unsuitable for low pressure leaks, under certain conditions in-
acoustic) loading/offloading tects pressurized leaks irrespective of gas type), unaffected by fluenced by artificial or natural ultrasonic sources, requires es-
facilities, gas turbines, ambient conditions (fog, heavy rain and others), minimal main- timation of background noise levels before installation, cannot
flow stations, tank tenance, absence of consumable parts, robust, fail-safe, insen- determine concentration of gas, cannot pin-point leak source.
farms etc. sitive to gas dilution and changing wind direction, wide area
coverage, gas must not be at the device for detection.
IR gas cloud Large gas clouds mon- Wide field of view and detection coverage, no gas calibration is Detectability of gases is poor when the contrast with the back-
imaging itoring in unmanned required in the field, highly immune to spurious alarm sources, ground is poor, heavy fog and rain reduces detection range, suit-
platforms, pipelines simultaneous detection of multiple gases. able only for large leaks - not a small leak detector.
4. REQUIREMENTS FROM NORWEGIAN REGULATIONS AND STANDARDS
Gas detection in the Norwegian offshore petroleum industry is being regulated by some standards and
regulations briefly described in Tables 3 and 4.
The role of gas detection as stipulated in NORSOK S-001 (subsection 12.1) shall encompass the con-
tinuous monitoring of flammable or toxic gases. The standard focused primarily on hydrocarbon (HC)
gas detection (including H2 as relevant), H2 S gas detection, CO2 gas detection and CO gas detection
wherein it sets alarm limits for each of these. For hydrocarbon gas detection (including H2 as relevant),
i.e. flammable gas detection, the alarm limits (both low and high) are fixed in relation to the types of de-
tectors in use whether point detectors or IR open path detectors. It is possible to use a single alarm limit
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
Table 4: Requirements from Norsok S-001 Standard
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
for hydrocarbon gas detection, but this must be the low alarm limits. The alarm limits for area detection
systems (e.g. ultrasonic/acoustic detectors) are left to the operators to decide and adjust on the basis of
the background noise peculiar to their operating environment. However, guidelines on the use of IR gas
cloud imaging, a type of area detection, has yet to be treated by the standard. This is probably due to
its being a new technique that has yet to be applied extensively in the Norwegian industry. Furthermore,
the alarm limits for toxic gases are defined in the standard based on the effect of toxic gas in relation
to concentration or exposure time and these vary for H2 S gas detection, CO2 gas detection and CO gas
detection.
The performance standards for gas detection do specify the performance levels to which gas detectors
should be tested and operated, and several variations of these exist across the geographical regions of
the world. The variations are probably as a result of diversity of regulatory agencies. Some of the
standards available in different countries have little differences, whereas the differences between some
are significant. However, they all have a common goal which is the prevention of accidents.
In North America, as regards flammable gas detection performance specifications, FM 6310/6320 (used
mainly in the US) is similar to C22.2 152 (used mainly in Canada) and both of them are closely re-
lated to ANSI/ISA 12.13.01-2000 [4]. As regards offshore toxic gas detection, the ANSI/ISA 92.00.01
is widely used worldwide [4] and emphasizes on repeatability, step-response and recovery as part of
requirements for toxic gas detection performance tests with the worst case accessory attached [2]. The
ANSI/ISA 12.13.04 recommends instrument measurements in LEL-m (lower explosion limit meters) or
ppm-m (parts per million meters) for flammable gas open-path detection [2]. It also recommends several
rigorous tests covering solar immunity, simulated fog/mist and water vapor, partial obscuration of optics,
long range operation with 95% obscuration of optics, vibration and temperature extremes and long term
stability, either while under stress or before and after stress [2]. The ANSI/ISA 92.00.04 also demands
measurement in ppm-m (only) of the toxic gas in the optical beam of the open-path toxic gas detector as
well as a misalignment test [2].
In Europe, the national standards are becoming harmonized with the European standards and the IEC
standards. For example, as regards both point and open-path flammable gas detection performance
specifications, the IEC 60079-29 series have been adopted by many European countries [4]. The same
also applies for IEC 45544 series which are dedicated to toxic gas detection [4]. The IEC/EN 60079-
29 series recommends that a detector for flammable gas should be used where the accumulation of a
combustible air-gas mixture can pose a hazard to life and assets. Furthermore, such a detector is required
to sound alarms, show visual warnings or initiate mitigative actions. In addition, IEC/EN 60079-29 and
IEC/EN 45544 series advise on considering the effects of variations in temperature and humidity of the
gas marked for detection.
In Norway, NORSOK standards which are developed by the Norwegian petroleum industry are widely
in use. They are a range of standards intended to serve as references or bases upon which relevant Nor-
wegian regulatory bodies can prescribe statutory requirements and evaluate their compliance. In addi-
tion, NORSOK standards serve as replacements for oil company specifications and they normally make
necessary additional provisions to recognized international standards in order to address some needs
peculiar to the Norwegian petroleum industry [17]. The NORSOK standard that treats gas detection is
NORSOK S-001 (Technical safety) which has been described to some extent earlier. NORSOK S-001
is an all-in-one standard generally covering point, open-path and area detection of both flammable and
toxic gases. This is unlike the other standards that are separated such that each covers not more than one
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
of the following aspects: flammable-gas point detection (IEC/EN 60079-29-1 and ANSI/ISA 12.13.01),
toxic gas point detection (IEC/EN 45544 series and ANSI/ISA 92.00.01), flammable gas open-path de-
tection (IEC/EN 60079-29-4 and ANSI/ISA 12.13.04), toxic gas open-path detection (IEC/EN 45544
series and ANSI/ISA 92.00.04) and area detection of flammable or toxic gas.
A table briefly juxtaposing performance specifications for toxic-gas point detection across Norway, Eu-
rope and America is shown in Table 5.
Toxic gas detection NORSOK S-001 IEC/EN 45544 series ISA 92.00.01 to 92.06.01,
specifications FM 6341, NFPA 70
Gas concentrations 0, 20%, 50%, 90% of full 10 to 100 ppm H2S
scale
Temperature range -10 to 40o C 14 to 122o F (–10 to 50o C)
Relative humidity range 20% RH, 50% RH, 90% 15 to 90%
RH
Response time T90 < 2 seconds T50 < 60 seconds, T90 < T20 < 10 seconds, T50 <
2.5 minutes 30 seconds
General alarm limits Maximum is 10 x 10- 70 Db(A) at 0.3 meters
6 /20 x 10-6 (low/high from apparatus
for H2S), maximum is
5000 x 10-6 /15000 x
10-6 (low/high for CO2),
maximum is 30 x 10-6
/200 x 10-6 (low/high for
CO)
Accuracy/Linearity 0.3% (for 0.5 STGC to 10% of applied gas con-
10 STGC) to 0.5% ( centration or 3 ppm
for 0.1 STGC to 0.5%
STGC)
According to recent statistics, a significant percentage (about 44%) of gas releases remain undetected in
spite of the application of the detection technologies in use [19]. The main objective of the paper has
been to present a state-of-the-art knowledge of gas detection for offshore application.
This paper has given more insights into the various aspects of applicable gas detection and will be useful
to students and practitioners in offshore petroleum related fields. The paper has reviewed literature,
standards and guidelines in relation to gas detection in the offshore oil and gas industry. It has covered
the description of the various gaseous releases, the applicable detection technologies and their pros and
cons as well as standards and guidelines being applied in the offshore industry in Norway and worldwide.
In addition, a comparative study of performance requirements across international boundaries has been
done.
Based on the aforementioned, it can be inferred that no single detection technology is a complete solution
to offshore gas detection. There is the need to link various technologies together in order to achieve
complete coverage and enhanced redundancy. In this way, detection layers of protection (barriers) will
be established and made independent. This will enhance the prevention of major accidents characterized
by fire, explosion and toxic release. Besides, the associated flammable and hazardous gases, of which
exposure is inevitable, need continuous monitoring since the processes generating them are continuous.
Probabilistic Safety Assessment and Management PSAM 12, June 2014, Honolulu, Hawaii
Furthermore, it has been seen that no single detection standard across the world areas can be regarded
as "‘the standard of everything about gas detection offshore"’. Hence, there is the need for continuous
improvement as regards the harmonization of standards.
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