How Welding Habitats Mitigate Risks Associated with Hydrocarbon Releases
In the oil, gas, and petrochemical industries, hydrocarbons can create serious risks. These risks are especially high during important hot work activities. Managing these risks properly is crucial. Here we discuss the use of Welding Habitats to aid in risk mitigation, protecting people, plant and equipment.
What are Hydrocarbons?
Hydrocarbons are organic chemical compounds naturally occurring from plant and animal fossils found deep underground. Petroleum is the collective term for hydrocarbons in their various states – solid, liquid, or gas. They form the basis of important energy sources such as natural gas, crude oil, and coal.
In the 21st century, hydrocarbons are still the most sought-after energy source. Many of the world’s largest companies work in this field. This covers Petrochemical Industries, Oil and Gas Facilities both Offshore and Onshore.
Why do Hydrocarbon Releases Occur?
A study published in 2020 reported that 75% of fires and explosions on offshore facilities are a result of human error, in combination with process disruptions.
The risk of hydrocarbon releases is often much higher on brownfield sites. A brownfield site refers to the redevelopment or expansion of an existing facility. Around the world, you will find several oil & gas refineries that have been in operation for over 30 years or more, a common lifespan for offshore oil rigs. Like all facilities with a long lifespan, due to the length of time in operation, requirements for maintenance and redevelopment are essential to remain safe and operational. The platform then moves into a preservation effort before decommissioning.
Consequences of Hydrocarbon Releases
Hydrocarbon releases pose serious risks for oil refineries and the petrochemical industry.
Risk of Fire & Explosions
The risk of fires and explosions when conducting hot work is extremely high. Many hydrocarbons have low flash points, meaning they can ignite with very minimal heat or sparks. When present within classified hazardous environments, such as Zone 1 and Zone 2 DSER, it is important to use equipment and take precautions to ensure safety.
It’s also a legal requirement that you must use explosion proof equipment and Use equipment that is certified for safe use in hazardous areas i.e hot work activities, as the probability of hydrocarbon release coupled with the ignition from the welding activities is far greater. Hydrocarbon fires are considered one of the most dangerous, reaching temperatures of 1,100 degrees Celsius in under 5 minutes and will continue to burn even in contact with water. They will not only ignite a fire but can cause catastrophic explosions if not controlled.
The risk to personnel health and safety is a major concerning factor. Hydrocarbons can cause many issues for those who come into contact, including poisoning, trouble with breathing, irritation of skin and eyes, and even cardiac arrest. In its gaseous state, this can be difficult to detect and prevent once released into the atmosphere. The high level of toxicity that hydrocarbons present can pose severe and chronic health conditions even when exposed for a short period of time.
Advantages of Welding Habitats to Mitigate Hydrocarbon Risks
Isolation of Flammable Environments
One of the main advantages of a Cunningham Safezone Welding Habitat is to create a controlled environment. For personnel carrying out hot-work activities, the erection of the habitat around the maintenance area creates a sealed section, physically isolating the hot work area from the surrounding flammable atmosphere. Hydrocarbons, in all three states, can be present in oil refineries. Paired with its low ignition temperature, minimal heat is required to spark flames, so the risk of igniting is substantially higher. Our Safezone welding habitats feature fire-resistant materials, alongside a gas detection and shutdown system. As a result, a welding habitat will always provide the quickest and safest isolated environment for such activities to be carried out.
According to the Energy Institutes EI 15 guidelines, “where materials are released under pressure forming mist or spray, a flammable liquid can be ignited at temperatures far below the flash point.”. In other environments, people may not deem liquids with high flash points hazardous, so this would not cause concern. However, in classified hazardous areas, the potential for danger here is credible and will be a contributing factor.
Regulatory Compliance
Strict HSEQ regulations (Health, Safety, Environment, and Quality) govern onshore and offshore refineries. The use of a welding habitat will enable such industries to meet these requirements.
For all hot work activities, the company must adhere to a permit to work system for hot work permits. A new permit must be authorised for each project and the habitat would be added as part of an ‘Engineered Control’. A welding habitat from Safezone Habitats will help simplify the process when it comes to reducing your risks to ALARP (As low as reasonably Practicable) as a term that is used throughout the industry to ensure that you are risk assessing your activities to as low a risk as possible.
ATEX stands for ‘ATmospheric EXplosible’ or ‘Atmosphere Explosive’ is a regulation for industries in the European Union. The ATEX directive refers to the use of equipment in areas classified as ‘potentially explosive’.
IECEx stands for the ‘International Electrotechnical Commission for Explosive Atmospheres’. It is the internationally accepted certification for these activities. It is often used by companies outside of Europe, mainly in the Americas. Our Safezone Welding Habitat maintains IECEx 60079-13 certification for use across the globe.
To view all certifications relating to Cunninghams Safezone Welding Habitat System, click here.
Cost Effective Solution
On oil refineries, daily operations with natural gas and crude oil will always include the presence of hydrocarbons. As a result of this, any planned or emergency facility repairs will consistently require a separation between the elements. In previous years, a complete shutdown would have been the only viable solution to facilitate this hot work activity.
A welding habitat can help avoid an industrial shutdown. The readily available protective solutions allow for ‘Simultaneous Operations’ (SIMOPs), which as it suggests, facilitate continued maintenance activities and facility operations.
The nature of the habitats modular design allows for setup at any facility and around any obstacle. This creates a fully enclosed solution when required.
It eliminates the need for shutdowns by creating a pressurised and controlled environment for hot work activities. These activities include welding, grinding, cutting, soldering, and more. This has a direct impact on the reduction of time and repair costs, as well as the potential loss of earnings.
Structural & Environmental Impact
Upgrades are essential for brownfield sites. They must maintain structural integrity and account for a large portion of hot work activities. With engineering and technological advancements, this could result in years of ongoing upgrade projects. To minimise the risk of further damage, avoiding shutdowns would be an ideal solution.
The risks associated here are two-fold;
1. The continuous presence of hydrocarbons paired with ongoing structural updates creates an ongoing risk of potentially hazardous environments.
2. Fires or explosions caused by hydrocarbons can cause structural damage and create a domino effect.
The welding habitat allows for quick and accurate repairs without the risk of further structural damage. The ongoing risks can lead to severe environmental implications. This may damage reputations and raise insurance costs. In the end,, it can fail to protect people, production and assets. Our habitat aids in the prevention of accidental crossovers between hot work and hazards.
Safeguarding People
The main purpose of Cunninghams Safezone Welding Habitat is to protect people and equipment in dangerous environments. The welding habitat is highly durable, making it suitable for onshore and offshore facilities exposed to harsh elements. Our habitat is designed with flexible panels that allow quick and easy assembly and deconstruction. This allows for habitat construction in even the smallest of spaces for essential hot work.
Our habitat ifeatures an extraction and ventilation system, This keeps the air safe and free from harmful elements for everyone inside. We also offer an air conditioning system for added comfort for companies operating in warmer climates.
We created our welding habitat with enhanced safety features The system activates audio and visual alerts when it detects harmful gases. These are present both inside and outside the habitat for a complete system detection.
Mitigate Hydrocarbon Hazards with Safezone
Our Cunningham Safezone Welding Habitat is a proactive solution for the oil & gas industry, helping to effectively manage hazardous areas and maintaining safe working environments. By combining enhanced safety measures with compliance, your company’s ability to protect people, plants, and operations is enhanced. Contact us today for a consultation or to schedule a demo of our innovative Safezone habitat.
