Small, Portable Oil & Gas Production Facilities: Recommended Solutions For Design and Operation
Small, Portable Oil & Gas Production Facilities: Recommended Solutions For Design and Operation
                        2014-0029
                  The Canadian Association of Petroleum Producers (CAPP) represents companies,
                  large and small, that explore for, develop and produce natural gas and crude oil
                  throughout Canada. CAPPs member companies produce about 90 per cent of
                  Canadas natural gas and crude oil. CAPP's associate members provide a wide
                  range of services that support the upstream crude oil and natural gas industry.
                  Together CAPP's members and associate members are an important part of a
                  national industry with revenues of about $110 billion-a-year. CAPPs mission, on
                  behalf of the Canadian upstream oil and gas industry, is to advocate for and
                  enable economic competitiveness and safe, environmentally and socially
                  responsible performance. Competitiveness, in North America and globally, is
                  necessary so as to attract the capital necessary to grow production and expand
                  markets to deliver value to the Canadian public and to our investors. Social
                  License, from governments, Aboriginal peoples, the public, stakeholders and the
                  communities in which we operate, will be determined by our collective
                  performance and the effectiveness of our communications and outreach.
                                                           Disclaimer
                        This publication was prepared for the Canadian Association of Petroleum
                        Producers (CAPP). While it is believed that the information contained herein is
                        reliable under the conditions and subject to the limitations set out, CAPP does
                        not guarantee its accuracy. The use of this report or any information contained
                        will be at the users sole risk, regardless of any fault or negligence of CAPP or
                        its co-funders.
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Canada T2P 3N9              Canada K1P 5H9            Canada A1C 1B6                            Canada V8W 0B5
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                                         www.capp.ca  communication@capp.ca
Overview
This guide describes design and operation practices that support safe working conditions at
small, portable oil and gas production facilities, often classified as high hazard industrial
occupancies. The objective of the guide is to limit the probability that a person in or adjacent to a
facility may be exposed to an unacceptable level of risk of injury or illness.
This guide is an update of the 1993 CAPP Safety Guidelines and reflects subsequent national and
provincial amendments. The new guide is intended to supplement other applicable standards and
regulatory codes. It recommends solutions for safe design, operation and maintenance practices
for field facilities including worker training and competency. The guide addresses common
safety issues and establishes minimum safety standards. There are three main areas of focus:
process safety, public safety and occupational health and safety. Owners should assess their own
requirements to establish design, operating, maintenance, and worker competency standards to
create a safe work environment.
July 2014                   Small, Portable Oil & Gas Facilities Guide                         Page i
                                                             Contents
1   Introduction ................................................................................................................ 1-4
         1.1        Background .............................................................................................. 1-4
         1.2        Mission, Purpose and Scope .................................................................... 1-5
         1.3        How to Use This Guide............................................................................ 1-5
2   Objectives .................................................................................................................. 2-6
         2.1        Process Safety .......................................................................................... 2-6
         2.2        Public Safety ............................................................................................ 2-6
         2.3        Occupational Health and Safety............................................................... 2-6
3   Recommended Solutions for an Integrated Safety Management System .................. 3-7
         3.1        Introduction to Process Safety Management (PSM) ................................ 3-8
         3.2        Integrated Management System Recommendations ................................ 3-8
         3.3        Hazard Assessment and Risk Management ............................................. 3-9
                    3.3.1 Regulatory Requirements........................................................... 3-10
                    3.3.2 When Hazard Assessments are Required .................................. 3-10
         3.4        Applicable Regulations, Codes, Standards, and Industry Practices....... 3-10
                    3.4.1 Manufacturers Specifications and Engineering Certifications .. 3-10
                    3.4.2 Energy Regulator Directives ...................................................... 3-10
                    3.4.3 Industry Recommended Practices .............................................. 3-10
         3.5        Integrity Management Programs............................................................ 3-11
4   Recommended Solutions for Facility and Building Design .................................... 4-12
         4.1        Equipment Layout and Spacing ............................................................. 4-13
         4.2        Skid Mounted Equipment ...................................................................... 4-16
                    4.2.1 Packaged Skid-Mounted Equipment.......................................... 4-16
                    4.2.2 Piping Design on Skid-Mounted Equipment ............................. 4-17
                    4.2.3 Minimizing Hazards In and Around Skid-Mounted Buildings.. 4-18
         4.3        Oil and Gas Processing Packages .......................................................... 4-19
                    4.3.1 Compressor Packages ................................................................ 4-19
                    4.3.2 Heater Packages ........................................................................ 4-21
                    4.3.3 Pump Packages .......................................................................... 4-21
                    4.3.4 Separator Packages .................................................................... 4-22
                    4.3.5 Treater Packages ........................................................................ 4-22
         4.4        Dehydrator Units .................................................................................... 4-22
         4.5        Fired Equipment..................................................................................... 4-23
                    4.5.1 Design of Fired Equipment ........................................................ 4-23
                    4.5.2 Installation of Fired Equipment ................................................. 4-24
                    4.5.3 Operation and Maintenance of Fired Equipment ....................... 4-24
         4.6        Liquid Petroleum Gas (LPG) Handling Facilities ................................. 4-24
         4.7        Refrigeration Process Units ................................................................... 4-24
                    4.7.1 Piping, Connections and Valves ................................................ 4-25
         4.8        Oil and Water Production Tanks............................................................ 4-25
         4.9        Flare Systems and Vent Stacks .............................................................. 4-26
July 2014                                 Small, Portable Oil & Gas Facilities Guide                                                Page 1-1
                4.9.1 Flashback Protection .................................................................. 4-26
        4.10    Detection and Emergency Shutdown Systems ...................................... 4-27
                4.10.1 Safety Systems ........................................................................... 4-27
                4.10.2 Personal Safety........................................................................... 4-28
5   Recommended Solutions for Operating and Maintenance Practices ....................... 5-28
        5.1     Site Safety Management ........................................................................ 5-28
                5.1.1 Safe Work Permits ..................................................................... 5-28
                5.1.2 Concurrent Operations ............................................................... 5-29
        5.2     Hazardous Substance Exposure and Control ......................................... 5-29
                5.2.1 Hydrogen Sulphide (H2S) .......................................................... 5-30
                5.2.2 Benzene ...................................................................................... 5-30
                5.2.3 Chemicals ................................................................................... 5-30
                5.2.4 Other Potential Occupational Exposures ................................... 5-31
        5.3     Critical Safe Operating Procedures ........................................................ 5-31
                5.3.1 Confined and Restricted Space Entry ........................................ 5-31
                5.3.2 Critical Lifts and Safe Lifting Certifications ............................. 5-31
                5.3.3 Electrical Safety (Including Working near Overhead Power
                        Lines) ......................................................................................... 5-32
                5.3.4 Energy Isolation (Including Lock-Out/Tag-Out) ....................... 5-32
                5.3.5 Flammable Atmospheres (Including Hot Work and Fire and
                        Explosion Prevention)................................................................ 5-32
                5.3.6 Ground Disturbance (Including Damage Prevention) ............... 5-32
                5.3.7 Hydrate Handling ....................................................................... 5-32
                5.3.8 Purging ....................................................................................... 5-33
                5.3.9 Vehicle OperationsJourney Management .............................. 5-33
                5.3.10 Working Alone........................................................................... 5-33
                5.3.11 Working at Heights .................................................................... 5-33
        5.4     Site-Specific Procedures ........................................................................ 5-33
                5.4.1 Knowledge of Equipment .......................................................... 5-33
                5.4.2 Commissioning and Start-up...................................................... 5-34
6   Recommended Solutions for Worker Competency ................................................. 6-36
        6.1     Worker Orientations............................................................................... 6-36
        6.2     Basic Training & Competency Requirements ....................................... 6-37
                6.2.1 Core Safety Training (Pre-Hire Confirmation and
                       Documentation).......................................................................... 6-37
                6.2.2 Technical Training: Core and Operations-Specific ................... 6-38
        6.3     Competency Management and Development ........................................ 6-40
July 2014                            Small, Portable Oil & Gas Facilities Guide                                             Page 1-2
                                                       Figures
Figure 4.1 Surface Equipment Spacing ......................................................................... 4-14
Figure 4.2 Equipment Spacing for Well Servicing ........................................................ 4-15
                                                        Tables
Table 6.1 Required certification and training ................................................................ 6-38
Table 6.2 Technical Training: Core and Operations-Specific ....................................... 6-39
July 2014                            Small, Portable Oil & Gas Facilities Guide                                   Page 1-3
1    Introduction
              This document was developed to outline some design, operating procedures and
              training recommendations to help mitigate facility accidents at small, portable oil
              and gas facilities. The goal of these recommendations is to communicate the
              design and work practices that facilitate safe working conditions. Much of the
              content is based on CAPPs Safety Guidelines published in 1993.
              Twenty years later, the original intent of this guideline continues to be relevant.
              That said, over the past 20 years there have been significant regulatory changes in
              Alberta. This new Safety Guide reflects amendments to the Alberta Occupational
              Health and Safety (OHS) Act, Regulations and Code, Alberta Safety Codes Act
              and Regulations, Energy Regulations, and the National Building and Fire Codes.
              The recommended solutions outlined in this guide were developed with the help
              of experienced facility operators. It is strongly recommended that this guide be
              used to supplement other applicable standards and regulatory codes. These
              recommendations address some of the most common issues, but are not all-
              inclusive. Owners should assess their own requirements to establish:
                 design specifications and standards to meet their specific needs,
                 operating and maintenance procedures, and
                 worker competency programs.
              This document is focused on Alberta Safety Code requirements. It is important to
              keep in mind that each provincial jurisdiction may have its own unique
              requirements that operators must be aware of and address.
        1.1   Background
              Accidents at oil and gas facilities can be prevented by a combination of the
              following:
                 employer commitment to safety in every phase of facility development and
                  operation;
                 use of qualified personnel in every aspect of facility design, installation or
                  operation;
                 appropriate work plans and procedures during engineering, construction or
                  operation of the facility;
                 adequate training for operating personnel to ensure competency; and
                 safety awareness with an emphasis on hazard identification during
                  engineering, installation and operation.
              To create a safe work environment, many oil and gas companies, in cooperation
              with various government agencies, have researched and developed equipment
              standards, work procedures and training to produce safety packages more
              specific and more comprehensive than the Alberta Building Code or the Alberta
              Fire Code.
July 2014                    Small, Portable Oil & Gas Facilities Guide                    Page 1-4
                  1993 CAPP Safety Guidelines
                   In 1992, the Production Facility Safety Committee (PFSC) was established to
                   develop the original guideline document. The committee was made up of
                   representatives from government including OH&S and the AER (formerly
                   ERCB), key industry associations including CAPP, EPAC (formerly SEPAC),
                   the Alberta Pressure Vessel Manufacturers Association (APVMA), and
                   insurance industry representatives. The resulting guideline was released in
                   August 1993.
                  2007 STANDATA Building Code Variance
                   Effective September 2007, the Alberta Municipal Affairs Building Code
                   Variance STANDATA 06-BCV-001 Oil and Gas Processing Facilities
                   references the CAPP publication. This variance outlines the provisions which
                   exempt oil and gas processing facilities from the requirements of Group F,
                   Division 1, high hazard industrial occupancies of the 2006 Alberta Building
                   Code. Without this guideline, the variance will be removed.
        1.2   Mission, Purpose and Scope
               The original mission, purpose and scope for the 1993 guideline were
               Mission
               To promote safety in small, portable oil and gas production facilities
               Purpose
               To identify unsafe work practices and develop guidelines for design standards and
               safe work procedures
               Scope
                  To make recommendations for the safe design, operation and maintenance of
                   small, portable oil and gas production facilities with the aim of preventing
                   injury and loss of property
                  To address common safety issues identified by regulators, operators and
                   insurers for small, portable oil and gas production facilities
                  To establish the minimum safety standards and recommendations for design,
                   operation and maintenance of production facilities
                  To be a resource for industry and government agencies in matters pertaining
                   to safety in small, portable oil and gas production facilities, and to foster
                   exchange of information
        1.3   How to Use This Guide
               There are five key components to the working content of the new Safety Guide.
               They are as follows
                  Section 2 outlines the Objectives of this Safety Guide. These are based on and
                   consistent with the objectives of the 2010 National Building and Fire Codes of
                   Canada.
July 2014                    Small, Portable Oil & Gas Facilities Guide                  Page 1-5
                  Section 3 outlines the Recommended Solutions for Process Safety
                   Management Systems. This section also provides related risk assessment
                   recommendations for addressing the STANDATA Variance.
                  Section 4 summarizes the Recommended Solutions for Facility and Building
                   Design.
                  Section 5 summarizes the Recommended Solutions for Operating and
                   Maintenance Practices.
                  Section 6 summarizes Recommended Solutions for Worker Orientations and
                   Training.
2    Objectives
               Portable oil and gas processing buildings and facilities are often classified as
               Group F, Division 1, high hazard industrial occupancies because of the nature of
               the processes being housed. Consistent with both the Building and National Fire
               Codes of Canada, the objective of this guide is to limit the probability that a
               person in or adjacent to the oil and gas processing buildings or facility will be
               exposed to an unacceptable risk of injury or illness as a result of
                  activities related to the construction, use or demolition of the building or
                   facility
                  the condition of specific elements of the building or facility
                  the design or construction of the specific elements of the building or facility
                  inadequate built-in protection measures for the current or intended use of the
                   building or facility
               More specifically, this guide focuses on three areas of safety:
                  process safety
                  public safety
                  occupational health and safety
        2.1   Process Safety
               An objective of this guide is to limit the probability that a person in or adjacent to
               a portable facility will be exposed to an unacceptable risk of injury or illness due
               to the loss of primary containment (LOPC) from that facility. Hazardous materials
               include toxic, explosive or flammable substances including the potential ignition
               of such a release and similar process safety incidents (PSI).
        2.2   Public Safety
               An objective of this guide is to limit the probability that, as a result of the design,
               construction or operation of the oil and gas processing buildings or facility, the
               public will be exposed to an unacceptable risk of injury or illness due to the
               uncontrolled release of a hazardous substance or energy.
        2.3   Occupational Health and Safety
               An objective of this guide is to limit the probability that, as a result of the design,
               construction or operation of the oil and gas processing buildings or facility, a
               worker in or adjacent to the facility will be exposed to an unacceptable risk of
July 2014                     Small, Portable Oil & Gas Facilities Guide                       Page 2-6
            injury or illness due to hazards. The risks of injury due to hazards addressed in
            this guide are those caused by the following:
               tripping, slipping, falling, contact, or collision,
               contact with hot surfaces,
               contact with energized equipment,
               exposure to hazardous substances,
               exposure to high levels of sound,
               persons being trapped in confined spaces, and
               persons being delayed in or impeded from moving to a safe place during an
                emergency.
3 Recommended Solutions for an Integrated Safety Management System
            Organizations are required to establish and maintain processes that implement
            preventive and protective measures for the management of hazards and risks
            identified. More specifically, preventive and control measures are normally
            implemented according to the priorities shown in the diagram and list below.
            1. elimination of the hazard                                      Hierarchy of
                                                                            Hazard Controls
            2. substitution with other materials, processes,
               or equipment                                         Eliminate or Substitute Hazard
            3. use of engineering controls
            4. use of safer work systems that increase                  Engineering Controls
               awareness of potential hazards (lights,                     Administrative
               signage, etc.)                                                  Controls
            5. implementation of administrative controls,
                                                                                  PPE
               such as training and procedures
            6. provision of personal protective equipment,
               including measures to ensure its appropriate use and maintenance
July 2014                  Small, Portable Oil & Gas Facilities Guide                        Page 3-7
              3.1        Introduction to Process Safety Management (PSM)
                            Recent process safety incidents have resulted in regulators and the oil and gas
                            industry becoming increasingly aware of the importance of process safety
                            management and its application to all phases of operations. It is recommended
                            that facility owners incorporate process safety concepts into their Health Safety
                            and Environment (HSE) management systems. Effective risk-based process safety
                            systems include the four main
                            accident prevention pillars 1 as
                            highlighted in the adjacent figure.
                            To address the principle of
                            process safety, the following
                            concepts must also be considered:
                                  quality assurance/quality
                                   control,
                                  supply chain management,
                                  operational readiness, and
                                  management of change.
              3.2        Integrated Management System Recommendations
                            It is important to develop an effective management system that integrates
                            operations and technical systems with the management of occupational health,
                            safety and environmental protection, and process safety to ensure compliance
                            with OHS Acts and Regulations.
                            The management system should correspond to the size, nature and complexity of
                            the operations and activities, hazards and risks associated with the operations.
                            System documentation should be controlled and set out in a logical and systematic
                            fashion to allow for ease of understanding and efficient implementation.
                            The management system should address the following basic safety considerations.
                                  Management involvement and commitment: the policies on which the
                                   system is based and personnel accountable for the establishment and
                                   maintenance of the management system and the personnel responsible for
                                   implementing it
                                  Goals, objectives and continued improvement: the processes for setting
                                   goals for the improvement of occupational health, safety and environmental
                                   protection and process safety
                                  Roles, responsibilities and accountability: the processes for making
                                   personnel aware of their roles, responsibilities and accountability with respect
                                   to them
1 American Institute of Chemical Engineers, 2007. Guidelines for Risk Based Process Safety. pp Iiii.
July 2014                                              Small, Portable Oil & Gas Facilities Guide           Page 3-8
                  Compliance with standards: the processes for identifying the applicable
                   company standards, industry codes and regulations that apply to the design,
                   construction, operation, and maintenance activities
                  Hazard identification and risk assessment: the processes for identifying
                   hazards and for evaluating and managing the associated risks including design
                   and operational readiness reviews
                  Training and competence: the processes for ensuring that personnel are
                   trained and competent to perform their duties
                  Emergency response planning: the processes for developing and
                   implementing emergency response procedures
                  Incident reporting and investigation: the processes for the internal reporting
                   and analysis of hazards, minor injuries, incidents, and near-misses and for
                   taking corrective actions to prevent their recurrence
                  Performance measurement and corrective action: the processes for
                   conducting periodic reviews or audits of the system and for taking corrective
                   actions if reviews or audits identify areas of non-conformance with the system
                   and opportunities for improvement
               Where applicable, the management system may need to incorporate process safety
               management considerations.
                  Information management: the processes for ensuring that all documentation
                   associated with the system are current, valid and have been approved by the
                   appropriate level of authority
                  Asset and equipment integrity: the processes for inspecting and maintaining
                   the quality and integrity of all facilities, structures, installations, support craft,
                   and equipment necessary to ensure occupational health and safety,
                   environmental protection and process safety
                  Workforce interaction: the processes for coordinating the management of
                   operations of the proposed work or activity among the owner, the prime
                   contractor, the contractors, the suppliers, the operator, and workers, as
                   applicable
                  Human factors: the processes for reducing the risk and the potential for
                   human error though engineering and design
                  Change management: the processes for ensuring that changes are reviewed
                   for hazards before implementation of the change
               An effective management system, together with operational discipline, is
               important to maintaining safe and reliable operations and regulatory compliance.
        3.3   Hazard Assessment and Risk Management
               In the past 20 years, there has been a significant shift towards risk and objective
               based regulation. The regulatory agencies responsible for oil and gas operations
               have each established requirements to identify hazards related to the operations
               being conducted and complete risk assessments.
July 2014                     Small, Portable Oil & Gas Facilities Guide                         Page 3-9
               3.3.1 Regulatory Requirements
               The Alberta Occupational Health and Safety Code requires hazard assessments of
               all worksites including a documented report of the methods used to control or
               eliminate the hazards identified. Other acts and regulations also include a
               requirement for hazard assessment and risk management. Employers must
               identify all applicable requirements and ensure that management systems address
               them.
               3.3.2 When Hazard Assessments are Required
               Workplace hazard identification, assessment and control are on-going processes.
               They should be undertaken at various times, including:
                  if they have not been done before,
                  when a hazard has been identified,
                  when a change to the workplace occurs,
                  after an incident or workplace illness,
                  at regularly scheduled times appropriate to the workplace, and
                  when a change in personnel occurs.
        3.4   Applicable Regulations, Codes, Standards, and Industry Practices
               There are a number of regulations and industry standards important to the design
               of oil and gas processing buildings and facilities which, when adequately
               implemented, greatly contribute to the safe design and operation of oilfield
               facilities.
               3.4.1 Manufacturers Specifications and Engineering Certifications
               Part 3 of the Alberta OHS Code identifies the engineering certification
               requirements that dictate oilfield equipment requirements.
               Those responsible for the planning and supervision of work should be familiar
               with those circumstances that require the use of certified equipment.
               3.4.2 Energy Regulator Directives
               The AER has established regulations and directives specific to oil and gas
               equipment design standards.
               3.4.3 Industry Recommended Practices
               In addition, the upstream petroleum industry has established a number of industry
               recommended practices (IRPs) that drives equipment standards for wells. When
               identified by the key petroleum industry associations, additional industry
               recommended practices are developed. The Enform website should be checked
               regularly to confirm the availability of new or revised IRPs.
               Other regulatory considerations related to equipment standards include:
                  Equipment must be registered, certified or licensed in accordance with federal,
                   provincial and local requirements, even when equipment is used on private
                   property.
July 2014                    Small, Portable Oil & Gas Facilities Guide                  Page 3-10
                  All licences and certifications required to operate equipment must be available
                   to the worker responsible for operating the equipment. If not, the equipment
                   must not be operated.
                  When purchasing manufactured equipment, the required engineering
                   specifications and certifications will normally have been addressed. As
                   highlighted in Part 3 of the Alberta OHS Code on specifications and
                   certifications, there are two situations where added care and attention is
                   required, specifically:
                   o whenever equipment is being specially constructed for circumstances
                       identified on that equipment that require certification by an engineer; and
                   o whenever certified equipment is being repaired or modified in a manner
                       that may affect the structural integrity or stability, the repairs or
                       modifications must be certified by an engineer.
                  International Standard NACE MR0175/ISO15156Petroleum and Natural
                   Gas IndustriesMaterials for use in H2S-containing Environments in Oil and
                   Gas Production must be consulted when designing sour service facilities and
                   equipment. Refer to CAPP Guide on the use of the NACE MR0175 Standard.
        3.5   Integrity Management Programs
               Current regulations governing the design and operation of oil and gas processing
               buildings and facilities require companies to establish integrity management
               programs. The focus of the programs is to improve both process and occupational
               safety by reducing the number and severity of process-related incidents,
               especially loss of primary containment events.
               Key plans and programs integral to meeting the objectives of this guide include:
                  Well Equipment Standards
                   The critical issue is ensuring the equipment provided by each contractor is
                   aligned with objectives of the owners well program and the technical
                   requirements needed to achieve the drilling objectives. Well equipment
                   standards are based on a combination of AER well-related directives and
                   industry recommended practices developed by the Drilling and Completions
                   Committee (DACC).
                  Boilers and Pressure Equipment Safety Code Compliance
                   Owners and contractors are responsible for the safe operation of their boilers
                   and pressure equipment. They are required to establish an inspection program
                   to ensure that these responsibilities are met, ensuring that the inspection of all
                   boilers, fired heaters, pressure vessels, and piping systems that contain an
                   expansible fluid above 103 kPa (15 psi) are completed under an approved
                   pressure equipment integrity management plan, as required under the
                   provincial pressure vessel regulations (ABSA AB 512: Pressure Equipment
                   Integrity Management Requirements in Alberta). Important: ABSA AB-512
                   requires that key components of a process safety management system be
                   addressed including: management of change (MOC), hazard assessments,
                   design documentation, and purchasing controls.
July 2014                     Small, Portable Oil & Gas Facilities Guide                    Page 3-11
                Management Plan Requirements for Storage Equipment
                 The owner, and in some cases contractors, are responsible for implementing
                 an integrity management plan for storage equipment to ensure that operation
                 of all storage facilities is in compliance with AER Directive 055: Storage
                 Requirements in the Upstream Petroleum Industry. Similar requirements have
                 been established by both the British Columbia and Saskatchewan energy
                 regulators.
                Pipeline Integrity Management Plans
                 Once a pipeline is successfully constructed and tested for operation, it is the
                 responsibility of the owner/licensee to ensure that it is operated and
                 maintained in a manner consistent with the regulations. To address this
                 requirement, owners are required to develop a Pipeline Integrity Management
                 Plan Manual (formerly referred to as Pipeline Operating and Maintenance
                 Manual) to provide guidelines for the operation and maintenance of their
                 production pipeline systems.
                Electrical Safety Code Compliance
                 It is important to utilize licensed contractors to ensure that the design,
                 construction, maintenance, and operation of electrical equipment are in
                 compliance with provincial electrical regulations and standards. Both the
                 owner and service contractors are responsible for ensuring electrical
                 inspections and maintenance are completed in accordance with CSA C22.1-06
                 Canadian Electrical Code Part 1, the Code for Electrical Installations at Oil
                 and Gas Facilities (2006) and provincial regulations established by the
                 responsible authority.
                Gas Safety Code Compliance
                 To comply with provincial gas safety requirements, all fuel gas installations
                 for gas fired equipment are to be installed in accordance with CSA B149.1-05,
                 Natural Gas and Propane Installation Code and provincial gas regulations.
                 This includes the installation of propane tanks at wellheads and installations
                 where raw gas is being used as fuel.
                Measurement Equipment QA/QC
                 The owner is responsible for ensuring measurement activities at each facility
                 are completed in accordance with regulations AER Directive 017:
                 Measurement Requirements for Oil and Gas Operations or BC OGC 07-21.
4    Recommended Solutions for Facility and Building Design
             This section provides design recommendations for small, portable oil and gas
             production facilities. Key areas of concern include the following
                layout and spacing of equipment, particularly with respect to ignition sources
                 such as fired equipment and flare stacks
                potential for entrapment of hydrocarbon liquids and vapours beneath the skid
                 floor
                electrical area classifications needs to be determined for portable facilities to
                 ensure that the correct electrical equipment is purchased and installed
                building design and layout to ensure adequate ventilation and heating
                 including confirmation of building air changes to maintain electrical
July 2014                   Small, Portable Oil & Gas Facilities Guide                    Page 4-12
                   classifications is an important consideration for winter operation for skid
                   packages (Note: The Division 2 electrical classification may be voided if the
                   proper air changes are not provided in winter and may require an upgrade to
                   Division 1.)
                  equipment spacing and separation distances as required to comply with AER,
                   OHS and Canadian Electrical Code requirements
                  safe worker egress in an emergency, safe location of equipment air intake, and
                   gas exhaust
                  flare and closed-drain systems design
                  fire, gas and H2S detection and shutdown systems
                  protection from freeze-up of lines, vents and equipment
                  dehydration unit design, particularly with respect to freeze-up, pressure relief
                   on reboilers and separators for wet gas
                  fired heater design, particularly with respect to location of the heaters, design
                   of flame arrestors and use of ignition systems
                  product loading facilities, including design of safety systems and location
                   away from hazardous areas
               There are other design concerns that have not been covered here. Owners should
               do their own hazard assessments to identify specific design requirements.
               Design of oil and gas facilities should be carried out by a professional engineer
               registered with the Association of Professional Engineers and Geoscientists of
               Alberta (APEGA) or a qualified technologist. The design should be in accordance
               with all codes and regulations referenced in this document and other relevant
               sources. This guide is intended as a supplement to, not a replacement for, existing
               guidelines and regulations.
               Owners should remember that not all safety-related concerns can be designed out.
               In these cases, written operating procedures will need to be put in place and
               operating personnel must be trained to identify hazards and implement site-
               specific operating procedures.
               Construction and installation of small portable oil and gas production facilities
               should be performed by competent personnel under the direction of a prime
               contractor with control over the work being performed.
        4.1   Equipment Layout and Spacing
               All storage areas, facilities and rigs must comply with the equipment spacing
               requirements identified and detailed in the Alberta Oil and Gas Conservation
               Rules and summarized in AER Directives 036, 055 and 056. IRP Volume #20
               Wellsite Design Spacing Recommendations provides guidelines on wellsite size
               and spacing. Specifically, this IRP provides a set of best practices to ensure
               consistent and legal lease size information for typical drilling, completions, and
               production facilities in Western Canada and the North West Territories. Diagrams
               illustrating Alberta Energy Regulator spacing requirements are included on the
               following pages.
July 2014                     Small, Portable Oil & Gas Facilities Guide                   Page 4-13
Figure 4.1 Surface Equipment Spacing
(source: AER Directive 056: Energy Development Applications and Schedules, Appendix 6)
July 2014                  Small, Portable Oil & Gas Facilities Guide             Page 4-14
Figure 4.2 Equipment Spacing for Well Servicing
(source: AER Directive 037: Service Rig Inspection Manual, Schedule 11)
Note: The doghouse and light plant shall be positioned in accordance with smoking and open
flame regulations under the Electrical Protection Act.
All distances shown are minimum distances.
July 2014                   Small, Portable Oil & Gas Facilities Guide              Page 4-15
        4.2   Skid Mounted Equipment
               Skid-mounted equipment must be installed with an understanding of the hazards
               involved. This section provides recommendations for the following:
                  packaged skid-mounted equipment,
                  piping design on skid-mounted equipment, and
                  minimizing hazards in and around skid-mounted buildings.
July 2014                     Small, Portable Oil & Gas Facilities Guide                    Page 4-16
                4.2.2 Piping Design on Skid-Mounted Equipment
                Piping design recommendations include issues encountered during installation,
                applicable specifications, connections, valves, and instrumentation.
                4.2.2.1 Facility Piping Installation
                The following specifications apply to carrying out piping installations:
                   Check that the vendor has supplied all materials and equipment as specified.
                   Use only professional engineers or qualified technologists to design piping
                    additions or modifications to existing facilities. Update drawings in
                    accordance with Alberta Boilers Safety Association (ABSA) requirements.
                   Use only qualified personnel to perform and direct field construction and
                    facility installation.
                   Do not install pressure piping under floors. If required, under-floor piping
                    should be butt or socket welded.
                   If packaged equipment includes flare piping, set elevations to prevent the flare   .,1.
                    header from being trapped at the skid boundary. Flare piping should slope
                    towards the flare knockout drum.
                4.2.2.2 Piping Specifications
                Make sure piping meets all necessary specifications.
                   Use insulation or protective guards in accordance with OHS regulations to
                    protect workers against contact with high temperature piping.
                   Consider the weldability of the materials (e.g., low carbon content as per
                    NACE MR-01-75) and the need for post-weld heat treating (e.g., stress
                    relieving of the welds as per ASME B31.3) in specifying sour process piping
                    when required by the welding procedure or in circumstances where it is
                    required to mitigate hardness or residual stress.
                   Do not use copper or brass in sour service.
                   Comply with the applicable American National Standards Institute (ANSI)
                    ratings for relief valve protection and piping both upstream and downstream
                    of packaged units.
                4.2.2.3 Valves
                The following recommendations apply to valves:
\                  Provide over-pressure protection for all specification breaks (changes in pipe
                    pressure rating), taking temperature effects into consideration.
                   Do not use check valves for isolation. Use spectacle blinds or double block
                    and bleed if pressure piping is frequently opened.
                   Use indicating-type isolation valves below relief valves in accordance with
                    ABSA requirements. (Valves must be car-sealed or chained and locked open.)
                   Install double-block valves at sampling points. Do not use process
                    connections for routine sampling.
    July 2014                  Small, Portable Oil & Gas Facilities Guide                  Page 4-17
            4.2.2.4 Connections
            The following recommendations apply to piping connections:
               Use a minimum of Schedule 80 material for threaded connections. Note: This
                is the recommended minimum up to 60.3 mm (2 in) for mechanical strength,
                but not above 60.3 mm (2 in).
               Avoid using threaded connections if H2S partial pressure is more than 0.30
                kPa for the main process connections.
               For small diameter side branch connections in vibrating service, consider the
                use of gusseting and ensure that the design and installation of piping supports
                will be adequate for the design loads. Consider the use of armoured flex
                connections to minimize the use of threaded connections in vibrating service.
            4.2.2.5 Instrumentation
            The following recommendations apply to piping instrumentation:
               Use dry air for instruments if possible. If a flammable or inert gas is used,
                ensure instruments are safely vented outside and instrument housing seals are
                periodically checked for leaks.
               Never use sour gas for instruments (i.e., gas with detectable concentration of
                H2S).
               Never interconnect air and gas instrumentation systems without purging.
                System purging is necessary if gas is to be used as a backup to eliminate the
                potential for explosive mixtures. (Note: A nitrogen cylinder is preferred.)
               Externally mount level switches if possible. If internal switches are used, they
                must be tested while in service.
               Match level gauges to the design pressure of the equipment and blow down
                into the drain system. Leave valves turned off, or use appropriate automatic
                shut off valves when not taking a reading. Use level gauge valves with ball-
                check shut-off valves.
               Install compression-type tube fittings in strict accordance with the
                manufacturers recommendations. Check fittings with a gap gauge.
            4.2.3 Minimizing Hazards In and Around Skid-Mounted Buildings
            Minimize potential hazards in buildings by doing the following:
               Ensure adequate gravity ventilation or exhaust fan activation if hydrocarbon-
                containing equipment is inside a building. In buildings where sour gas may be
                present there should be a minimum of 12 air changes per hour; in sweet gas
                packages there should be at least six changes per hour.
               Have a minimum of two doors with panic hardware in buildings larger than
                7.4 m2.
               Incorporate alternate escape routes (including windows) in the building
                layout.
               Leave a clearance of at least one meter between major equipment for easy
                evacuation.
July 2014                  Small, Portable Oil & Gas Facilities Guide                  Page 4-18
                       Install canopies and/or ice rakes above doors located under the down slope of
                        the roof.
                       Locate hydrocarbon accumulators outside buildings and making sure building
                        heaters, for structures where hydrocarbons are present in piping or vessels, are
                        approved for use in hazardous locations.
                       Vent and install catalytic heaters with start-ups, shut-offs and guards in
                        compliance with electrical protection branch regulations. Fuel gas scrubbers
                        supplying catalytic heaters should have a high-level shut-off device.
                        o Note: Propane is acceptable as an alternate fuel in catalytic heaters. Sour
                            gas should never be used in catalytic heaters.
                        o Prevent liquid hydrocarbons (which have a lower ignition temperature
                            than natural gas) from coming into contact with catalytic heaters.
           4.3    Oil and Gas Processing Packages 2
                    Additional recommendations are provided for the following types of packages:
                       compressor
                       heater
                       pump
                       separator
                       treater
                    4.3.1 Compressor Packages
                    To help ensure compressor packages operate safely:
                       Minimize flow through rotating equipment (especially centrifugal
                        compressors) during depressurizing or purging as this will also help
                        prevent damage to the equipment.
                       Use engine ignition systems approved for use in hazardous locations.
                       Use gussets for Pressure Safety Valve (PSV) in vibrating service.
                       Install industry standard shutdown devices in all packages in accordance
                        with risk assessment results.
                    4.3.1.1 Compressor Intake and Start Gas Systems
                    The following steps help ensure compressor intake and start gas systems function
                    safely:
                       Direct start gas exhaust piping to the building exterior above the building eave
                        following the precautions outlined in CAPP's Flammable Environments
                        Guideline.
2
    Section 4.3 References
American Petroleum Institute. RP7C-11F, Recommended Practice for Installation, Maintenance, and Operation of
Internal Combustion Engines.
Occupational Health and Safety Act (OSHA) Fact Sheet, Internal Combustion Engines as Ignition Sources.
CAPP. Flammable Environments Guideline.
July 2014                          Small, Portable Oil & Gas Facilities Guide                          Page 4-19
               Avoid the intake of hydrocarbon vapours by making sure the combustion air
                intake draws from outside air for gas-enginedriven compressors at hazardous
                locations. Make sure that air intakes are at a safe distance from gas headers.
            4.3.1.2 Compressor Piping, Connections, and Valves
            The following steps help ensure compressor piping, connections and valves
            function safely:
               Insulate or guard engine exhaust piping inside the building.
               Minimize the use of threaded piping in vibrating service.
               Threaded piping is acceptable for:
                o low-pressure service such as fuel and start gas,
                o connections for pressure and temperature indicators,
                o small pipe sizes (e.g., Nominal Pipe Size [NPS] less than 48.3 mm [1.5
                    in]).
               Use vibration analysis to pinpoint sources of vibration and correct problems
                before piping fails.
               Provide adequate support to process piping. Vibration effects must be
                considered.
               Separate drain-line headers for glycol and oil waste storage tanks.
               Install fire-safe valves on makeup controls and day tanks.
               Use flanged connections, not threaded control and drain connections, in sour
                service.
               Locate pressure taps on adjacent upstream/downstream piping.
               Minimize the number of flanged connections on compressor cylinder
                pulsation bottles to reduce the risk of failure from equipment vibration.
               Use external level cages with flanged isolating valves for mounting
                instrumentation on sour service scrubbers. Ensure that adequate drains and/or
                vents are installed on external level legs and gauge glasses.
               Provide flanged spool pieces to allow adequate maintenance access or access
                as required by process considerations. Mount breaking flanges on supports.
               Locate unit block valves outside the package building if possible. If the valves
                are located inside, they must be installed as close to the building wall as is
                allowable.
               Install relief valves on each compression stage of the unit with set points
                appropriate for the maximum working pressure of the compressor.
               Provide over-pressure protection from shut-in pressures occurring upstream.
                Connect relief valves to the flare system or above the building eave line and
                secure them against reaction forces.
               Use socket or butt welding on sour gas piping for packing vents and drains.
               Connect compressor distance piece vents and drains to an independent vent-
                and-drain system to prevent back pressure on the system. Also provide
                integral packing vent- and drain-tanks with drain-out and atmospheric-vent
                connections.
               Keep oil drains independent of all other drain systems. Provide waste oil tanks
                with drain-out and atmospheric-vent connections.
July 2014                  Small, Portable Oil & Gas Facilities Guide                  Page 4-20
               Locate glycol/water header tanks so leakage will not drain onto exhaust piping
                or insulation.
               Provide gauge glasses, protected against mechanical damage, for glycol/water
                and lubricating oil header tanks. (Lube oil header tank auto shut-off valves
                may be used.)
               Install crankcase explosion-relief valves on compressor engines.
            4.3.1.3 Compressor Instrumentation
            The following recommendations apply to compressor instrumentation:
               Use intrinsically safe instrumentation systems or systems approved for use in
                hazardous areas.
               Use gas detection and fire detection equipment as specified in Section 4.10 of
                this guide.
            4.3.2 Heater Packages
            The following steps help ensure heater packages operate safely:
               Install adequate expansion tanks on bath heaters.
               Protect heater shells with a tank hatch outside the building or a pressure-
                relieving device that discharges outside the building.
               Use heater coils designed to withstand full field shut-in pressure or that are
                protected by PSVs.
               Provide a stack-inspection/clean-out port at the bottom of the stack.
               Use stainless steel flame arrestors on combustion air intake of salt bath heaters
                or arrange arrestor to prevent contact with nitrate/nitrite salts in the event of
                fire-tube failure.
               Size the fuel gas scrubber PSV to handle full upstream flow and pressure.
                (Design must consider possible fuel gas regulator failure.)
               Install liquid knockout facilities with a high-level shutdown on the fuel gas
                supply.
            Also consider the recommendations in Section 4.5, Fired Equipment.
            4.3.3 Pump Packages
            The following steps help ensure pump packages operate safely:
               Use belt drives of the approved static conductive type.
               Use pulsation dampeners on plunger-type positive displacement pumps as
                required by the manufacturer.
               Use vibration analysis to pinpoint sources of vibration and correct problems.
                (Concrete mass for foundations should be sufficient to minimize vibration.)
               Install vibration shutdowns on pumps where appropriate.
               Install PSVs between the pump and pump discharge block valve that are of
                adequate size rating for use with positive displacement reciprocating pumps.
               Install a filter separator upstream of the pump if there is a possibility that the
                fluid contains abrasives.
July 2014                  Small, Portable Oil & Gas Facilities Guide                      Page 4-21
                   4.3.4 Separator Packages
                   The following steps help ensure separator packages operate safely:
                    Use inlet separators that have high-level and high-pressure alarm and
                     shutdown switches and can handle the predicted quantities of liquids,
                     including slugging.
                    Use dump valves that are fail-close and provide shut-off at the maximum
                     vessel operating pressure differential.
                    Consider the addition of abrasives (e.g., sand) filter upstream if abrasives are
                     anticipated (e.g., frac sand or reservoir sands).
                    Provide man ways that are a minimum of 500 mm (20 in) internal diameter
                     (I.D.) on vessels with an I.D. greater than or equal to 900 mm.
                   4.3.5 Treater Packages
                   The following steps help ensure treater packages operate safely:
                      Use packages that contain the following shutdowns: high and low level, high
                       temperature, high pressure, and flame failure.
                      Use electrostatic treaters that have circuit breakers and an indicator light that
                       shows if the grid is energized.
                      Install vent hoods and drains on sample boxes.
                      Use coalescing media (other than wood excelsior) to minimize the hazards
                       associated with confined space entry to treater for cleanout.
                      Use purge-gas connections on treaters designed to eliminate potential air trap
                       points so a complete purge can be made.
                      Use corrosion coupons and internal coatings for the treater if in corrosive
                       service.
                      Use external caged level controls to provide a safe means of isolation and
                       removal.
                      Use high-pressure transparent or reflex-type level gauges instead of tubular
                       glass columns.
                   Also consider the recommendations in Section 4.5, Fired Equipment.
          4.4    Dehydrator Units 3
                   The following steps help ensure dehydrator units operate safely:
                      Install heat tracing to prevent freezing on the top of the still column and on
                       any extension of the piping on the vapour outlet connection of glycol
                       regenerator still columns. Insulate with foam glass or a non-permeable
                       material. Alternatively, reroute the still column vent down through the
                       packing section.
                      Slope the vent line continuously to drain.
3
    Section 4.4 References
CAPP. Control of Benzene Emissions from Glycol Dehydrators.
CAPP. Guideline for the Prevention and Safe Handling of Hydrates.
July 2014                         Small, Portable Oil & Gas Facilities Guide                    Page 4-22
                       Route the vent line off the still column to a storage tank with a heat-traced
                        vent to make sure the vapour steaming off is visible.
                       Install the storage tank as far as possible from the reboiler flame arrestor, and
                        provide for level gauging and pump out.
                       Prevent overpressure of the reboiler by installing a U-tube, a witch's hat cone-
                        type check, a liquid relief regulator, or other pressure relief device on the
                        reboiler.
                       Use pressure regulators and PSVs on gas-powered glycol pump installations.
                       Vent gas lines to the eave line away from openings and provide protection
                        against water surges.
                       Use hydrocarbon flash tanks complete with skimmer connections on
                        dehydrators treating rich gas.
                       Install a 0-to-70 kPa pressure gauge on the reboiler that is big enough to be
                        easily visible to the operator.
                   Also consider the recommendations in Section 4.5, Fired Equipment.
           4.5    Fired Equipment4
                   The following recommendations for fired equipment apply to the design,
                   installation, operation and maintenance and shall be in accordance with CSA
                   B149 Code and Provincial Regulations.
                   4.5.1 Design of Fired Equipment
                   The following recommendations apply to the design of fired equipment:
                       Use burner pilots that will shut down in an ESD situation.
                       Install ignition systems that eliminate the need for torch lighting.
                       Add safety floats to ensure dry fuel.
                       Use appropriate sight glass and burner-access ports. Where possible use
                        screwed-on access ports instead of bolted types.
                       Use only fired equipment that has high-temperature, flame failure and low-
                        level shutdown devices.
                       Mount the high temperature shutdown thermostat below the temperature
                        control thermostat and above the fire tube to ensure liquid coverage.
                       Provide a clean-out port at the bottom of the stack.
                       On the pilot piping, do not use a burner that has a trap where liquids can
                        accumulate.
                       Use five-piece mitred firebox returns and a removable fire tube.
                       Bolt flame arrestor housing to an external flange.
4
    Section 4.5 References
American Petroleum Institute. RP 12N Operations, Maintenance and Testing of Firebox Flame Arrestors.
Occupational Health and Safety. Safe Operation of Fired Equipment in Hazardous Locations Bulletin, SH014.
July 2014                          Small, Portable Oil & Gas Facilities Guide                          Page 4-23
               4.5.2 Installation of Fired Equipment
               The following recommendations apply to the installation of fired equipment:
                  Locate fired equipment outside of areas classified as hazardous locations. It is
                   better to use remote/indirect heating of process equipment than direct fire-tube
                   heating.
                  For existing facilities where it is not possible to locate fired equipment outside
                   hazardous locations:
                   o never locate firebox ends of fired equipment in enclosed hazardous areas,
                   o equip firebox air intakes with adequate flame arrestors,
                   o do not locate points of hydrocarbon venting near firebox air intakes, and
                   o use a firebox that is air tight except for the air intake flame arrestor's
                       element.
               4.5.3 Operation and Maintenance of Fired Equipment
               The following recommendations apply to the operation and maintenance of fired
               systems:
                  Maintain clean flame arrestor cells.
                  Never increase fuel pressure to burners above maximum pressure suggested
                   by the manufacturer.
        4.6   Liquid Petroleum Gas (LPG) Handling Facilities
               The following recommendations will help ensure the safe operation of LPG-
               handling facilities:
                  Provide for the safe venting of any LPG trapped between the truck and
                   loading line valves after loading or unloading.
                  Locate loading and unloading facilities in well-ventilated areas that are well
                   separated from site facilities and equipment.
                  Install back check valves in process rundown lines and unloading lines close
                   to storage tanks.
                  Install excess flow valves in truck loading lines from pressure storage tanks.
                  Install emergency shut-off valves on truck loading lines to ensure valves close
                   when trucks pull away or start up.
                  Install bulkheads and shear points downstream of valves to ensure there is a
                   reliable failure point downstream of valves.
                  Ensure grounding cables and clamps are in place and are used.
        4.7   Refrigeration Process Units
               The following recommendations will help ensure the safe operation of
               refrigeration units:
                  Locate propane accumulators outside buildings because propane can be a
                   significant hazard if it remains in the plant. (Propane refrigerant is not
                   normally depressurized to flare, but it can be blown down to flare if fire is
                   detected in the plant.)
                  Double-valve all propane drain and vent lines.
July 2014                     Small, Portable Oil & Gas Facilities Guide                    Page 4-24
                  Use indirect-fired reboilers if possible. If it is necessary to use direct-fired
                   reboilers, locate them away from hazardous areas. Also see this guide, Section
                   4.5, Fired Equipment, for more information.
                  Use antistatic belts on belt-driven engines.
                  Sleeve and air cool the engine exhaust. The crankcase vent should be short
                   and vented to the atmosphere. Mount the engine air intake on a natural-gas-
                   driven engine outside hazardous areas.
                  Provide engine oil-change facilities for motors and compressors to avoid
                   and/or contain spills.
                  Use a glycol flash tank to prevent hydrocarbon carryover into the glycol
                   reboiler.
               4.7.1 Piping, Connections and Valves
               The following recommendations will help ensure the safe operation of
               refrigeration piping, connections and valves:
                  Match low-temperature cast steel valves to the pressure rating of standard
                   flange materials. Both A352 LCB and A352 LCC valves are suitable for
                   service at -45oC (-50oF). (The A352 LCB has a lower pressure and
                   temperature rating than Standard A-105 or A350-LF2 flanges.)
                  Use flexible connections as little as possible. If vibration is a problem, use
                   high-pressure rated steel wire reinforced flex connections.
                  Install adequate ESD stations with shutdown logic to ensure the safe and
                   timely shutdown of the facility.
                  Install isolation valves on sensing points.
        4.8   Oil and Water Production Tanks
               The following recommendations will help ensure the safe operation of production
               tanks and oil batteries:
                  Use emergency venting of tanks for storage of production liquids that
                   complies with API 2000.
                  The design of tank vents and pressure relief devices shall consider potential
                   overpressure from high pressure gas discharged through the liquid side of the
                   upstream pressure vessel if the liquid dump valve fails to open or the manual
                   bypass is left open.
                  Make provision for upsets or flows in overpressure/vacuum protection,
                   including the failure of blanket gas regulators and emergency relief systems.
                  Use remote level gauges on tanks to eliminate the need to climb a tank to
                   gauge the fluid level.
                  Locate all truck loading/unloading stations outside designated hazardous
                   areas.
                  Use grounding cables and clamps.
July 2014                     Small, Portable Oil & Gas Facilities Guide                    Page 4-25
           4.9    Flare Systems and Vent Stacks 5
                   The following recommendations will help ensure the safe operation of flare
                   systems and vent stacks:
                       Lock off in the field all valves identified by "CSO" (car-seal open) or "CSC"
                        (car-seal closed). This includes block valves under relief valves and bypasses
                        around emergency shutdown valves.
                       Install and record the locks in compliance with ABSA requirements.
                       Provide for venting and blowing down instruments and instrument manifolds
                        during design.
                       Provide flare knockout drums that are large enough and have the required
                        instrumentation to prevent the liquids blowing out the flare stack.
                       Protect fuel gas purge/high-pressure piping connections from backflow to the
                        fuel system. If sweet gas is used to purge sour gas piping, the connection must
                        incorporate a double block with bleed between to a safe location. If sweet gas
                        is not used, the connection should be removed.
                       Do not direct dump valves from hot oil heaters to the flare system in an ESD
                        condition as a major fire may result.
                       Do not restrict relief vent lines by swages or any obstructions. Ensure the
                        relief system is carefully designed if field-gathering lines have a design
                        pressure higher than that of the plant.
                       If fuel gas is used as the instrument medium, use a flare header that will not
                        backpressure the system (ESD valve open) and over-pressure the actuators.
                       Design gas plants and production facilities to minimize escape of low-pressure
                        vapours and comply with AER regulations and CAPP flaring guideline.
                       Design relief systems for facilities with multiple compressors to provide
                        protection for all possible combinations of suction pressure and number of
                        operating units.
                       Size flare headers to handle the total volume of gas that the facility could
                        receive during an ESD.
                       Slope flare headers to allow liquid drainage into the flare knockout drum. Use
                        rain covers and weep holes to protect relief valve vent stacks against water
                        accumulation.
                   4.9.1 Flashback Protection
                   The following considerations help ensure adequate flashback protection:
                       For permanently lit flares, maintain a minimum purge pressure of sweet
                        natural gas flow to protect against air inflow and to keep flowing vapours
                        above the upper explosive limit (UEL).
5
    Section 4.9 References
CAPP. Best Management Practice for Fugitive Emissions Management.
CAPP. Best Management Practices for Facility Flare Reduction,
CAPP. Best Management Practices for the Efficient Use of Fuel Gas in Flaring Operations.
July 2014                         Small, Portable Oil & Gas Facilities Guide                  Page 4-26
                Install an adequate means of protection when venting off of a tank system.
                 Alternatives include installing a positive purge gas system or a flame arresting
                 device at the bottom of the flare stack as a secondary means of protection.
                Do not use in-line flame arrestors marketed as UL-listed because they are not
                 capable of stopping flashback under most conditions that may occur in the
                 flare system. Use detonation or second-generation flame arrestors that have
                 been tested according to API RP 12N.
                Be aware of the hazard of flame stabilization at the flame arrestor.
        4.10 Detection and Emergency Shutdown Systems
             Safety systems and personal safety are integral to effective facility design. Process
             designers use a variety of safeguards or layers of protection to provide a defence
             system against serious incidents. Potential safeguards include
                inherently safe design features
                safety instrumented systems
                physical protection such as relief devices
                post-release protection systems
                facility and community emergency responses
             4.10.1 Safety Systems
             A risk assessment of each facility should be performed and the following
             equipment installed as required:
                Install emergency shutdown device (ESD) stations with remote activators and
                 locate ESD valves outside of skid limits. ESD valves should be of a fireproof
                 and fail-safe design and must be accessible and unobstructed.
                If reliable power supplies are available, install combustible gas and fire
                 detection equipment. This gas detection equipment should activate alarm/call-
                 out devices and auxiliary ventilation at gas readings of 20 per cent of the
                 lower explosive limit (LEL). The facility should be shut down at 40 per cent
                 LEL.
                If reliable power is not available, use temperature-rated plastic tubing or alloy
                 plugs in steel tubing as a simple fire detection shutdown system.
                Install a reliable pilot in the flare stack to ignite the sour gas in case the
                 facility depressurizes as a result of high H2S.
                Install H2S detection (if power is available) to
                 o activate alarm/call out devices
                 o start auxiliary ventilation at 10 ppm H2S
                 o start shut in and depressurize at 20 ppm H2S
                Install fire detection equipment to automatically shut down and depressurize
                 the facility.
                In sour gas facilities, mount alarm-activated warning beacons inside and
                 outside buildings.
                If H2S exceeds, or may exceed 10 ppm, use wind direction indicating devices.
July 2014                   Small, Portable Oil & Gas Facilities Guide                   Page 4-27
               4.10.2 Personal Safety
               The following steps help ensure the safety of workers:
                  Ventilate the building as required to maintain a safe work environment.
                  Insulate engine exhaust piping to protect workers from burns.
                  Include escape routes and access to escape windows in the layout design.
                  Install adequate guards for fans, belts and all moving equipment.
                  Install combustible gas and fire detection equipment.
                  Install appropriate signage to alert operators and maintenance personnel to
                   specific hazards.
                  Provide enough clearance around equipment for safe access.
                  Carefully evaluate the use of quarter-turn valves that open to the atmosphere.
                   They can be accidently knocked open and result in equipment damage or
                   injury to workers.
                  Vent sample lines to the outside.
                  Provide adequate clearance for drain valves that terminate close to the floor or
                   ground level.
5    Recommended Solutions for Operating and Maintenance Practices
               Ensure workers follow these recommendations for facility operations and
               maintenance or equivalent as determined through risk assessment. Review the
               guidelines during employee orientations, post them in appropriate locations at the
               site and discuss them at regular safety meetings. The guidelines address the
               following unsafe practices:
                  failure to take precautions around ignition sources near vents or blow downs
                  using poorly maintained or incorrectly calibrated gas/explosive meters
                  installing non-specification piping components
                  failure to develop and follow equipment start-up, shutdown, operating and
                   maintenance procedures
                  failure to take account of the ramifications of process changes
        5.1   Site Safety Management
               5.1.1 Safe Work Permits
               Before an operation begins, it is important to establish a plan for controlling and
               coordinating the work including the what, who, where, how, and when of
               completing the operation. This information should be included on safe work
               permits issued to permanent, temporary and contract personnel involved in critical
               or hazardous equipment maintenance tasks.
               Ensure workers obtain a hot work permit before proceeding with any work
               involving pressurized or live equipment, or using equipment that could ignite a
               flammable source. When there are unanticipated upsets, ensure workers follow
               company procedures or prepare special work permits before responding. Do not
               allow workers to improvise.
July 2014                     Small, Portable Oil & Gas Facilities Guide                  Page 5-28
               Alberta Workplace Health and Safety Bulletin SH013General Safety provides
               additional guidance on safe work permits.
               5.1.2 Concurrent Operations
               In those situations where multiple activities are taking place on the same worksite,
               the development of a site-specific, concurrent operations plan is recommended.
               The purpose of the plan is to address the operational safety risks and should
               consider the following:
                  chain of command and supervisor/worker responsibilities for the site
                  regulatory requirements related to minimum equipment and operational
                   spacing, fire control requirements and risk assessments
                  the identification and communication of unique hazards related to the planned
                   drilling, well servicing, construction, and operating activities and the
                   confirmation of any required safe work procedures
                  communication and coordination with other operators if well(s) owned by
                   different companies
                  physical and fire safety protection of in-place wellheads, facilities, etc. when
                   working on adjacent well(s) and confirmation of emergency response
                   procedures
        5.2   Hazardous Substance Exposure and Control
               WHMIS is an information system about hazardous and potentially hazardous
               materials which are found in the work place and which, when handled, may cause
               injury, illness or death to the worker.
               Key WHMIS requirements include the following:
                  All controlled products, including all hazardous waste, on a worksite or used
                   by workers of the owner and all contractors are required to have the
                   appropriate WHMIS labels affixed.
                  Material safety data sheets (MSDS) are required for all production streams
                   and for all controlled products being used at each worksite. Copies must be
                   kept on site in such a manner that they are easily accessible to all workers
                   using controlled products.
                  All workers, including contractor workers, on worksites where controlled
                   products may be handled, shall be fully trained in understanding and using the
                   WHMIS system and the safe handling of controlled products and hazardous
                   waste.
                  Clients and contractors are required to review their WHMIS program at least
                   annually, or more frequently if required by a change in work conditions or
                   available hazard information, with instruction and training provided to
                   workers concerning controlled products.
                  Owners and contractors are required to update all MSDS every three years.
               The Canadian Environmental Protection Act (CEPA) also includes important
               requirements such as the following:
July 2014                     Small, Portable Oil & Gas Facilities Guide                  Page 5-29
               Companies who own or manage specified toxic and hazardous substances at
                or above the specified thresholds must provide required information on the
                substance(s), including quantities and must prepare and implement
                environmental emergency plans.
            Hazardous substances commonly associated with portable oil and gas processing
            buildings and facilities include hydrogen sulphide (H2S), benzene and other
            chemicals.
            5.2.1 Hydrogen Sulphide (H2S)
            Hydrogen sulphide is a common petroleum contaminant. It may be present as a
            gas or may be dissolved in produced water, crude oil or natural gas condensate.
            Hydrocarbons contaminated with H2S are called sour.
            For health and safety purposes, all facilities processing hydrocarbons
            contaminated with any concentration of H2S should be evaluated for the potential
            of worker overexposure. If the potential exists, then a code of practice should be
            implemented.
            CAPP has developed a Hydrogen Sulphide (H2S) Guideline to assist member
            companies in the development of their codes of practice.
            5.2.2 Benzene
            Benzene and the associated compounds of toluene, ethylbenzene and xylene
            (commonly referred to as BTEX) have an anesthetic effect and primarily attack
            the central nervous system. Prolonged exposure to benzene concentrations of 100
            ppm (IRP 14) will have adverse consequences.
            BTEX compounds are normally found as liquids in gas condensates and crude oil
            streams. If liquid hydrocarbon streams at a gas plant have concentrations of
            benzene that exceed the 0.1 per cent level and are in the range of 0.5 to 1.5 per
            cent, extra caution must be taken. Normally, condensate is stored and transported
            in a closed system of vessels, lines and pumps but workers can be exposed when
            those systems are opened for maintenance.
            CAPP has developed a Best Management Practice for the Control of Benzene
            Emissions from Glycol Dehydrators.
            5.2.3 Chemicals
            Owners and employers are required to identify the potential for worker exposure
            to harmful chemicals as part of the hazard identification and assessment process.
            It is important to ensure that a workers exposure to any substance does not
            exceed occupational exposure limits specified in Part 4 of the Alberta OHS Code.
            Employers are required to assess the need for atmospheric testing before workers
            are exposed.
            Regulations and recommended industry practices may require an exposure control
            plan (ECP) to be prepared to protect workers and building occupants from
            potential risks identified in a risk assessment.
July 2014                 Small, Portable Oil & Gas Facilities Guide                  Page 5-30
               5.2.4 Other Potential Occupational Exposures
               Other potential occupation exposures include
                  asbestos
                  hantavirus
                  normally occurring radioactive materials (NORM)
                  silica
               Under normal circumstances, the development of a code of practice will be the
               responsibility of either the prime contractor or the employer completing the work.
        5.3   Critical Safe Operating Procedures
               As previously stated, any critical task to be undertaken by workers must be
               preceded by a hazard assessment of that task. Codes of practice may be required
               for the following critical tasks. In addition, a hazard assessment may be
               completed prior to commencing the task:
               IMPORTANT: Company representatives are responsible for ensuring that a code
               of practice is available and being applied for key critical tasks. When critical tasks
               are undertaken by a contractor, the contractor will be responsible for development
               of a code of practice pertinent to the equipment and personnel required for
               completing the work safely. In most circumstances, the contractor completing the
               work should have an acceptable code of practice. If not, the owners code of
               practice must be referenced and applied as required.
               5.3.1 Confined and Restricted Space Entry
               A written code of practice is required that outlines the procedures to be followed
               whenever a worker enters a confined space. This practice must identify existing
               and potential confined space work locations at a worksite, training, hot work, and
               confined space entry permit requirements.
               5.3.2 Critical Lifts and Safe Lifting Certifications
               Prior to performing a lift, the operator shall determine the weight of the object to
               be lifted and ensure that cables, lifting devices, slings, wire ropes, chains, etc., are
               of sufficient strength, in safe condition and positioned to support the weight of the
               load. Lift/load calculations MUST be conducted for lifts exceeding 75 per cent of
               lifting device capacity. Only competent/qualified, authorized workers shall
               operate lifting devices. Critical lifts are further defined in provincial OHS
               regulation and can include heavy lifts, lifts over process equipment, lifts involving
               two cranes, lifts where the operator cannot see the load, lifts using personnel-
               baskets, etc.
               When critical lifts are being made, a critical lift plan must be developed and
               communicated to all personnel involved in the critical lift at a documented pre-job
               meeting. A critical lift plan identifies the minimum requirements that must be
               evaluated before completing a critical lift.
July 2014                     Small, Portable Oil & Gas Facilities Guide                     Page 5-31
            5.3.3 Electrical Safety (Including Working near Overhead Power
                  Lines)
            Contractors are required to take precautions when working near overhead power
            lines.
            5.3.4 Energy Isolation (Including Lock-Out/Tag-Out)
            A written Code of Practice is required that outlines the minimum requirements for
            locking out and tagging equipment.
               This practice is to be applied when a worker removes or bypasses a safeguard
                on equipment that is not under the workers direct control. In these cases, the
                worker must control hazardous energy (e.g., lockout), as required by Part 15
                of the Alberta OHS Code and Part 10 of the BC OHS Regulation. This
                ensures that the equipment cannot be activated by another worker.
               This is an important consideration any time a worker is required to work on or
                near active production equipment (e.g., pumps jack, pressurized piping and
                vessels, etc.). In these cases, lockout protocols must be reviewed to determine
                who is required to place a lock on the equipment in question.
            5.3.5 Flammable Atmospheres (Including Hot Work and Fire and
                  Explosion Prevention)
            The OHS regulations highlight the need for having a process for managing hot
            work. In addition, AER 033 requires licensees to have a documented fire and
            explosion prevention plan available at the wellsite for the safe management of the
            potential for explosive mixtures and ignition in wells and associated surface
            equipment.
            5.3.6 Ground Disturbance (Including Damage Prevention)
            The Alberta OHS Code and the AER under the Pipeline Act identify the specific
            procedures required for ground disturbances. This includes digging sumps,
            placing anchors and other similar ground disturbances associated with drilling and
            completion operations. Also refer to IRP 17 Ground Disturbance Checklist and
            AER Backfill Inspection Report.
            5.3.7 Hydrate Handling
            Hydrates in wells, gas piping and pipelines are very hazardous. The uncontrolled
            removal of hydrates has caused pipes to be knocked off supports, equipment
            damaged due to ruptures, and injuries and even death to occur. Therefore, it is
            extremely important for workers to know about the prevention and safe removal
            of hydrates in gas lines.
            The purpose of the CAPP Guideline for Hydrate Prevention and Handling is
               to provide an understanding of the conditions under which hydrates are
                formed so that, when possible, they can be prevented
               to ensure that hydrates are removed safely
July 2014                 Small, Portable Oil & Gas Facilities Guide                  Page 5-32
               5.3.8 Purging
               Purging operations may require a code of practice to provide pertinent
               information, minimum requirements and a consistent approach to safely remove
               air, combustible, chemical, toxic, or other reactive gases or liquids from vessels,
               equipment and piping.
               5.3.9 Vehicle OperationsJourney Management
               Vehicle operation and driving practices are a significant hazard for Canadian
               oilfield workers. Companies should consider developing minimum vehicle
               operating practices and journey management guidelines.
               5.3.10 Working Alone
               Employers are not required to have a written code of practice for workers working
               alone. Notwithstanding this, companies are required to develop a code of practice
               outlining the working-alone risk assessment strategy adopted by the company. It
               is important for company representatives and contractors to establish working-
               alone procedures when applicable.
               5.3.11 Working at Heights
               An employer must develop procedures in a fall protection plan for a worksite if a
               worker at the worksite may fall three metres (3 m) or more and workers are not
               protected by guardrails. This plan must specify the fall hazards, the fall protection
               system to be used at the worksite, and the procedures for maintenance, inspection
               and rescue.
        5.4   Site-Specific Procedures
               In some cases it may be necessary to develop site-specific procedures to better
               address unique equipment and operating hazards not addressed by standard
               operating and maintenance procedures.
               5.4.1 Knowledge of Equipment
               Ensure workers understand the process, equipment and materials they use. For the
               safety of themselves and fellow workers, it is important that workers
                  Follow site-specific procedures to lock out mobile equipment.
                  Know the locations and operations of all safety equipment and portable fire
                   extinguishers.
                  Exercise caution when draining a vessel (flashing liquid becomes cold and
                   metal failures can occur).
                  Isolate, depressurize and purge before working on equipment vessels and
                   piping.
                  Install blind flanges on all nozzles before working on a vessel, section of
                   piping or other equipment.
                  Lock out and tag all valves, switches and brakes used to isolate systems and
                   equipment.
                  Use appropriate test equipment such as "sniffers to detect gases, and
                   voltmeters to detect live circuits before proceeding with maintenance.
July 2014                     Small, Portable Oil & Gas Facilities Guide                   Page 5-33
               Ensure all electrical equipment is adequately grounded.
               Use the correct fuses and breakers on all electrical equipment installed.
               Ensure that all relief valves required to protect pressurized equipment are
                correctly installed and maintained.
               Steam out or chemically wash vessels in sour service to remove all traces of
                hydrogen sulphide and iron sulphides before anyone enters the vessel.
               Cold cut the checker plate and check for explosive vapours before working on
                or under skid floors.
            5.4.2 Commissioning and Start-up
            The start-up of operations can be especially hazardous. Develop start-up
            procedures and communicate them to all persons involved in start-up operations.
            See Sections 5.4.2.1 to 5.4.2.8 for methods to reduce key safety risks during start-
            up.
            5.4.2.1 Air Blowing (Depressurizing Lines of Air)
            Make sure workers
               Notify all personnel in blow-off areas and keep them away from blow-off
                points.
               Wear ear protection (if noise levels are high) and safety goggles.
               Check the entire system before blowing.
            5.4.2.2 Water Flushing
            Make sure workers
               Check lines to be flushed before starting.
               Notify all personnel in the area and limit access if necessary.
               Discharge flushing fluids into areas where they will not create a hazard.
               Drain all dead legs (low points in the piping) during winter to prevent damage
                from freezing.     
            5.4.2.3 Leak Checking with Air
            Make sure workers
               Thoroughly check equipment for loose connections before starting (an
                overlooked leak at this stage may later develop into a serious hazard).
               Isolate equipment that is not designed for pressure.
            5.4.2.4 Purging
            Use an inert medium for purging. If an inert medium like nitrogen (N2) cannot be
            used, take the following precautions:
               Tightly control or prohibit all sources of ignition in the area (including
                smoking).
               Allow only essential personnel in areas where purging is done.
               Purge at atmospheric pressure.
               Purge very slowly to keep gas velocities low.
July 2014                  Small, Portable Oil & Gas Facilities Guide                    Page 5-34
               Use hoses to direct vented gas outside buildings and confined areas. Make
                sure hose ends are secured.
               Purge each line separately and track using colour coding on a mechanical flow
                diagram.
            5.4.2.5 Pre-start-up Check
            Operations personnel need to be satisfied that the facility is safe to start.
            Operational readiness considerations include
               procedures in place
               maintenance plans in place
               documentation necessary to manage risks in the facility are available
               action items from risk assessments that are necessary to be completed prior to
                start-up have been completed
               commissioning activities completed, etc.
            After purging and before start-up, make sure workers complete the following:
               Test oxygen levels in lines or vessels. Oxygen levels must be below 5 per
                cent.
               Visually check the facility for any tools or purging equipment left behind that
                could create hazards during start-up.
               Complete a full electrical and controls system check.
               Refer to manufacturer's start-up manuals (or contact manufacturer) for safe
                procedures.
               Evaluate hazardous conditions before start-up (Refer to HAZOP API RP750).
            5.4.2.6 Production Chemistry
            The potential effect of downhole chemistry on the operation of surface equipment
            needs to be reviewed. Consideration may have to be given to corrosion protection,
            hydrate management, scale, etc. A production chemistry consultant may need to
            be engaged to develop an appropriate chemical program.
            5.4.2.7 Building Entry
            There are many hazards involved when entering buildings on various locations,
            personnel must be aware of all the risks and challenges of completing this task.
            An obvious increase in risk is encountered when dealing with buildings in sour
            applications and should be dealt with accordingly. Employers must ensure all
            reasonable precautions are taken to ensure the safety of personnel and property
            when entering onto a lease and into buildings that may contain toxic gas vapours,
            combustible atmosphere or lack of sufficient oxygen.
            5.4.2.8 Working with Steam
            Ensure workers take the following precautions when using steam hoses:
               Use only approved steam hoses that have a sufficiently high pressure rating.
               Always shut off the steam supply to the hose before closing the valve at the
                discharge end.
July 2014                  Small, Portable Oil & Gas Facilities Guide                       Page 5-35
                  Wear leather gloves and appropriate hearing protection when noise levels
                   warrant.
                  Do not blow off steam where workers may be endangered.
                  Secure open ends of the blow-off hose (if used) and fence off the blow-off and
                   drain areas.
                  When steaming lines, watch line expansion, check pipe supports, sliders and
                   hangers. Stop steaming if undue stress occurs.
               5.4.2.9 Housekeeping
               Make sure the following basic "good housekeeping" rules are part of every
               workers daily routine:
                  Keep floors, stairs and platforms clean and free of tools and other loose
                   materials.
                  Keep oily rags and paint rags in tightly sealed metal containers.
                  Clean up oil spills immediately using only approved solvents, never gasoline.
                  Have a place for everything and keep everything in its place.
6    Recommended Solutions for Worker Competency
               This section describes the safety and technical training workers and contract
               operators at oil and gas facilities need to understand in order to respond to the
               hazards they may encounter in their daily work.
               It is important that training prepare workers to both recognize the hazards in a
               task and to take appropriate safety measures. Basic safety training must be
               supplemented with technical training and site-specific safety training.
               Employers are responsible for ensuring workers complete this training and work
               in a manner that safeguards everyone on or near the
               worksite.
        6.1   Worker Orientations
                                                                           Site Specific    Employer
               As shown in the adjacent diagram, the industry
                                                                           Orientation     Onboarding
               has identified four phases of the safety
               orientation process:
                                                                              Prime
                                                                            Contractor     GSO/eGSO
               1. employer onboarding                                       Orientation
               2. oil and gas industry General Safety
                  Orientation (eGSO)
               3. prime contractor messaging (optional)
               4. site specific orientation
               The responsibility of company representatives is to ensure that all on-site workers
               (workers and contractors) receive a site-specific safety orientation. The
               orientation process is an introduction to critical aspects of an HSE Management
               Program and provides immediate information that workers need to know,
               including a review of any relevant company policies and practices,
               responsibilities and expectations, as well as relevant administrative issues.
July 2014                     Small, Portable Oil & Gas Facilities Guide                     Page 6-36
        6.2   Basic Training & Competency Requirements
               Section 1(g) of the Alberta OHS Regulation defines a competent worker as one
               who is adequately qualified, suitably trained and with sufficient experience to
               perform work safely. Specific to worker training, the above regulation requires
               the following:
                  Section 13General Protection of Workers
                   o the employer shall ensure that work is done only by a competent worker
                   o workers must be familiar with any procedures developed by employer
                   o workers must be competent in care and use of safety equipment
                   o employers must ensure workers perform duties
                  Section 15Safety Training
                   o workers must be trained in safe operation of equipment
                   o worker training must include: use of equipment, limitation of the
                      equipment, inspections and basic maintenance, and associated hazards
                      specific to the operation of the equipment
                   o workers must participate in training provided by employer
                   o workers must apply training
               In consideration of this, the following components should be considered by
               employers when establishing worker competency standards:
                  core safety training
                  technical training
               6.2.1 Core Safety Training (Pre-Hire Confirmation and
                     Documentation)
               Core safety training requirements should be determined and scheduled as soon as
               possible. It is recommended that companies maintain a detailed file for their
               worksite supervisors to ensure that the training certifications are maintained for
               all required courses, with an expiry date. In addition to training certifications,
               copies of a current rsum, orientation completion, and other documents relevant
               to the competency and safety performance of personnel should be obtained.
July 2014                     Small, Portable Oil & Gas Facilities Guide                 Page 6-37
Table 6.1 Required Certification and Training
                                                                                        On-Site
     Certification Required     Training Requirements                      Supervisor
                                                                                        Worker
     General Safety
                                Best Practice (ENFORM)                     Recommended Required
     Orientation
     Safety Management          Industry Recommended
     and Regulatory             Practice 7                                 Recommended Recommended
     Awareness for Wellsite
     Supervision (3 Yr)         Alberta OHS Act Section 3
     Note: The majority of safety courses are valid for a three-year period. Employers are
     responsible for ensuring training is kept current and training records are maintained. Where
     a project or regulation requires certificates of competency to perform designated tasks, a
     record of the certificates will be taken at time of employment or orientation prior to workers
     being able to perform those tasks. The certificates of competency must be readily available
     for management review.
July 2014                     Small, Portable Oil & Gas Facilities Guide                     Page 6-38
Table 6.2 Technical Training: Core and Operations-Specific
 Type of Training      Training Elements
 General Technical     Introduction to oil and gas operations and equipment:
                       Flow measurement: orifice plates
                       Level measurement
                       Pressure measurement
                       Pumps (including pd and centrifugal pumps)
                       Static electricity
                       Temperature measurement
                       Valves
                       Gas and fire detection equipment
                       Handling of hydrocarbon fluids
                       Hydrates and ice plugs
                       Hydrocarbon fluid storage and loading
                       Internal combustion engines
                       Isolation of mechanical and electrical equipment
                       Oil and gas composition and sales specifications
                       Pressure safety devices
                       Purging
                       Produced water handling and disposal
                       Worksite inspection and hazardous area classification
 Oil Well Operations   Oilfield operations overview
                       Pumpjacks
                       Sucker rod strings
                       Bottomhole pumps
                       Pipeline pigging
                       Production testing
 Battery Operations    Battery operations overview
                       Oil and emulsion treating
                       Operation of fired vessels
                       Oil and water storage and custody transfer
 Gas Well Operations   Gas production overview including problem prevention
                       Field operations
                       Design and normal operation
                       Gas dehydration
                       Gas-line heating
                       Separation procedures and equipment
                       Properties and characteristics of natural gas
 Compressor Station    Classification and types of gas compressors
 Operations            Basic controls
July 2014                 Small, Portable Oil & Gas Facilities Guide           Page 6-39
                          Compressor components
                          Drivers and operational controls
                          Lubrications
                          Valve and rod packing
 Gas Plant Operations     Condensate stabilization systems
                          Dehydration chemicals, liquid desiccants dehydration, testing
                          Development and types of gas plant processes
                          Glycol equipment and operation
                          Inlet equipment and operation
                          Inlet separation process description
                          Process flow refrigeration
                          Stabilization equipment
                          Sweetening processes, equipment and chemicals
July 2014                     Small, Portable Oil & Gas Facilities Guide                   Page 6-40
                o An on-the-job validation should be completed by a qualified person to
                    confirm each workers knowledge level and verify competency.
               Competency development and support
                Upon completion of the on-thejob validation, appropriate measures are taken
                to address any knowledge and skill gaps. A worker-specific training plan may
                be developed in those circumstances where a more structured learning plan is
                required. Once skill gaps are addressed, the worker validation is updated. A
                wide range of capability development tools are available to support the
                program, including standard operating practices which are supplemented as
                company activities evolve.
July 2014 Small, Portable Oil & Gas Facilities Guide Page 6-41