The Top 5 Deadly Gases in the Oil and Gas Industry

If you work in the oil and gas industry, then you know how dangerous the job can be. The
conditions can be harsh and the weather unpredictable. Not to mention the hazards that exist
with complex industrial equipment. But did you know that one of the most serious hazards
you’re exposed to is something you can’t even see? That’s right. The invisible hazards we
discuss here are some of the deadliest gases in the industry.

1) Petroleum Gases

What they are: Petroleum gases and vapors consist of harmful toxins like benzene, butane,
and methane. In the oil and gas industry, petroleum gases are often referred to as “sweet gas”
or hydrocarbon gas.

Employees that work with oil storage tanks have the highest risk of exposure. OSHA records
show that there were 9 deaths from exposure to petroleum gases since 2010.

These deaths occurred while employees were gauging and thieving oil storage tanks. They
experienced sudden exposure to high levels of gases. Most were killed instantly.

Why they’re dangerous: Some of these gases, including benzene, are carcinogens. Petroleum
gases can cause both short-term and long-term health effects. If employees are exposed to high
concentrations, they can experience acute toxicity to the nervous system, liver, and
kidneys. This toxicity could be severe enough to result in death. For more info on the dangers
of the oil industry read our blog "The Dangerous Life of a Roughneck: The truth about oil
drilling safety hazards".

How to control: The best way to control exposure to petroleum gases is to wear a Self-
Contained Breathing Apparatus (or SCBA). Wearing SCBA’s is now a common and
recommended practice for these employees.
To review this guideline from the National STEPS Network and more information on
how to work safely when gauging and thieving tanks CLICK HERE

2) Hydrogen Sulfide
What it is: Hydrogen sulfide, or H2S, can be one of the deadliest hazards in the oil and gas
industry. It’s formed in the decay process of organic material. In the oilfields, it’s commonly
found in formations that are being drilled for oil.

Oilfield workers, service workers, and contractors are all at risk for exposure.

H2S is sometimes referred to as “sour gas” because of its unmistakable odor of rotten eggs.
However, in high concentrations of H2S, the gas becomes odorless as it deadens the sense of
smell. So, employees should not rely on their sense of smell for detecting this type of gas.

Why it’s dangerous: H2S is a toxic gas that can cause both short-term and long-term health
effects. Here’s a list of symptoms associated with H2S exposure:
  Fatigue
 Headache
 Dizziness
 Nausea
 Irritation to the eyes and nose
 Loss of consciousness

Sudden, high concentrations of H2S can cause immediate death. OSHA classifies the
cause of death as poison.

Hydrogen sulfide is also considered to be a flammable gas, and is explosive under extreme
conditions. Do not allow smoking or hot work in areas where H2S may be present.

How to Control: There are many ways to reduce the risk of exposure to H2S. Below is a list of
controls you can put into place to protect your employees.

 Monitoring Equipment: Employees should wear personal monitors, such as a 4-Gas

monitor, when working in high risk area. These monitors detect the levels of H2S in the
surrounding area. Pair drilling equipment with electronic H2S monitors that have audible
and visual alarms.

 Respiratory Protection: Employees must wear appropriate respiratory protection in

areas that have concentrations above OSHA’s Permissible Exposure Limit (PEL).
SCBA’s are the best option.

 Engineering Controls: Use wind socks in outdoor areas where there is potential for
hydrogen sulfide exposure. If monitoring equipment detects H2S, employees should
move upwind and away from the hazard.

 Training: Train employees on the hazards of H2S exposure. They should be able to
recognize symptoms of exposure, and know how to respond in an emergency.

3) Diesel Exhaust
What it is: Much of the equipment used in the oil and gas industry is powered by diesel
engines. Diesel exhaust is a mixture of gases and particulates produced during
combustion of the diesel fuel.

Why it’s dangerous: Workers exposed to diesel exhaust are at risk of developing a
wide range of health effects, including:

 Headaches
 Nausea
 Irritation to eyes and nose
 Respiratory disease
 Lung cancer
How to Control: OSHA does not have any specific standards or PEL’s for diesel
exhaust. But, there are a number of ways you can reduce the risk of exposure.

 Use low emission engines and low sulfur fuel

 Use appropriate exhaust after treatment devices, such as filters and oxidation
catalysts
 Beware of black smoke, which is a result of improper fuel-to-air ratio. Black
smoke indicates engine is in need of maintenance.
 Use monitoring equipment, such as CO detectors, when working in areas
concentrated with diesel exhaust.
 Always make sure mobile equipment is in open air. If that’s not possible, use a
large, well-ventilated room when engine is running.

4) Mercury Vapor
What it is: Liquid mercury has hazards of its own. But, in the oil and gas industry, mercury
vapor is a major concern.

Mercury is a natural component in oil and gas. During drilling operations, it can accumulate on
steel pipes and other processing equipment. As processing fluids are cooled, the liquid mercury
condenses within heat exchangers, separators, valves, and piping.

When this equipment is later handled, taken apart for repair, or maintained, workers can
become exposed to mercury vapor.

Why it’s dangerous: Over time, workers can experience health issues in their central nervous
system. Such issues include tremor, nervousness, and changes to their personality.

Other known health effects from mercury include damage to the kidneys and loss of vision or
hearing. Women exposed to mercury are at risk of passing on the poison to unborn fetuses and
any future children.

How to Control: Owners should conduct a risk assessment for mercury at their job site.

Avoid equipment that has potential for absorbing or accumulating mercury.. There are certain
sampling components that can be heated and/or coated with a material that does not react with
mercury. Read this article from Hart Energy to learn more.

5) All Flammable Gases

What they are: Most of the deadly gases discussed in this article are not only toxic, but
also flammable. There are several other flammable gases used in this industry.
Examples include:

 Compressed gases used in maintenance and production operations

  Various chemicals used for maintenance, production, and everyday use
 Natural gases found during the drilling and production stages of operation
 Diesel fuel and gasoline used by mobile equipment operators

Why they’re dangerous: The oil and gas industry is at high risk for fires and
explosions. Fires can be devastating to your organization. Employees could lose their
lives, property destroyed, and your company’s reputation ruined. A small fire could lead
to severe and lasting repercussions. Check out our blog, "Fire Prevention in the Oil
and Gas industry", to learn more.

How to Control: Control the risk of fire by having an adequate safety program in place.
The safety program should cover these fire-related topics:

 Training
 Hot Works
 Fire Risk Assessments
 Emergency Response

Engineering controls will also help reduce the risk of fires and explosions. Equip your
worksite with alarms and monitoring equipment that detects fires and alerts employees.

Control Measures for These Deadly Gases

The use of engineering controls and monitoring equipment will go a long way in
protecting your employees. But just like any other safety equipment, you must maintain
them.

Calibrate personal monitors on a regular basis. For the most part, this means at least
once every 30 days. Check the manufacturer’s recommendations for your particular
monitor. You also need to make sure that the monitors are fully charged before putting
them into use. Check the integrity and accuracy of your monitors by performing “bump
tests” every day, or before each use.

Conclusion
Keeping your employees safe involves more than just providing them with PPE. Train
them on the specific hazards of your industry. Teach them how to recognize high risk
situations. Prepare them as best as you can for the dangers that come with the job. And
don’t forget to review the dangers of these invisible, deadly gases often