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1.6 SOUR GAS WELL TESTING

THIS IS A MANDATORY SAFETY REQUIREMENT AND MUST BE COMPLIED WITH

Hydrogen Sulphide (H2S) can be found at any worksite or at any process plant. It may also be found in the yard
when breaking down equipment, even if the equipment has come from a 'sweet' field, due to the effects of
sulphate reducing bacteria.

CHARACTERISTICS

1. It is extremely toxic (poisonous).

2. It is heavier than air, and colourless (S.G. 1.1895).
3. It has the odour of rotten eggs, in small amounts.
4. It burns with a blue flame and produces sulphur dioxide (SO2) gas, which is very irritating to the eyes and
lungs. The SO2 is five times more toxic than H2S and can cause serious injury.
5. H2S forms an explosive mixture, with air, between 4.3% and 46% by volume.
6. H2S is almost as toxic as hydrogen cyanide and is between 5 and 6 times as toxic as carbon monoxide.
7. Produces irritation to eyes, throat, and respiratory tract.
8. H2S dangerously corrodes equipment not designed for H2S (sour) service.

POISONING BY INHALATION

1. The sense of smell cannot be depended upon to detect H2S because:-

a) The sense of smell can be lost in 2 to 15 minutes of exposure to low concentrations, due to paralysis of
the olfactory nerve.
b) The sense of smell is lost in 60 seconds or less, at higher concentrations.

2. Susceptibility to H2S poisoning varies according to the number of exposures by an individual. A second
exposure is more dangerous and so on.

3. The results of inhalation are:-

a) Asphyxiation may occur after a few seconds of exposure to high H2S concentrations. This produces
such symptoms as panting, pallor, cramps, paralysis of the pupil, and loss of speech. This generally is
followed by immediate loss of consciousness.
b) Death may occur quickly from respiratory and cardiac (heart) paralysis. One deep sniff of high
concentration can cause death.
c) Coughing, eye burning and pains, throat irritation, and sleepiness come from exposure to low
concentrations.

TREATMENT

H2S acts so quickly that there is often no time to call assistance before beginning to revive the victim.

1. Remove the victim to fresh air IMMEDIATELY.

NOTE: Remember to protect oneself before entering a suspected area with H2S present in the atmosphere.

2. Keep the victim warm and at rest.

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3. If the victim is not breathing, begin applying artificial respiration at once. Exercise care due to possible lung
congestion. Although breathing is paralysed, the heart may continue beating for a few minutes after the
attack. It is of the utmost importance that artificial respiration be given as quickly as possible and continued
until medical aid is available or until the victim resumes natural breathing.

NOTE: Do not await the arrival of a resuscitator, when available someone else can set it up, while you
continue to apply artificial respiration. In acute poisoning, continuous use of oxygen is of great
value.

Figures 1.6.5 and 1.6.6 on pages 10 & 11 of this section demonstrate artificial respiration methods. These
examples can be photocopied and placed around the test area in pre-determined safe areas, to aid personnel
should an incident occur where artificial respiration is required.

As with other hazardous substances, safe working with H2S is controlled by the COSHH regulations.
Management Procedure HSEP 0802, rev C details the procedures that have to be followed to control exposure
to H2S. An uncontrolled copy of this document is available for reference here HSEP0802.

TABLE 1.6.A - TOXICITY OF HYDROGEN SULPHIDE GAS

TOXICITY OF HYDROGEN SULPHIDE GAS
Moderate to strong odour. People may experience nausea, tearing of the eyes, headaches or loss of sleep following
10 ppm
prolonged exposure. The effects are reversible and not considered serious, although more susceptible individuals
(1/1000 of 1%)
may respond more severely.
10-20 ppm Strongly offensive odour. Lung and eye irritation are increased. People may experience loss of appetite after
(2/1000 of 1%) prolonged exposure

50+ ppm People may experience a burning sensation in the yes and throat, headaches. Some individuals may temporarily
(5/1000 of 1%) lose their sense of smell.

100 ppm The above symptoms may progress more rapidly and be more severe. The respiratory tract becomes irritated, which
(1/100 of 1%) may lead to bronchitis. Temporary loss of smell is prevalent in most individuals.

250 ppm
Continued exposure may cause lung tissue to swell and fill with fluid as wells as inflammation of the eyes.
(2/100 of 1%)

500 ppm The victim loses the sense of reasoning and balance. Respiratory paralysis in 2 to 15 minutes and prompt artificial
(5/100 of 1%) resuscitation is required. Rapid unconsciousness; breathing stops, and without immediate rescue death will result.

700 ppm
Rapid unconsciousness; breathing stops and without immediate rescue death will result.
(7/100 of 1%)

1,000 ppm
Unconscious at once. PERMANENT BRAIN DAMAGE MAY RESULT UNLESS RESCUED PROMPTLY.
(1/10 of 1%)

EFFECT OF H2S ON EQUIPMENT

Exposure of stressed steel to H2S and water may result in failure because of sulphide Stress Corrosion Cracking
(SSC). This can be defined by the following:-

“The brittle failure by cracking under the combined action of tensile stress and corrosion in the presence of water
and hydrogen sulphide.”

This may occur in carbon and low alloy steels, severely cold-worked austenitic stainless steels, some
precipitation hardened stainless steels and some high nickel alloys under severe conditions.

Susceptibility to attack of most carbon and alloy steels is approximately proportional to the steel strength with the
resistance to stress cracking decreasing with temperature. This means that the maximum danger occurs under
low temperature operations, particularly when testing gas wells.

It is important to be aware that embrittlement can occur at very low H2S concentrations as Figures 1.61 and 1.6.2
show.

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SOUR GAS SYSTEMS

Materials shall be selected to be resistant to SSC or the environment should be controlled if the gas being
handled is at a total pressure of 65psia or greater and if the partial pressure of H2S in the gas is greater than
0.05 psia. The partial pressure is determined by multiplying the mole fraction (mol% / 100) of H2S in the gas by
the total system pressure.

Figure 1.6.1 below provides a method for determining whether the partial pressure of H2S in a sour environment
exceeds 0.05psia. The following examples explain how to use the chart:

1. A partial pressure of H2S in a system containing 0.01 mol% H2S (100 ppm or 6.7 grains per 100 standard
cubic feet) at a total pressure of 1,000 psia exceeds 0.05 psia (point A on Fig 1.)

2. A partial pressure of H2S in a system containing 0.005 mol% H2S (50 ppm or 3.3 grains per 100 SCF) at a
total pressure of 200 psia does not exceed 0.05 psia (point B on Fig. 1).

FIGURE 1.6.1 – SOUR GAS SYSTEMS

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SOUR OIL AND MULTIPHASE SYSTEMS

Sour crude oil systems require the selection of sour service equipment when the fluids being handled are either
oil or oil, water and gas when the following limitations are exceeded.

a) Maximum gas oil ratio is 5000 SCF/bbl

b) Gas phase contains a maximum of 15% H2S
c) The partial pressure of H2S in the gas phase is a maximum of 10psia
d) The surface operating pressure is a maximum of 265psia and when the pressure exceeds 265psia and
0.05psia

NOTE: Partial Pressure can be defined as follows: In a mixture of gases, each component exerts the pressure
which it would exert if present alone at the same temperature in the total volume occupied by the
mixture. The partial pressure of each component is equal to the total pressure multiplied by its mol
fraction in the mixture. For most gases, the mol fraction is equal to the volume fraction of the
component.

FIGURE 1.6.2 – SOUR OIL & MULTIPHASE SYSTEMS

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STRESS CRACKING

Stress cracking can be avoided by the following:-

a) Controlling the environment of susceptible materials by the use of inhibitors etc.

b) Isolating the components from the sour environment.
c) The use of H2S resistant materials.

Generally the latter method is preferred.

EQUIPMENT FABRICATION

NACE Standard MR-01-75 covers metallic material requirements for resistance to sulphide stress cracking for
petroleum, drilling gathering and flowline equipment, and field processing facilities to be used bearing
hydrocarbon service.

All EXPRO equipment supplied for the testing of sour wells is rated to MR-01-75 (latest revision).

NOTE: A copy of which is available at EXPRO facilities onshore.

To ensure that equipment does not suffer embrittlement over a long period of time it is periodically checked
through the means of hardness testing. For the materials used by EXPRO generally, the hardness should not be
above HRC = 22 for the equipment to remain serviceable.

PYROPHORIC IGNITION

While pyrophoric iron sulphide is a widely recognised ignition source in shore based operations, it has rarely
been cited as the cause of a marine ignition and in those few cases the hydrogen sulphide levels were very high.

In an oxygen-free atmosphere or where the concentration of hydrogen sulphide exceeds that of oxygen,
hydrogen sulphide can convert iron oxide (rust) into iron sulphide.

Fe2O3 + 3H2S ¾ Fe2S3 + 3H2O

When the iron sulphide formed is subsequently exposed to air, it is oxidised back to iron oxide and either free
sulphur or sulphur dioxide gas is formed. This oxidation can be accompanied by the generation of considerable
heat so that individual particles may become incandescent. Rapid exothermic oxidation with incandescence is
called pyrophoric oxidation. The heat evolved from this pyrophoric oxidation is capable of igniting flammable
hydrocarbon gas/air, petroleum/ air and oil/ air mixtures.

The industry-wide conversion to the use of inert gas systems on crude carriers has probably increased the
possibility of forming pyrophoric deposits, but as long as the cargo tanks remain inert there is no danger of
ignition from pyrophoric exothermic reaction. However it is imperative that the atmosphere in the tank is not
allowed to become flammable. Flammable atmospheres would inevitably arise if the tanks are discharged while
the inert gas plant is inoperable.

This does not mean that the probability of ignition is high if discharge without atmospheric control takes place.
Various factors may inhibit pyrophor formation or a pyrophoric reaction. These factors include:

a) The lack of sufficiently thick deposits of iron oxide.

b) The inclusion of elemental sulphur and crude oil in tank deposits.
c) The introduction of some oxygen by repressurising.

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TRAINING FOR PERSONNEL PRIOR TO TEST

It is imperative that all personnel receive proper H2S training prior to commencing a well test on an H2S
producing well. Any training received onshore should be complemented by training on the particular installation
that the test will be taking place on, with the relevant safety equipment to ensure familiarity with the type of
equipment, safety procedures that will be used on that installation.

1. When EXPRO is involved in the testing of a well with suspected H2S, it is the operating company
responsibility to provide a specialist H2S company to provide all the relevant safety equipment, together with
all the training of all personnel prior to commencing any testing operations. This training should cover the use
of breathing apparatus, resuscitation equipment and safety procedures.

2. EXPRO can also provide additional specialised H2S training at RGIT Montrose. However, personnel who
have had previous H2S training should still be additionally trained at the offshore location, to ensure familiarity
with the equipment being utilised.

OPERATIONAL GUIDELINES

Where H2S is known, suspected or found to be present, an atmospheric tank (ie. a gauge tank) SHOULD NOT
be used. Flow should be directed to a surge tank, with the subsequent gas produced piped to a designated
area.

1. Prior to commencing the test, all personnel should have received the training laid out above.
2. Warning signs should be posted and testing area roped off.

NOTE: Where high concentrations of H2S are present, only essential personnel should be out on deck, the
remainder should remain within the accommodation, with doors sealed, etc.

3. If an H2S leak is suspected or confirmed and cannot be contained immediately, then persons in areas of risk
must withdraw to a safe area, generally upwind and in an elevated position of the hazardous
4. Never enter an enclosed space or area where H2S may have accumulated without wearing B.A. sets. If the
worker is over an arms length away, a safety belt should be secured to a life line and held by a responsible
person in a safe area.

OPERATIONAL SAFETY PROCEDURES

1. EXPRO personnel will generally be required to follow the rig operators procedures and use their safety
equipment.
2. The testing area and other areas where a potential danger of H2S is present, personnel should have
continuous gas monitoring taking place using either fixed or portable monitors, with audible and visual
alarms. The set point of these alarms should be whenever the concentration of H2S in air exceeds 10 ppm.
Well test operators should also wear personal H2S monitors (eg. Compur).
3. All testing equipment will be rated to NACE MR-01-75 and all safety relief lines will be routed to an area
where there discharge will present no hazard.

NOTE: Where equipment cannot be positively identified as H2S resistant, it must be considered as non H2S
resistant.

4. Prior to the well test commencing, a meeting with all parties concerned with any operations during the test
must be held to establish hazardous areas, safe areas, escape routes, etc. This meeting should also decide
the area of responsibilities between EXPRO and the operating/drilling company particulary at which point the
test should be terminated.
5. First hydrocarbons should be produced to surface in daylight hours only.

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6. As soon as first reservoir returns to surface (ie. the tubing contents have been displaced) are observed,
checks should be made for the presence of H2S. These checks should continue periodically throughout the
duration of the well test - please refer to Figures 1.6.3 and 1.6.4 below for information on the use of a
Draeger tester.
NOTE: There should be an adequate supply of detector tubes (various ranges) readily at hand, to measure
the H2S concentration should a leak occur. Should H2S be detected in the wellstream, the test
supervisor must be informed so that action can be taken to control the risk.

TABLE 1.6.B - EXPRO'S RECOMMENDED H2S POLICY

10-50 ppm in well stream
> 50ppm in well stream
100-10,000 ppm in well stream
> 10,000 ppm in well stream
> 50 ppm in air
Mask up with BA set for an operations that vent gas
BA sets to be masked up and worn continuously.
Well to be flowed in daylight hours only
Test should be terminated
Test should be suspended/terminated

7. Where the H2S levels are greater than 50 ppm, then during the course of a test, a "buddy" system should be
implemented, ie. where every operator must constantly be in sight of another person who can raise the alarm
in case of emergency. Arrangements with the operating / drilling company must be made to provide
sufficient help in watching personnel and to define how the alarm will be triggered.

8. A communication network (eg. radio) between all crew members is recommended.

NOTE: This may prove in-operable where personnel are masked up with B.A. sets and also due to noise
levels when testing.

FIGURE 1.6.3 – USE OF A DRAEGER TESTER

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FIGURE 1.6.4 – INSERTING DRAEGER TUBES

SPECIFIC SAFETY RECOMMENDATIONS

1. No H2S should be allowed to escape to atmosphere in a place where it can accumulate and be dangerous.
Wind direction should be monitored constantly.
2. If a leak develops, every effort should be made to stop the leak at once.
3. While flowing, all effluent should be sent to the burners.

NOTE: Flow periods should be limited to when the wind direction is suitable for carrying the gasses away
from the selected burner and the installation, eg. if there is no wind, then flaring should not be
considered. If in doubt as to whether the well should be shut in, checks should be made of the H2S
concentration around the boom and if it rises above 10 ppm (concentration in air) the well should be
shut in.

4. Every effort should be made to keep the flare alight at all times during flow periods. This can be done by
leaving the propane/diesel pilot system running continuously or by using a propane lance.

NOTE: If using a propane lance, this should be lit only when the well is shut-in, personnel should not go on
the boom to light the lance while flaring.

5. Gauge tank should NOT be used on H2S tests, if it is required to measure tank rates, then a surge tank
should be used as an atmospheric vessel however EXTREME caution should be used when running the
vent lines. Make sure vent lines are run to an area where the vented gas will not prove hazardous.
6. Any shrinkage measurements must be performed with the shrinkage tester in a well ventilated position.

NOTE: B.A. sets should be used.

7. B.A. sets must be used in all operations where personnel might be in contact with effluent eg. sampling,
changing orifice plates, changing chokes, etc.

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EMERGENCY PROCEDURES

When an H2S alarm is activated, the following procedures should be followed by EXPRO personnel.

1. Obtain a B.A. set/escape mask and mask up immediately.

NOTE: B.A. sets may already be worn by the test crew, dependant on H2S levels for the test in progress. If
it is obvious that an equipment failure to atmosphere has occurred, the well should be closed in
immediately via the safety shut down system and surface process equipment vented to zero
pressure via the flare boom.

2. Warn other crew members/personnel in the area and leave immediately.

3. The rig floor/control room/radio room should be informed of the situation.
4. Two testers with air masks and B.A. sets (properly fitted and checked with air sufficient for 30 minutes)
should return to the area and investigate the source of the leak.

NOTE: One of these testers should be of senior status.

Life lines should be worn and held by a responsible person in a safe area.

5. The H2S levels should be checked by Draeger tester while the investigation is ongoing.
6. Once the source of the leak has been found then the appropriate remedial action should be taken (shutting
in the well if required).
7. If the source of the leak cannot be identified, and the H2S concentration remains at a level which is
considered unsafe for testing operations to continue, the test should be terminated and surface process
equipment bled down to zero pressure via the flare. The system should be flushed then filled with water and
rechecked for the source of the leak.

NOTE: B.A. sets should still be worn and masked up while this operation is continuing, especially if
breaking out equipment etc.

SUPERVISORY RESPONSIBILITY

The supervisor has prime responsibility for accident prevention. It is most important to:-

1. Know the company policy on H2S.

2. Know safe working practices and include them in instructions when teaching job methods. Every new
employee must clearly understand the hazards of H2S gas and the safe practices, which will be necessary to
prevent accidents.
3. Be alert to unsafe conditions and actions.
4. Take immediate and appropriate action when H2S is suspected or detected.
5. Know the workers under your control well enough to notice quickly any changes in attitudes or physical or
mental conditions.
6. Set a good example. Attention to safety must be consistent and employee's interest in safety must be
maintained. Initiate and direct regular on-the-spot meetings to discuss accident prevention matters and
allow employees to make safety suggestions.
7. See that safety meetings are held for employees. These meetings will be used to instruct, review or discuss
the safe working practices, or to discuss and take action on unsafe conditions or actions that have been
observed. Employees should be encouraged to take an active part in these meetings, since their
constructive suggestions are an aid in keeping safe practices up-to-date.
8. Conduct training sessions regularly for employees, in the use and maintenance of breathing apparatus.
TRAINING SESSIONS ARE A MUST.

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ARTIFICIAL RESUSCITATION METHODS

All personnel should be aware that by applying mouth-to-mouth resuscitation to a victim to revive him, may
endanger the rescuer (due to the intake of H2S gas into the victims lungs) and it's extreme toxicity.

FIGURE 1.6.5 MOUTH-TO-MOUTH RESUSCITATION METHOD

1.
Place victim on his back, loosen clothing
around neck and waist. Turn victim’s head to
the side, wipe out the mouth quickly, using
your fingers to get rid of any foreign matter.
2.
Insert thumb in the mouth. Grasp lower jaw
and lift it forcibly upwards and forwards.

3. 4.
Hold the lower jaw up and with the other hand Take a deep breath, place your mouth firmly
close the victim’s nostrils. over the victim’s mouth and breathe out.

5. 6.
While breathing into victim, watch chest rise Remove your mouth from the victim’s to allow
to indicate air passage is clear. breath to exhale. Count to three and repeat.

NOTE: Every moment lost before beginning artificial resuscitation reduces chances for success.
Artificial respiration should be continued until the patient recovers or rigor mortis sets in.

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FIGURE 1.6.6 ARTIFICIAL RESPIRATION

Elbows bent, one hand on the other.

Head on hands, face to one side.
Kneel at victim’s head on either or both sides.

Fingers spread, thumbs touching, heels of Rock forward slowly until arms are vertical.
hands just below a line between armpits. Keep elbows straight.

Rock back slowly. Raise arms until tension is felt for maximum
Grasp victim’s arms just above elbows. chest expansion.
Continue backward. Lower arms to complete cycle.

REPEAT CYCLE 12 TIMES PER MINUTE

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