Safety Alert Purity of N2 supply

Approximately 2 weeks ago, we received some Safety Critical information, regarding a serious High
Potential Well Operations incident.
The incident involved a pulsation dampener on a high pressure mud pump, exploding catastrophically.
See the following images.

Close up view of the exploded Pulsation

dampener wall thickness of this
material is 8 cms plus Pressure Rating
approximately 5000 psi.
One of the bomb fragments

It is also possible to see the explosive

power, which destroyed an adjacent
Pop valve line, wall thickness 1.5 cms

Below, it is possible to see the normal Pulsation

Dampener, as well as the exploded one.

In addition the viewer can see the Catwalk, pipe

slide, V-Door stairs in the upper right background

Again it is also possible to see the explosive power, which destroyed an adjacent Pop valve line, wall
thickness 1.5 cms
Red arrow indicates possible direction of one exploded fragment, toward the derrick tower, with stands of
drill pipe, as well as the V Door/catwalk stairs on which at least eight stair steps were destroyed.

Preliminary investigation has identified that the source bottle of Nitrogen that had been used to precharge
this Pulsation dampener, had more than 20% oxygen. Weakly emulsified diesel oil in the mud, may have
phase-separated, and accumulated under the diaphragm/bladder. If oil under pressure in a closed system,
can mix with oxygen and explosion can take place.
Post accident investigation analysis indicated the diaphragm material was in poor condition.
This may be the fragment that went toward the rig
monkey board, hitting two stands of pipe 8 meters
above the rig floor [15+ meters above the pump]

Two stands of drill pipe damaged from the velocity

and energy of the impact.

http://www.pulsationdampenerservice.com/repair-kitsand-parts/

this link takes the reader to a graphic that

provides a simple demonstration of how a
pulsation dampener works.

Catwalk Stairs damaged by flying fragment of Pulsation

Dampener

3 essentials for a fire/explosion to take place are 1) fuel, 2) O2 and 3) ignition.

Oil [relatively high gravity oils like diesel, higher API gravity crude oils, can ignite with pressure and Oxygen,
this is the principle of Rudolph Diesels engine http://inventors.about.com/library/inventors/bldiesel.htm
Subsequent investigation of many more N2 bottles indicated the presence of up to 30% Oxygen.
One contractor recently checked the N2 bottles in one Accumulator and found 13 bottles had oxygen
present.
It is a common practice with local Compressed gas vendors, that are not respecting QA/QC standards, or
safe handling practices, regularly mix bottles of different colors and manufacturers intended applications.
There is no respect for [or perhaps even knowledge of standards such as BS 349 which provides that All gas
cylinders should be colour coded in accordance with - Oxygen ="Black", Nitrogen ="Gray body with black
top", Acetylene = "Maroon".
In addition the name of the gas contained within the cylinder should be clearly stenciled on the cylinder
body . See pictures below

The 3 black bottles - manufactured and identified as to gas type according to BS 349 standard have been
filled locally with N2. Grey bottles to the side in upper right corner are colored and stenciled correctly for
N2.

More examples of the variety of color cylinders available for pressurized gases.

Oxygen Cylinders with two different colored code!!!!!!!!!

It has been confirmed that Oxygen and Nitrogen bottles have the same size of valve / connection.
It has been established that during routine maintenance in the recent past, nitrogen bladders (e.g. from
BOPs Koomey unit / mud pumps pulsation dampener) appear to have been charged / re-charged without
prior checking the contents of the HP bottles. This unsafe practice must be stopped with immediate effect.
Contractors must recognize this hazard now, and develop procedures and controls to manage the risk.
Good practice and responsible management will also ensure that this hazard is captured in each
Contractors overall operations hazards/risk register [HIRCAs etc], and further more will be included in JHAs
which will support PTW for energized / pressure works.
As a minimum,
1. Develop a system to inspect nitrogen bottles on the rig to ensure no other gases are present.
2. Develop a procedure to check all nitrogen cylinders upon being received at the work site and before
placing in use.
3. Adopt an international standardized color code system for all gas cylinders used [such as BS 349].
4. Develop a program to require testing and documentation of all nitrogen cylinders contents at rig
site.
5. Standardize valves used for nitrogen to be different from other valves used in other gas cylinders.
6. work on energized systems should be performed under PTW, under which the potential hazard of
O2 being present in N2 bottles is identified and the mitigation controls are specified. .

Recently rig F-17 introduced a new method to verify the gas bottle content .

The best method is by using N2 purity tester to verify the gas bottle content accurately
Due to the completely unreliable and therefore dangerous condition, where there is no Quality Control at
the local Gas Bottle Resupply centers, this seems like an achievable, realistic solution, to an explosively
dangerous condition.
COMPANY requests that all of Contractors take these previous alerts/warnings seriously, [the exploded
Pulsation Dampener on the Lukoil Project] and are considering or hopefully are introducing similarly
Please reply, with the actions your Organization is taking to ensure this risk is managed properly.

K-Series Dampeners

K-SERIES

Combination K-Series and R-P ASAFE

Lifting Eye and Protective Cover

Stainless Steel Pressure Gauge
Charging Valve
Cover Plate

HOW THE HYDRIL ACCUMULA TOR WORKS

Hydril's torispherical body shape, left, results in smoother flow

COMBINED PERFORMANCE OF
R-PASAFE WITH K-SERIES

and longer diaphragm life. This means greater efficiency and

Pulsation control equipment comes in various types and

better economy.

configurations. The basic dampening mechanisms are pneumatic and

liquid. Combining of the two types provides the unique benefits of
each mechanism.
The K-Series dampener provides excellent pulsation control when the

Diaphragm Stabilizer

operating pressure is above the nitrogen precharge pressure,

10 Diaphragm Elastomer
Materials Available
Diaphragm Insert
(Intergral to the Diaphragm

Nitrogen gas fills the entire internal volume.

however, no dampening occurs when the system operating pressure

is below the set precharge pressure and dampener performance
decreases as the system operating pressure increases. The

Replaceable Bottom Plates

R-Pasafe is designed to operate over the entire operating pressure

range while limiting the peak to peak pulsation levels to

Introduced over 50 years ago to solve pulsation problems with oilfield

below 100 psig.

reciprocating mud pumps, the K-Series accumulator has built an

unmatched reputation for dependability and durability. A stabilizer disk
enhances reliability by precluding the trapping of fluids in folds of the

pressures to 7,500 psi for a variety of large scale pulsation and surge
control applications such as airport fueling systems, tank truck

the K-Series and the R-PASAFE Series Dampeners.

nitrogen gas is compressed, absorbing energy

in the system.

Peak to Peak Pulsation - psi

The K-Series accumulators feature a replaceable bottom plate,

desirable for abrasive slurries such as coal and mud. All K-Series
bottom plates are field replaceable, eliminating costly shop repairs
and down time.
A large cover plate allows fast diaphragm replacement without

also serves as a lifting device.

shown a synergistic effect by dramatically lowering the peak to peak

5.5'' X 14'' Single Acting Triplex Mud Pump

and sewage lines.

valve are protected from damage by a heavy duty cover which

The chart below validates the synergistic performance by combining

During periods of peak system pressure, the

and marine loading racks, pipeline slurries, fire water systems

removing the body from a line. The pressure gauge and charge

Combining the K-Series and R-PASAFE in these applications has

pulsation levels.

diaphragm, which increases diaphragm life and predictability.

Accumulators are available in capacities of 10, 20 and 80 gallons and

Combination discharge dampeners used in a mining/slurry

application.

During periods of minimum pressure, the gas

expands, forcing liquid from the accumulator
into the system.

All K-Series accumulators are pressure vessels which are ASME

code stamped.

Pump Operating Pressure - psi

K20 - 7500 w/2500 psi precharge only

R120 - 7500 PSAFE & K20 - 7500 combination

R120 - 7500 PSAFE only

HYDRIL

HYDRIL