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0002 - 709 Gas Testing Using Portable Gas Monitors
0002 - 709 Gas Testing Using Portable Gas Monitors
Approved
CONTENT
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 REQUIREMENTS
SUPPLEMENTS:
Supplement 2.709-1, Confined Space Entry Atmospheric Limits
Supplement 2.709-2, Portable Gas Monitor Alarm Set Points
Supplement 2.709-3, Portable Gas Monitor Limitations and Precautions
Supplement 2.709-4, Daily Inspection and Function Test Log
1.0 PURPOSE
The purpose of this general Instruction (GI) is to provide information regarding performing atmospheric gas tests
using portable gas monitors (Industrial Scientific [ISC] models MX4 and MX6) as required by GI 2.100, Work
Permit System. Tests for hydrogen sulfide (H2S), oxygen concentration, combustible gases, and/or any other toxic
substances (e.g., carbon monoxide [CO]) shall be performed before issuing work permits and either continuously or
periodically during work activities, as necessary. The Saudi Aramco-approved gas monitoring equipment and their
accessories are used to continuously and simultaneously monitor the presence of combustible gases or vapors, toxic
substances and oxygen concentration in air.
2.0 SCOPE
2.1 This instruction applies to all gas testing activities during construction, commissioning, start-up, operation,
maintenance, decommissioning and demolition at Saudi Aramco (SA) facilities and SA project sites in
accordance with GI 2.100.
2.2 This instruction is not a manual of how to operate portable gas monitors.
2.3 The equipment manufacturer's instruction manuals shall be consulted and utilized where applicable when
operating, calibrating or function testing portable gas monitoring instruments.
2.4 Any conflict with this instruction and other applicable engineering standards (SAES), engineering procedures
(SAEPs), or codes used by Saudi Aramco shall be referred to the appropriate standards committee chairman
for resolution.
3.0 REFERENCES
4.0 DEFINITIONS
4.1 Alarm Set Point: The selected gas concentration level at which an alarm is activated.
4.2 Asphyxiant: A vapor or gas which can cause unconsciousness or death by suffocation (lack of oxygen).
4.3 Atmosphere-Supplying Respirator: A respirator that provides breathing air from a source independent of the
surrounding atmosphere. These include supplied air (airline) breathing apparatus (SABA) and self-contained
breathing apparatus (SCBA).
4.4 Asset Task Tracking System (ATTS): A corporate solution in SAP plant maintenance, which can be used to
track the calibration of portable gas monitors and issue a notification to asset owners when the periodic
calibration is due.
4.5 Calibration Gas: A gas of known concentration(s) used to set the instrument span or alarm level(s).
4.6 Confined Space: Any space that:
Has limited or restricted means of entry or exit.
Is not designed for human occupancy.
Contains or has the potential to contain a hazardous atmosphere.
Contains any other recognized serious safety or health hazard(s).
Examples of confined spaces include tanks, vessels, vessel skirts, vaults, manholes, sewers, valve boxes,
lift stations, and structures or excavations 1.2 m (4 ft.) deep or deeper. Areas above floating roof tanks
where the top of the roof is more than 1.2 m (4 ft.) below the rim of the tank are also considered confined
spaces.
4.7 Flammable Mixture: Hydrocarbon mixtures composed of various volatile compounds. Flammable materials
contain vapors or gases which are potentially explosive and can ignite when exposed to an open flame or
ignition source.
4.8 Function Test: A function test, or bump test, involves exposing the instruments sensors to a known gas
concentration to indicate that the instrument will respond accordingly and that all alarms operate as they were
designed and calibrated.
4.9 Gas Test: Analysis, using a company-approved gas monitoring instrument, of an atmospheric sample to
determine the concentration of oxygen, and presence of combustible or toxic gases.
4.10 Hazardous Atmosphere: An atmosphere in which workers are exposed to the risk of death, injury,
incapacitation or illness.
4.11 Immediately Dangerous to Life and Health (IDLH): An atmospheric concentration of any toxic, corrosive or
asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse
health effects or would interfere with an individual's ability to escape from a dangerous atmosphere.
4.12 Lower Explosive Limit (LEL): The lower vapor concentration boundary for a specific compound or material
of interest at which the vapor-air mixture will propagate a flame (i.e., explode) if ignited. When testing for
combustible gas using gas monitoring instruments, the amount of combustible gas present is specified in
terms of % LEL: 0% LEL being a combustible gas-free atmosphere and 100% LEL being an atmosphere in
which the gas is at its lower explosive limit.
4.13 Oxygen Deficient: An atmosphere that contains less than 20.0% oxygen.
4.14 Oxygen Enriched: An atmosphere that contains more than 23.5% oxygen.
4.15 Parts Per Million (PPM): A unit of measurement used for small portions or concentrations. In gas
analysis, it expresses the volume of gas present in terms of its relationship to a whole of 1 million parts
of air. 1% = 10,000 ppm. 1% of volume = 10,000 ppm, 100% of volume=1,000,000 ppm.
4.16 Sensor: A sensor (also called detector) is a converter that measures a physical quantity and converts it into a
signal which can be read by an electronic instrument. A gas detecting sensor converts the presence of a gas or
vapor into a measurable signal.
4.17 Threshold Limit Value (TLV): A time-weighted average concentration under which most people can work
consistently for 8 hours a day, day after day, with no harmful effects. A table of these values and
accompanying precautions is published annually by the American Conference of Governmental Industrial
Hygienists.
5.0 RESPONSIBILITIES
5.1.9 Verify that each instrument is properly calibrated every three months, at a minimum.
5.1.10 Ensure that each instrument calibration is tracked through ATTS. Guidance information on how to
add portable gas monitors to ATTS can be found on the LPD intranet site
(http://lp.aramco.com.sa/site/education/publications/special).
5.1.11 Immediately notify the vendor and arrange for any defective or damaged MX4 and MX6 instruments
and any key accessories (such as the Docking Station, charging units, etc.) to be sent to the vendors
service center for necessary repairs.
6.0 REQUIREMENTS
6.1 Only personnel having a valid gas testing certificate issued by T&D and signed by the gas testers division
head may perform gas tests in accordance with the requirements of GI 2.100 and use the ISC MX4 and/or
MX6 devices to monitor atmospheric conditions.
6.2 Gas testing personnel shall be trained, tested and re-certified every two years in the correct use of gas testing
equipment. Training includes the curriculum offered by T&D (BET #40069981, Gas Testing Program).
6.3 Gas testers shall carry a valid certificate issued by T&D and signed by the gas testers respective division
head.
6.4 Atmospheric gas testing is required at all locations where injury to personnel or damage to property could
occur due to the presence of combustible gases, toxic gases, or oxygen enriched/deficient atmospheres.
Atmospheric gas testing shall be performed, but not be limited to the following work activities/situations:
6.4.1 Oxygen (O2) testing shall be conducted for:
a) All confined space entry activities.
b) All areas which may have a potential for an oxygen deficient or enriched atmosphere.
6.4.2 Combustible gas testing (i.e., LEL) shall be conducted for:
a) All confined space entry activities.
b) All hot work in restricted areas, as defined in GI 2.100.
c) All work locations where combustible gases are or may be present.
6.4.3 Hydrogen sulfide (H2S) gas testing shall be conducted for:
a) All confined space entry activities where H2S may be present.
b) Jobs in areas where sour crude/gas is produced, transported, stored or processed and where
proponent organizations determine that H2S gas testing is necessary.
c) Jobs in close proximity to sewage treatment plants and sewer lift stations.
d) All work locations where H2S monitoring is required for work or operational purposes.
6.4.4 Carbon monoxide (CO) gas testing shall be conducted for all confined space entry activities.
6.5 Other toxic gas testing should be conducted for all work locations where other toxic gas(es) or vapor(s) is
(are) or may be present. Examples of other toxic gases include carbon dioxide (CO2), sulfur dioxide (SO2),
chlorine (Cl2), ammonia (NH3), hydrogen chloride (HCl), and mercury vapor (Hg). The Saudi Aramco Loss
Prevention Department should be consulted when questions arise regarding other toxic gas testing.
6.6 The work permit issuer must determine when periodic, frequent or continuous gas monitoring is required,
specify the requirement on the associated work permit, and make arrangements to have a certified gas tester
available to perform required tests.
6.7 The person conducting gas tests in an atmosphere known or suspected of being potentially hazardous should
enter the area only after donning adequate personal protective equipment, including but not limited to
appropriate atmosphere-supplying respirator equipment, (e.g., self-contained breathing apparatus [SCBA]).
Refer to GI 1780.001 for details.
6.8 Hot work is not permitted if the atmosphere is above 0% of the lower explosive limit (LEL).
6.9 Work is not permitted if the atmosphere has an O2 concentration above 23.5%.
6.10 Work is not permitted in areas where the atmosphere is at or above 10% LEL, H2S concentration is at or
above 100 ppm or CO concentration is at or above 1000 ppm even if atmosphere-supplying respirator
equipment is used.
6.11 An atmosphere-supplying respirator shall be used if any of the following atmospheric conditions exist:
6.11.1 O2 concentration is less than 20.0%.
6.11.2 Flammable/combustible mixtures are at or above 5% and less than 10% of the LEL.
6.11.3 H2S concentration is at or above 10 ppm and less than 100 ppm.
6.11.4 CO concentration is at or above 35 ppm and less than 1000 ppm.
* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION X
Saudi Aramco: Company General Use
SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. No. Approved
6.12 The proponent organization division head must sign applicable work permits when H2S concentration is at or
above 10 ppm and below 100 ppm, or O2 concentration is below 20.0%, per GI 2.100.
6.13 Atmospheric conditions prior to entry or during work inside a confined space shall meet the requirements as
specified in Supplement 2.709-1, Confined Space Atmospheric Limits.
6.14 Atmospheric gas tests for a confined space shall be performed and immediately recorded:
6.14.1 Prior to entry.
6.14.2 After breaks or interruptions in the work.
6.14.3 Changes to the conditions inside the confined space.
6.14.4 At periodic intervals specified on the permit (e.g., every 2 hours) or continuously as necessary to
determine whether acceptable atmospheric conditions are being maintained during the course of the
confined space entry.
6.15 Initial gas testing prior to entering a confined space shall be performed with all mechanical ventilation shut
down at least 15 minutes prior to testing. Additional testing (e.g., after breaks) shall be conducted with the
ventilation system turned on to ensure that contaminants are being removed and that the ventilation system is
not the source of contamination.
6.16 Confined space entry is not permitted if the atmosphere is at or above 10% LEL, H 2S concentration is at or
above 100 ppm, carbon monoxide (CO) concentration is at or above 1,000 ppm or oxygen (O2) concentration
is above 23.5%.
6.17 Whenever testing of the atmosphere results in a gas monitor alarm condition (see Supplement 2.709-2,
Portable Gas Monitor Alarm Set Points), work shall be stopped until proper controls are implemented, which
may include establishing appropriate work procedures and complying with work permit requirements per GI
2.100.
6.18 SA-approved portable gas monitoring equipment (i.e., MX4 and MX6) and their accessories (e.g., Docking
Station, calibration gas cylinder) are available via B2B. The appropriate material numbers for these items are
listed on the LPD intranet site:
(http://lp.aramco.com.sa/site/services/equipment/other/default.aspx?equipment_id=9).
6.19 Operation of ISC models MX4 and MX6 shall follow manufacturers instructions and the curriculum
provided in BET #40069981. Guidance information on the operation of portable gas monitors can be found
on the Ventis MX4 Features and Functions and iBrid MX6 Features and Functions pamphlets, respectively.
These guidance pamphlets can be found on the LPD intranet site:
(http://lp.aramco.com.sa/site/education/publications/special).
6.20 The ISC models MX4 and MX6 have certain limitations which must be adhered to per Supplement 2.709-3
in order to avoid potentially dangerous consequences.
6.21 Each gas testing instrument shall receive a full calibration of all sensors every three (3) months, at a
minimum. Information on how to request calibration service from the vendor can be found on the Guidelines
for Requesting Calibration Service for Ventis MX4 and iBrid MX6. These guidelines can be found on the
LPD intranet site: (http://lp.aramco.com.sa/site/education/publications/special).
Note: Serial number of each equipment that requires calibration service shall be included in the calibration
request.
6.22 Each portable gas monitor instrument shall be calibrated either via the vendors service center or via the on-
site Docking Station. The location of installing Docking Station devices shall be decided by the proponent.
6.23 Users of portable gas monitors shall conduct daily inspection & function test and pre-use checks. Results of
the daily inspection & function test shall be recorded on a daily log sheet (see Supplement 2.709-4).
6.23.1 The daily inspection and function test shall include the following:
a) Visual inspection
b) Pump leak test
c) Function test
d) Zeroing
e) Clearing the peaks
6.23.2 The pre-use instrument checks shall include the following:
a) Visual inspection
b) Zeroing
c) Clearing the peaks
d) Pump leak test if air-sample accessories to be used (e.g., sample tubing, probe)
6.24 Function tests shall be conducted per the manufacturers instructions. Instructions for conducting function
tests are found on the respective portable gas monitor operating instructions.
Note: The purpose of the daily function test is to check for sensor and alarm functionality. The installed
sensors are briefly exposed to expected concentrations of calibration gases that are greater than the sensors
alarm set points. When one or more sensors pass the test, they are functional and the unit will alarm. For
the unit to pass the function (bump) test, all sensors shall pass the test. The function test is not the same as
a calibration test and does not measure for sensor accuracy.
6.25 If a portable gas monitor instrument does not successfully pass the pre-use instrument checks, it shall be
removed immediately from service and repaired/calibrated accordingly.
6.26 The useful life of function test gas canister is designated by expiration date on canister. Any expired or spent
canisters are to be disposed of by sending them to the nearest Storehouse Operations Reclamation facility.
Completion of Saudi Aramco Form 112 (Material Disposal Form) is required to request this service.
1.0 The following conditions are required prior to entry into or work inside a confined space:
1.0 The following alarm set points have been established for Saudi Aramco portable gas monitoring instruments
(i.e., ISC MX4 and MX6):
1.1 Oxygen (O2):
Low Alarm: 20.0%
High Alarm: 23.5%
1.2 Lower Explosive Limit (LEL): 5%
2.0 Alarm set points for substances/gases not covered under this GI will be established through consultation with
LPD and the Environmental Protection Department.
1.0 The Industrial Scientific (ISC) models MX4 and MX6 have certain limitations which must be adhered to in order
to avoid potentially dangerous consequences.
2.0 Function test the instrument in a clean environment at the beginning of each day using a known concentration of
test gas. If the monitor does not pass the function (bump) test, a full calibration is required. Only use a portable
gas monitor with a valid calibration date.
3.0 Servicing the unit, replacing or recharging battery packs, or using the communications port (for MX4/MX6
models) must only be performed in a nonhazardous environment.
4.0 Portable gas monitors are susceptible to poisoning of the sensors when exposed to vapors containing appreciable
concentration of contaminants such as:
4.1 Tetra Ethyl Lead (e.g., from leaded gasoline or associated sludge/residue).
4.2 Silicone vapors (e.g., from greases). Silicone compound vapors or other contaminants may affect the
combustible gas sensor and cause readings to be lower than actual gas concentrations.
4.3 The effects of these poisons are that they reduce sensitivity to respective sensors. Any instrument exposed
to such vapors without an appropriate filter in place to remove the contaminants must be function tested. If
it fails the test, the affected instrument must be sent for service prior to use.
5.0 To ensure combustible gas testing accuracy (i.e., LEL), the sampled atmospheres should contain at least 16%
oxygen by volume (unless the IR sensor of the MX6 is being used). Oxygen deficient atmospheres may cause
combustible gas readings to be lower than actual concentrations.
6.0 Oxygen enriched atmospheres (i.e., O2 greater than 23.5%) may cause combustible gas readings to be higher than
actual concentrations.
7.0 Obstructions of the sensor openings and/or contamination of the water barriers may cause readings to be lower
than actual gas concentrations,
8.0 The Ventis MX4 is certified for use in Class I, Zone 1 hazardous locations within an ambient temperature range
of -20 C to +50 C. The MX6 iBrid is certified for use in Class I, Zone 1 hazardous locations within an ambient
temperature range of -20 C to +40 C (with the alkaline battery pack) and -20 C to +55 C (with the lithium ion
battery pack).
9.0 Minimize prolonged exposure to high temperature environments.
10.0 High over-range conditions may indicate explosive gas concentrations.
11.0 Physical abuse such as crushing or drowning the instrument, using unapproved materials, or performing service
or repairs by an unauthorized provider will nullify the manufacturers warranty.
12.0 For maximum safety and operations performance, read and understand the respective operations manuals for each
portable gas monitor available online at http://www.indsci.com.
SUPPLEMENT 2.709-4
Date Visual Leak Test Gas Function Zeroing Clearing the Checked by Remarks
Inspection Test Peaks
P F P F P F P F Yes No
__________________________
Supervising Operator
Note: Conduct an inspection and function test at the beginning of each day or prior to use in accordance with GI 2.709,
Section 6.23. The results of the daily inspection & function test are recorded on the above Daily Inspection and
Function Test Log. Remarks should reflect failure of any pre-use checks or function tests.
P = Pass F = Fail (Check P or F)