ADVANCED TECHNICAL

CALIBRATION
SERVICE COMPANY
FOR INDUSTRIAL INSPECTION & RADIOLOGICAL SERVICES WLL LABORATORY

SINGLE GAS DETECTOR (BW GAS ALERT EXTREME)

Procedure No. L3-ATS-CAL-09

Revision No. 0

Date 01-January-2019

Purpose Implementation

Prepared By Manivasagan Subramanian

Reviewed By Jeffry Rozario

Approved By Jijo Chakkappan

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 2 of 11

REVISION RECORD SHEET

NOTES

i) Revisions after Rev. 0 are denoted by a vertical line in the left hand margin
against the revised text, with the revision number displayed next to the revision
line as shown on the left.

ii) Revision numbers are A, B, C, etc. up to the issue for management approval
and implementation, which is Rev. 0. Subsequent revisions shall be 1, 2, 3,
etc.

No. Date Description of Revision Prepared Review Approved

Issued for approval &

0 01-Jan-2019 MS JR JC
implementation

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 2 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 3 of 11

Table of Contents

S/No. Description Page No.

1.0 Purpose 4

2.0 Scope 4

3.0 Reference 4

4.0 Definitions 4

5.0 Responsibilities 5

6.0 Calibration Conditions 5

7.0 General Guidelines 5

8.0 Calibration Procedure 8

9.0 Records 11

10.0 Attachments 11

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 3 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 4 of 11

1.0 PURPOSE
1.1 The purpose of this work instruction is to ensure that standard practices /
methods of Calibration are followed to obtain reproducible and comparable
results and this document shall be revised as and when required to meet
specific requirements of the project to become a project specific work
instruction.

2.0 SCOPE
2.1 This work instruction is applicable for ATSi’s Calibration Laboratory to
carryout calibration of single gas detectors at Lab. temperature as per
applicable international standards/methods.
2.2 Calibration of Gas Alert Extreme model.

3.0 REFERENCE
3.1 Documents used: BW Technologies Gas Alert Extreme User Manual
3.2 Valid Calibration Check Gas (H 2S, O2, Cl2, NH3) from BW Technologies or
equivalent.

4.0 DEFINITIONS
4.1 Gas Alert Extreme : is a type of Single gas detector from BW Technologies
Company. A variety of gases can be detected depending upon the sensor
installed.
4.2 TWA : Time–weighted average (TWA) is the average exposure of a chemical
substance over a specified period of time, usually a nominal 8 hrs.
4.3 STEL : Short term exposure limits (STEL) is one that addresses the average
exposure of a chemical substance over a 15-30 minute period of maximum
exposure during a single work shift.
4.4 UUT : Unit Under Test
4.5 H2S : Hydrogen Sulfide
4.6 CO : Carbon Monoxide
4.7 O2 : Oxygen
4.8 Cl2 : Chlorine

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 4 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 5 of 11

4.9 NH3 : Ammonia

4.10 %LEL : % Lower Explosive Limit
4.11 ppm : Parts per million
4.12 %vol. : Percentage by volume
4.13 PPE : Personal Protective Equipment

5.0 RESPONSIBILITIES
5.1 All the Operators/Technicians perfoming the Calibration shall be trained by
ATS.

6.0 CALIBRATION CONDITIONS

6.1 Lab. Temperature : (21±2) °C
6.2 Relative Humidity : (<70) % RH

7.0 GENERAL GUIDELINES

7.1 The calibration should be performed in the controlled environment only. Both
the UUT and Reference Standard equipment should be placed in controlled
environmental condition as mentioned above for at least 30 min warm up.
7.2 The technician performing calibration shall ensure the following before starting
calibration:
 Calibration Check Gas validity need to be verified.
 Ensure required PPE are used such as Gas protective mask.
 Ensure required first aid kit is placed near to the calibration desk.
 Keep one calibrated gas detector in ON condition on the calibration
desk near to the UUT for instant gas leak detection.
 Ensure adequate exhaust arrangement in the calibration area.
7.3 Activating / Deactivating the detector:

MODEL ACTIVATION DEACTIVATION

Press button in a normal Press button and hold until the

Extreme
atmosphere OFF countdown is complete

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 5 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 6 of 11

Code Code
No. Description No. Description

1 Visual alarm indicators (LEDs) 5 Sensor and Sensor Screen

2 Liquid crystal display (LCD) 6 IR interface
3 Push Buttons 7 Alligator Clip
4 Audible alarm

Code
No. Description
5 Set alarm set point & user options
6 Maximum gas exposure
7 Alarm conditions
8 Battery life indicator
9 Data transmission
10 Alarm or alarm set point
Code Automatically zero sensor
Description 11
No.
1 Numeric values 12 Optional datalogger indicator
2 Gas cylinder indicator 13 Parts per million (ppm)
3 Automatically span sensor 14 Percentage by volume (%)
4 Pass Code Lock 15 Percentage by lower explosive limit

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 6 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 7 of 11

7.4 Detection ranges of Gas Alert Extreme:

RANGE RESOLUTION
DETECTOR TYPE
ppm ppm

H2S 0 – 100 1

H2S (High Range) 0 – 500 1

NH3 0 – 100 1

NH3 (High Range) 0 – 400 1

Cl2 0 – 50.0 0.1

O2 0 – 30 % vol 0.1 % vol

7.5 The detector shall be calibrated using the following reco mmended calibration gas
mixture:

REFERENCE CONCENTRATION
DETECTOR TYPE
GAS ppm

H2S H2S 10 – 100 (Balance N2)

H2S (High Range) H2S 10 – 100 (Balance N2)

NH3 NH3 20 – 100 (Balance N2)

NH3 (High Range) NH3 20 – 100 (Balance N2)

Cl2 Cl2 3 – 25 (Balance N2)

O2 Clean Air 20.9 % vol

7.6 Alarm set points:

ALARM H2S NH3 Cl2 O2

Low Alarm 10 ppm 25 ppm 0.5 ppm 19.5 % vol.

High Alarm 15 ppm 50 ppm 1 ppm 23.5 % vol.
TWA Alarm 10 ppm 25 ppm 0.5 ppm N/A
STEL Alarm 15 ppm 35 ppm 1 ppm N/A

7.7 Trouble Shooting:

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 7 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 8 of 11

PROBLEM POSSIBLE CAUSE SOLUTION

No battery Install a battery

Depleted battery Replace the battery

The detector does not
activate
Damaged or defective detector Contact BW Technologies

Reversed battery Reinstall battery correctly

Used sensor: wait 60s

The detector enters alarm
mode immediately after
activation
Sensor needs to stabilize
New sensor: wait 5 minutes
Low battery alarm Replace the battery
Sensors requires calibration Calibrate the sensors

General fault Contact BW Technologies

The startup self-test fails

Alarm set points are incorrect Reset the alarm set points
during one of the steps

Sensor error Replace the sensor

Detector does not function

Sensor may be expired Change the sensor
auto zero or calibration

8.0 CALIBRATION PROCEDURE

8.1 UUT shall be visually inspected and cleaned using a soft damp cloth or
standard meter cleaner prior to performing calibration of the detector.
8.2 To change the date and time settings, press and hold both the ▲ and ▼
arrow push buttons in the middle simultaneously until “OPTN” displays on the
screen.
8.3 If the detector is pass code protected, “PASS” displays on the screen. Press
▲ or ▼ button to bring the pass code value to 871 and press button (right
corner most push button) to select the value.

8.4 Press the ▲ or ▼ button to bring the user menu to “CLK” and press button.
Using the ▲ and ▼ button select the year, month, date and time, press
button to save each changes.
DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 8 of 11
TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 9 of 11

8.5 These settings are to be changed before calibration. Any setting changes
after calibration will result in a void calibration.
8.6 Select “EXIT” option from the user menu by scrolling ▲ or ▼ button and
press to exit.
8.7 If the calibration is due, the detector beeps and displays “CAL” “PAST”. Press
button to return to normal operation.
8.8 In a safe non-hazardous area, press ▼ and buttons simultaneously and
hold for 5 seconds. The detector beeps and vibrates four times and displays
“CAL” with a single beep.

8.9 In the display “AUTO ZERO” flashes while the detector zeroes the sensor. At
the end of auto zero, detector beeps twice. If the sensor fails Auto zero
detector displays “FAIL”.

8.10 If the detector is pass code protected, “PASS” flashes on the display. Enter
the pass code 871.
8.11 The detector displays previous calibration gas concentration. To accept the
same concentration press
8.12 The value should be same as the concentration given on the calibration gas
cylinder.
8.13 To change the value press ▲ or ▼ buttons and press to select. Kindly note
that if is not selected within 10 seconds, detector rejects the new value and
displays “NO”.

8.14 The detector beeps 6 times and retains the previous value. Once the value
has been selected, the detector automatically proceeds to the span screen.
Wait for the cylinder icon to be displayed on the screen before applying the
gas, otherwise auto zero fails.

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 9 of 11

TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 10 of 11

8.15 When the cylinder icon flashes, connect the gas cylinder to the sensor part of
the detector using the hose and test cap provided by the manufacturer open
the regulator slowly.

Code
No. Description

1 Test Cap

2 Hose

3 Regulator

4 Gas Cylinder

8.16 When the detector senses sufficient amount of gas, the detector beeps once.
At the end of span stage detector beeps three times and vibrates. Now
remove the gas connection.
8.17 After successful calibration, LCD displays “CAL.” “DUE”. Press ▲ or ▼ button
to bring the value to desired calibration interval of 90 / 180 days using the
push button as per customer request and press to select.
8.18 Detector displays CAL DUE and Calibration interval
8.19 If the detector fails to span the sensor, “FAIL” displays on the screen. Make
sure that:
 Gas is applied to the sensor.
 Sensor is detecting sufficient concentration of gas within 30 seconds.
 The gas concentration has not dropped significantly within 2 min. span.
 If the span is still unsuccessful, use a new gas cylinder.
8.20 Press button to bypass defining alarm set points. To change alarm set
points, use ▲ or ▼ button and press to save the new value.
8.21 After the alarm points have been set, the detector beeps and vibrates four
times at the end of calibration. As the sensor returns to ambient gas
concentration, high alarm and low alarm deactivates.
DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 10 of 11
TITLE : BW GAS ALERT EXTREME CALIBRATION PROCEDURE

Document No. Rev. No. Issue No. Date of Issue Page No.
L3-ATS-CAL-09 0 1 01-Jan-2019 11 of 11

8.22 Note down the readings against alarm set points.

8.23 Once the detector returns to normal mode, verify the alarm set points by
applying gas to the sensor.

9.0 RECORDS
9.1 Measurement/reading shall be recorded in the appropriate Check
List/Formats given the Attachment.

9.2 The test report should contain the following information as minimum.
 Client/Customer Name

 Instrument Manufacturer, Make, Model, Range, Serial No & Accuracy

 Test results

10.0 ATTACHMENT

S.No Format No. Description

1 L4-ATS-CAL-C-02 Single Gas Detector

DOC. NO. L3-ATS-CAL-09 Rev. 0 dt. 01-Jan-19 Page : 11 of 11