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PR-1154 - Gas Testing Procedure
PR-1154 - Gas Testing Procedure
Document ID PR-1154
Security Unrestricted
Version 4.1
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
Revision: 4.1
Petroleum Development Oman LLC Effective: Oct-14
i Document Authorisation
Authorised For Issue October 2010
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details
of all revisions prior to these are held on file by the issuing department.
Revision No. Author Scope / Remarks
4.1 Oct-14 Philip Hatherton Revision to incorporate minor
UOP61 amendments
Apr-11 Robin Norman UOP6 Added Section 1.6 ALARP
4.0 Oct-10 Robin Norman UOP6 Major revision and update. Informative
general text moved to Appendix.
Section 2 dedicated to Roles and
Responsibilities. Contents arranged to
be more concise.
3.0 May-07 UEV/11 Reformatted & Revised
TABLE OF CONTENTS
1 Introduction ............................................................................................................................ 7
1.1 Background ...................................................................................................................... 7
1.2 Purpose ............................................................................................................................ 7
1.3 Distribution / Target Audience .......................................................................................... 7
1.4 Changes to the Document................................................................................................ 7
1.5 Step-out Approval ............................................................................................................. 8
1.6 ALARP .............................................................................................................................. 8
2 Roles and Responsibilities ..................................................................................................... 9
3 Gas Testing .......................................................................................................................... 11
3.1 Scope ............................................................................................................................. 11
3.2 Potential Hazards ........................................................................................................... 11
3.2.1 Oxygen Enriched Atmosphere ...................................................................... 11
3.2.2 Oxygen Depleted Atmosphere ..................................................................... 11
3.2.3 Flammable or Explosive Atmosphere ........................................................... 11
3.2.4 Toxic Atmosphere......................................................................................... 12
3.2.5 Hydrocarbon Enriched Atmosphere ............................................................. 12
3.3 Gas Test Requirements ................................................................................................. 12
3.3.1 Breaking Containment .................................................................................. 12
3.3.2 Hot Work in a Process or Hydrocarbon Area ............................................... 12
3.3.3 Gas Freeing and Purging ............................................................................. 13
3.3.4 Confined Space Entry / Work within a Confined Space ............................... 13
3.3.5 Checking for Suspected Gas Leaks ............................................................. 13
3.3.6 Providing Clearance for Work Activities ....................................................... 13
3.3.7 Use of Diesel Engines in a Process / Hydrocarbon Area ............................. 13
3.3.8 Vehicle Entry to a Process / Hydrocarbon Area ........................................... 13
3.4 Testing Instruments ........................................................................................................ 13
3.4.1 Multigas Monitors.......................................................................................... 14
3.4.2 Explosimeter Monitors .................................................................................. 14
3.4.3 Detector Tubes ............................................................................................. 14
3.5 Gas Tester...................................................................................................................... 14
3.6 Pre-User Checks ............................................................................................................ 14
3.7 Gas Testing Process ...................................................................................................... 16
1 Introduction
1.1 Background
The requirements of Gas testing are clearly described in PR-1172 – Permit to Work
System Sections 3.5, 6.2.4 and 6.12. PDO Operations Staff and Contractors shall
require to employ only personnel who have been trained and certified competent to
perform gas tests and the procedure / methods that they use to carryout the tests shall
be as prescribed by the course.
Gas testing is mandatory prior to work being undertaken in a process or hydrocarbon
area that carries a risk to personnel or equipment from exposure to explosive,
flammable, toxic or life threatening vapours. Gas testing shall also be required in any
other area where the above risks are considered to exist which are covered by the PDO
rd
Permit to Work or a 3 Party compliant system.
NOTE: Gas testing shall be carried-out on facilities where NORM or Mercury is
identified or likely to be present. Specific procedures shall be used when testing for
these risks.
1.2 Purpose
The purpose of this procedure is to present the high level requirements for gas testing
and define the key hazards and methods of testing.
This procedure does not intend to duplicate methodology taught during the Gas Tester
course or information contained in PR-1172 Permit to Work System.
1.6 ALARP
ALARP is the acronym for ‘As Low As Reasonably Practicable’ which simplified means,
‘reducing the risk to a level at which the cost and effort (time and trouble) of further risk
reduction are grossly disproportionate to the risk reduction achieved’. Full Compliance
to PDO Standards and Procedures is a key element in achieving ALARP.
For more details refer to ALARP Definition
•
st
For Class A permits performs the 1 gas test each day, unless
authorised by Responsible Supervisor that this can be carried
out by Authorised Gas Tester
Authorised Gas Tester • Comply with PR-1172 Permit to Work System regarding gas
testing requirements and frequencies
• Performs all Gas testing for Class B permits
• Carryout ‘ad-hoc’ gas testing when required
• Enter gas test results and frequency of further tests on PTW
and Confined Space Entry Certificate / Additional Gas Test
sheet (if applicable),
NOTE: Authorised Gas tester to agree test results with area
authority and enter into PTW.
Permit Holder • Include gas testing requirements in the TRIC
• Agree gas test results
• Ensure compliance to gas testing requirements is adhered to
• Ensure correct type of gas detector is used for the gas testing
activity
Maintenance Staff • Comply with this procedure
• Ensure the procedures are read and understood and they sign
the Record of Procedure Understanding Form
3 Gas Testing
3.1 Scope
The scope of this procedure shall cover;
- the hazards which gas testing shall address;
- the requirements for gas testing;
- typical testing instruments used;
- the gas tester and;
- pre-user checks
The procedure shall make reference where appropriate to material located in other
documents and provide links to those documents where necessary.
1
The volume of sample required to be drawn through the detector tube varies with the gas being
sampled for. Reference shall always be made to the kit instructions to ensure that the correct
volume of sample is obtained.
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• Ensure that the gas detector ‘test’ is in date. Do not use a gas detector that is
‘out of test’
• Check the gas detector for signs of damage. If damaged record and report the
nature of the damage and exchange the gas detector for one that is undamaged
(if possible)
• Before using the gas detector ensure the ‘battery’ is fully charged
• After switching on purge the gas detector with uncontaminated air
• Allow the gas detector to complete the ‘startup sequence’ (if applicable) before
use
• If the gas detector uses a calibration gas check that the reading is correct to the
calibration gas
• Follow all manufacturers safety instructions for use
NOTE: If in doubt reference the Manufacturers O&M manual
In both cases, the Authorised Gas Tester must:
• Gas test at the frequency stated on the Permit or Confined Space Entry
Certificate.
• Fill in the result of the gas test on the Gas Test Record and Sign it.
When a test result indicates that it is NOT safe to work, the Authorised Gas
Tester must:
ENTERS
REQUIREMENTS ON
THE PERMIT TO
WORK
REVIEWS AND
AGREES/AMENDS
REQUIREMENTS
CLASS B
CLASS A OR B PERMIT?
CLASS A
The methodology for gas testing shall be in accordance with the recognised courses
conducted on behalf of PDO. The typical gas test requirements are detailed in Section
3.3. The process described here shall be typical of the normal gas testing carried out in
PDO in conjunction with the Permit to Work system.
1. The Permit Applicant shall identify the gas testing requirements for the work to be
undertaken.
The gas testing requirements shall be entered on the PTW
2. The Responsible Supervisor shall review the gas testing requirements and agree
or amend as required.
For Class A permits a site visit is mandatory for Class B it is recommended.
The Responsible Supervisor shall identify the gases to be tested for and the
frequency of the gas testing after the initial test.
The Responsible Supervisor shall authorise the PTW
3. The Permit Applicant shall ensure that gas testing requirements are clearly
explained to the Permit Holder. These shall be included in the TRIC
4 The Area Authority shall enter the gases to be tested for and the frequency of
testing on the PTW before validation (see 2 above)
5. Is the PTW a Class A or a Class B?
The class of the permit shall dictate who undertakes the initial gas test for the
work covered
For Class A permits the Area Authority will conduct the first gas test of each day in
accordance with PR-1172 – Permit to Work System
NOTE: This ruling can be changed to allow the Authorised Gas Tester (if not an
Area Authority) to conduct this test and requires the Responsible Supervisors
authorisation and approval
For Class B permits an Authorised Gas Tester can conduct all gas tests
6. The Permit Holder shall witness the initial gas test and agree the result.
7. The Area Authority / Authorised Gas tester shall conduct all subsequent gas tests
required by the PTW
8. The Area Authority / Authorised Gas tester shall maintain the gas testing log
Atmospheric testing is required to evaluate the hazards of the permit space and for verification
that acceptable entry conditions for entry into that space exist. Similarly where ‘hot work’ is to be
undertaken which is adjacent to live plant gas testing shall be undertaken to evaluate the risk of
hydrocarbon or toxic gas.
Evaluation Testing
The atmosphere of the permit space should be analysed using test equipment for the specific
gases expected to be present to identify and evaluate any hazardous atmospheres that may
exist or arise, so that appropriate procedures can be developed to conduct the required work
safely. Evaluation and interpretation of the gas measurement data, and development of the
procedure, should be done by, or reviewed by technically qualified personnel based on a Risk
Assessment.
Verification Testing
The atmosphere of a permit space which may contain a hazardous atmosphere shall be tested,
using the appropriate gas test equipment to evaluate conditions are safe, at the time of analysis,
to commence the required work. Results of testing (i.e., actual concentration, etc.) shall be
recorded on the Permit to Work (PTW). Measurement is by volume of the total atmosphere.
Duration of Testing
Measurement of values for each atmospheric parameter should be made for at least the
minimum response time of the test instrument specified by the manufacturer.
Testing Stratified Atmospheres
When monitoring for entries involving a descent into atmospheres that may be stratified, the
atmospheric envelope shall be tested a distance of approximately 4 feet (1.22 m) in the direction
of travel and to each side. If a sampling probe is used, the entrant's rate of progress should be
slowed to accommodate the sampling speed and detector response.
Order of Testing
A test for oxygen is performed first because most combustible gas meters are oxygen
dependent and will not provide reliable readings in an oxygen deficient atmosphere. Combustible
gases are tested for next because the threat of fire or explosion is both more immediate and
more life threatening, in most cases, than exposure to toxic gases and vapours. If tests for toxic
gases and vapours are necessary, they are performed last.
Oxygen content shall be determined by gas testing when considering the entry of
personnel into a ‘permit required confined space’. The tests shall generally include the
following
Oxygen Deficiency
At atmospheric level the normal atmospheric concentration of oxygen is 20.8% vol.
Atmospheres containing less than 20% vol. oxygen are considered to be oxygen-
deficient or hypoxic.
NOTE: The oxygen content of air reduces as altitude increases, therefore locations at
more than 1000 metres above sea level appropriate corrections should be made and
appropriate precautions taken.
Oxygen deficiency in an atmosphere can result in asphyxiation. A relatively small
reduction in the oxygen level can lead to impaired mental ability and can provoke a
feeling of euphoria or well being leading to an overoptimistic judgment of the situation.
The effects generally occur without alerting the senses. Loss of consciousness can
occur without warning. This can happen even in circumstances where only a person’s
head is inside a confined space. Very low oxygen concentrations, below 10%, can lead
to unconsciousness and death. Inhaling an atmosphere with no oxygen results in instant
death. There is no panic or discomfort; death is swift and silent.
Oxygen deficiency can result from:
• Displacement of air from low points in a confined space by heavier gases such
as hydrocarbons or carbon dioxide;
• Purging of the confined space with an inert gas to remove flammable or toxic
gases, fumes, vapours or aerosols;
• Naturally occurring biological processes that consume oxygen, which can occur
in sewers, storage tanks, wells etc.;
•
2
Leaving a vessel completely closed for some time, since the process of rust
formation on the inside surface consumes oxygen;
• Increased levels of carbon dioxide evolving from limestone chippings associated
with drainage operations;
• Burning and welding, which consume oxygen;
• Displacement of air during pipe freezing with liquid nitrogen;
• Gradual depletion of oxygen as workers breathe in confined spaces and where
provision of replacement air is inadequate.
Any reduction in the oxygen level from the atmospheric concentration shall be
accounted for or investigated, the risks assessed and appropriate measures taken.
Entry into confined spaces containing 16 to 20% by volume oxygen shall not be
allowed unless a Risk Assessment has been completed and approval has been
obtained from the appropriate authority.
CAUTION: The shall only be by exception, when the source of oxygen deficiency
is understood and it is not practical to ventilate the confined space to
atmospheric oxygen level.
2
Newly fabricated or shot blasted carbon steel vessels are especially vulnerable to rusting
Page 19 PR-1154 – Gas Testing Printed 14/01/19
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Revision: 4.1
Petroleum Development Oman LLC Effective: Oct-14
Atmospheres containing less than 16% vol. oxygen shall be treated in the same
way as toxic atmospheres that are Immediately Dangerous to Life and Health
(IDLH).
Oxygen Enrichment
At atmospheric level the normal atmospheric concentration of oxygen is 20.8% vol.
Atmospheres containing more than 21.5 % vol. oxygen should be treated as oxygen
enriched or hyperoxic.
Oxygen enrichment will significantly increase flammability of clothing, grease and other
combustible materials.
Oxygen enrichment can result from:
• Leaks from oxygen containing equipment such as gas cylinders, valves, hoses
and welding torches;
• Inadvertent use of oxygen instead of air for ventilation or breathing air;
• Deliberate addition of oxygen to increase the level of an oxygen deficient
atmosphere.
Any increase in the oxygen level above normal during confined space entry activities
shall be investigated, a Risk Assessment completed and appropriate measures taken.
The most common oxygen containing equipment is that used in gas cutting operations.
Cylinders, gas hoses, valves and welding torches shall be handled with care and should
be daily inspected for damage. Gas cylinders shall not be taken into confined spaces
unless the risks have been assessed and appropriate authorisation is obtained from the
Responsible Supervisor. If allowed into the confined space all such equipment shall be
removed during breaks and at the end of the working day.
Toxic gas testing shall be carried out to identify and detect toxic substances either in or
adjacent to the confined spaces or other places of work. Substances can be solids,
liquids or gases. Toxic vapours can cause injury, acute or long-latency illness, or death,
depending on the characteristics of the substances, the concentration and the duration
of exposure. For example, prolonged exposure to benzene can cause kidney damage or
even leukaemia.
Toxic hazards in confined spaces can result from the same sources as the flammable
hazards described in Appendix 3.
Common toxic substances in the oil and gas industry are:
• Acute toxic gases such as hydrogen sulphide, carbon monoxide, hydrogen
fluoride, ammonia and chlorine;
• Hazardous liquids such as benzene, polycyclic aromatics, lead/anti-knock
compounds, hydrazine and biocides;
• Narcotic gases and vapours such as butane, pentane, hexane, gasoline and
gas condensate;
• Catalyst dusts, such as nickel, platinum, and molybdenum.
Toxicity data for specific substances, e.g. Material Safety Data Sheets (MSDS) or Safe
Handling Of Chemical Cards (SHOC), shall be required from the supplier of materials or
from government authorities, and shall be made available on site. If these are not
available then a competent industrial hygienist shall assess the toxicity of the
intermediates and products.
Crude oil and refinery process streams are mixtures of many hydrocarbons that
individually have significant toxic or narcotic effects. The Health Risk Assessment
(HRA), as input to the Job Hazard Analysis (JHA), shall assess the hazards of the
mixture in the situation / areas where persons could be exposed. Specifically, the HRA
should make a recommendation on whether flammability measurements are sufficient to
detect harmful levels of the potentially toxic substance. Different criteria may be needed
for:
• Confirming that the atmosphere in the confined space is safe for entry, for
planned work, and
• Requiring persons to leave the space in case of an increased level during the
work
Substances that are harmful by inhalation normally have an assigned Occupational
Exposure Limit (OEL). An Action Limit of 50% of the published OEL shall be applied as
the trigger for implementing specific measures for controlling exposure to the toxic
substance during the confined space work, but the target should be to reduce the
airborne concentration to ALARP. OEL data may not be available for some toxic dusts,
sludge and other substances, in which case specialist occupational hygiene advice
should be sought.
Entry into confined spaces containing a concentration of toxic vapour, fume or dust
between the OEL and the IDLH value shall be allowed only by exception when and it is
not practical to ventilate the confined space or otherwise remove the hazard to reduce
the toxic concentration. In this case it shall only be allowed when the source, nature and
concentration of the toxic hazard is understood and exposure is adequately controlled by
other means.
Entry into confined spaces containing a concentration of toxic vapour, fume or dust
above the IDLH value shall not be allowed.
The most notable toxic gas encountered in PDO operations is hydrogen sulphide (H2S).
Allowable concentrations are related to the Threshold Limit Value (TLV) which
represents the concentration to which a worker may be exposed without suffering
adverse health effects.
For the H2S the TLV is 10 ppm, for an 8-hour period.
The short-term exposure level (STEL) for H2S is 15 ppm and is the concentration of H2S
gas in air above which protective equipment must be used.
Testing for hydrocarbon vapour shall be carried out prior to / and during Confined Space Entry
and at any time that hydrocarbon vapours are suspected of being present in or around a space,
vessel or tank where personnel are working. Detection of hydrocarbon vapour is by the use of
Drager Detection Tubes.
Appendix 5 – Abbreviations
UOP7
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