DAY 1

INTRODUCTION:
Many fatalities have occurred because gas testing had not been
conducted or the tests have been inadequate. Gas testing must be
completed by trained competent personnel. However, it is important that
everyone understands the basic requirements.
HAZARDS OF GASES:
In the oil/gas and petrochemical industries, gas hazards are of particular
importance. These hazards can be split into 3 main categories:
 The first are oxygen hazards, in the air we breathe if there’s too much
or not enough oxygen you or your work mates may die.
 Secondly explosive gases and flammable vapors, which, when mixed
with air in certain proportions can lead to fires or explosions.
 And finally harmful or toxic gas hazards; these cover everything
from inert gases like nitrogen, used in purging operations, which,
simply displace the oxygen out of the air we are breathing, right
through to the nerve gases like Hydrogen Sulphide, which chemically
interfere with the cells in our body.
THE FOLLOWING ABBREVIATIONS ARE USED:
Gas: any substance of very low density and viscosity. (No shape, fills the
free space of container)
Vapour: mist or fumes suspended in air.
Liquid : any flowing substance with little tendency to disperse. (No
shape, takes shape of container).
PPM: Parts Per Million.
TLV-TWA  : Threshold Limit Value – Time-Weighted Average
STEL : Short Term Exposure Limit
IDLH : Immediately Dangerous to Life and Health
LEL :  Lower Explosive Limit
UEL : Upper Explosive Limit
TO PREVENT AN INCIDENT 3 MAIN TYPES OF GAS TESTING
ARE UNDERTAKEN:
 Before entering a confined space or Excavation.
 Before undertaking any type of hot-work.
 During inerting.
GAS TESTING IS INVOLVED WITH THE FOLLOWING
ACTIVITIES:
Hot work of any type where heat is used or generated,
e.g. by welding, flame cutting and grinding, etc.
• Work which may generate sparks or other sources of ignition.
• Work which may cause an uncontrolled release of hydrocarbons,
other flammable or toxic materials.
• Electrical instrumentation work which may cause sparks.
• Entry into confined spaces and Gas alarm investigation.
WHY CARRY OUT A GAS CHECK?
Confined Space and Vessel Entry Gas Testing:
Oxygen deficiency – suffocation / death.
Oxygen enrichment – fire / explosion hazard.
Gas or flammable vapour – fire or explosive hazard.
Toxic gas – poisoning hazard.
To certify that the atmosphere within a confined space is free from
Flammable, Explosive or Toxic substances and that the Oxygen content is
20.9% .In other words, to certify that the atmosphere is safe to work in!
Hot Work Gas Testing:
To certify that there are no leaks or accumulations of Flammable Vapours
or Explosive gases at the worksite when hot work is being under taken.

Gas Detector:
Gas detector should be calibrated – Calibration validity is 3 months as
per KNPC.
• Gas testing only to be carried out by Authorised Gas Tester.

MULTI GAS DETECTOR CAN SHOW 4 GASES:

• O2 (Oxygen)
• LEL (Lower Explosive Limit)
• CO (Carbon mono oxide)
• H2S (Hydrogen sulphide)
Exposure Limits of Gases:
O2 (Oxygen)- required in between 19.5 to 23.5%
LEL- shall be zero for hot work and 10% for cold work is
allowed.

GAS TLVSTEL IDLH

H2S 10 PPM 15 PPM 33 PPM*
CO 25 PPM 400 PPM 1500 PPM
Cl 2 0.5 PPM 01 PPM 10 PPM
SO2 02 PPM 05 PPM 100 PPM
NH3 25 PPM 35 PPM 100 PPM
IDLH of H2S : 100PPM as per NIOSH, 33PPM as per KNPC
 CO (Carbon mono oxide)
 H2S (Hydrogen sulfide)  – IDLH -33ppm as per KNPC & 100PPM
as per NIOSH
 Cl 2 (Chlorine)
 SO2 (Sulfur dioxide)
 NH3 (Ammonia)
TLV-TWA: Threshold Limit Value – Time-Weighted Average:

Limit which is set for exposure up to 8 hours per day which results in
no short or long term ill effects

STEL: Short Term Exposure Limit:

Limit which is set for exposure for 15 minutes (limit 4 times per day
with 1 hour between exposures)
IDLH: Immediately Dangerous to Life and Health:
Limit which is set for no exposure – Work not allowed
PROPERTIES OF EXPLOSIVE GASES AND FLAMMABLE
VAPOURS:
All combustible gases and vapours are characterized by explosive limits
between which, the gas or vapour mixed with air is capable of
sustaining the spread of flame. These can be referred to as the Explosive
or Flammable limits

Explosive ranges of other gases

SUBSTANCE LEL (Vol%) UEL (Vol%)
ACETONE 2.15 13
ACETYLENE 2.4 88
BUTANE 1.5 8.5
ETHANE 3 15.5
ETHYLENE 2.7 34
HEXANE 1.2 7.4
HYDROGEN 4 75.6
METHANE 5 15
PROPANE 2 9.5
LEL – Lower Explosive Limit:
LEL of methane is 5% by volume i.e. 5 volumes of methane mixed
with 95 volumes of air. This is the minimum quantity of Methane in a
methane/air mixture that will ignite to produce a self-propagating flame if
exposed to a hot source or a spark from electrical or mechanical
equipment. If there is less than 5% of Methane in the air by volume the
mixture is too lean to support combustion.
UEL – Upper Explosive Limit:
UEL refers to the highest concentration of a gas in the atmosphere
which results in a combustible mixture. For example, the UEL of
Methane in air is 15% by volume, which means that if there is more than
15% of Methane in the air by volume the mixture is too rich to support
combustion.
LOW OXYGEN EFFECT AND SYMPTOMS :
15 to 19% : Strenuous work is difficult

12 to 14% : Respiration and pulse increases, co-ordination and

judgment impaired

9 to 11% : Nausea, fainting, blue lips, unconsciousness

6 to 8% : Death within 8 minutes, recovery if resuscitated within 4

minutes

Remember! That rusting of steelwork and some chemicals in confined

spaces can reduce the oxygen in the atmosphere to dangerous levels very
quickly.
HIGH OXYGEN EFFECTS AND SYMPTOMS:
Above 23% oxygen serious fire risk causing some materials to
spontaneously combust, for example, oily cloth and steel wool >(30%)

Prolonged exposure causes damage to breathe processes and

intoxication which seriously disturbs judgment with (industrial 02
gas)

Most gas detection apparatus is uncertified if the oxygen content is

increased above atmosphere levels

The minimum content of Oxygen required for a Catalytic Gas detector

reading LEL is 13% or more to read accurately.
How do I choose a gas detector?
How to Choose a Personal Gas Detector: 8 Features You Need
• Monitors the Right Gases for Your Environment. ...
• Measuring Ranges that Match Your PPE Requirements. ...
• Flexibility to Fit Your Application. ...
• Status Alerts and Maintenance Reminders. ...
• Alarm Action Messages and Full-Screen Alarms. ...
• Peer-to-Peer Connectivity
Gas Detection Bump Test and Calibration Frequency Regions
Affected:
Global This document is intended to provide a general guideline for
bump testing and calibration of Honeywell Analytics gas detection
products. The following gas detector tests should only be conducted in a
fresh air atmosphere containing 20.9% oxygen and free of any toxic or
combustible gas vapors. Corporate, local, regional or national regulations,
policies and procedures may take precedence over these recommendations.
Bump Test
Function Check:
A qualitative function check where a challenge gas is passed over the
sensor(s) at a concentration and exposure time sufficient to activate all alarm
indicators to a minimum of their lower alarm setting. The purpose of this
check is not to confirm the accuracy of sensor response, just that gas can
get to the sensor(s) and that all the alarms present are functional.
Accuracy Check:
A quantitative function check using a known concentration of gas that is
traceable to a recognized standard to confirm that the alarms are
functional and that the sensor(s) response is within acceptable limits.
Typically, a +/-10% to +/-20% of applied gas value is considered acceptable
unless otherwise specified by the manufacturer, internal company policy, or a
regulatory agency.
Calibration
Zero calibration: Establishes sensor(s) baseline
reading, 20.9% oxygen and free of any toxic or
combustible gas vapors. To maintain a stable
baseline, it is essential to perform zero calibration
in fresh air. In the event, fresh air cannot be
confirmed, use zero grade air or N2 to perform a
detector zero calibration. Perform a zero calibration to
reestablish baseline as required, and before a span
calibration.

Span calibration:
The adjustment of the sensor(s) response to match the
value of a known concentration of applied gas that is
traceable to a recognized standard. The calibration
procedure should be done in accordance with the
equipment manufacturer’s instructions.
NOTE: Consult the product manual for product specific recommendations.

Recommended Frequency
Fixed gas monitors:

Perform an Accuracy Check on a 4 to 6-month basis based on region at a

minimum
 Consult local regional codes for proper bump test intervals.

Perform a Zero calibration and Span calibration prior to first time use and
then on an annual basis at a minimum
 Factory calibrated sensors may not require a Span calibration at first
time use
 Infrared (sealed construction only) and ultrasonic based products
typically do not require e span calibrations and should be avoided
where possible Direct Reading Portable Gas Monitors:
• Perform a Function or Accuracy check prior to each day’s use at a
minimum.
• Perform a Zero and Span Calibration prior to first time use. Calibration
frequency can vary from every 30 to 180 days, or, calibrate following a
failed bump test.
Product Notice
• Perform a Function check periodically
• Perform a Zero Calibration as required; Span Calibration is typically
not required over the working life of the monitor.

Flame Detection Testing

Electro-optical flame detectors:
• Perform a lamp test on a semi-annual basis. Perform a complete fire
protection system function
• test annually.
What is a Gas Safety Record?
A Gas Safety Record is the documentation that may be given to you
by a gas engineer after they’ve done gas work at your property. The
documentation provided will often depend on the type of work they’ve
undertaken - be it a service or a safety check.

While all gas engineers are required by law to be on the Gas Safe
Register, it’s not a legal requirement for them to provide Gas Safety
Record documentation after they visit you. There’s one exception, and
that’s if you’re a landlord.
Landlord Gas Safety Record: the low down
As a landlord letting a residential property, you have a legal duty to ensure
it’s safe for your tenants. This means you’re required by law to get a Gas
Safe registered engineer to do an annual gas safety check on all gas
appliances - and it’s the results of these checks that are recorded in
your Landlord Gas Safety Record. You’ll receive a copy, and you’ll need
to provide a record of this check to your tenants.
In your record, you should find:

A description and location of each appliance or flue that was checked

The name, registration number and signature of the engineer who made
the checks
The date the checks were carried out
The address of the property where the appliances or flues are installed
Your name and address (or an agent’s where applicable)
Information on any safety defects and actions needed or taken to fix them
The results of all operational safety checks carried out on the appliances
The gas pipework in your rented property must also be kept in a safe
condition. Installation pipework is not covered by the annual gas safety
check, but both we and the HSE recommend that when you request a
safety check, you ask your Gas Safe registered engineer to:

Test for tightness on the whole gas system, including installation

pipework
Visually examine the pipework (so far as is reasonably practicable)