Authorised Gas Tester

Level 1, 2 & 3 Merged Initial Program

OPITO Standards Codes 9024, 9025 & 9026

8-Jun-18
Course Content:
Day 1
Am:
• Introduction
•Why & When we need a Gas test in Majnoon
•Confined Space Criteria
• Hot Work Criteria
•Atmospheric Hazards
•Risk assessment & Safe systems of work
•The implication of organizational and statutory requirements
•Personal Protective Equipments & Respiratory Protective Equipments

8-Jun-18
Course Content:

Day 1
Pm:
• Atmosphere measuring and monitoring equipments
•Gas Testing in Confined Spaces
•Gas Testing for Hot Work
•Interpreting and documenting gas test results

8-Jun-18
 Course Content:
Day 2

Am:
• Questions & Answers session
• Written assessment, 20 questions and passing grade 80 %
•Written assessment feed back and results
•Preparation to practical assessment

Pm:
• Practical Assessment
• Final Results
• Course evaluation & session closure

8-Jun-18
Performance Validation

Validation of the delegates' performance will be against the stated training

outcomes,
A multiple choice written test with a minimum of 20 questions and a pass
mark of 80% is used to gauge the delegates’ understanding of the topics
plus a practical demonstration of every students on a gas teat operation
according on a pre described job and circumstances on a Permit to Work.
Delegates successfully completing the course validation will be judged to
have been given the underpinning knowledge for Authorised Gas Tester
Level 1, 2 & 3.

8-Jun-18
 Conduct gas tests when required
You should…

• Confirm with the Supervisor or the Person

in Charge of the work that the air is tested

• Confirm with the Supervisor or the Person

in Charge of the work that it is safe to start
work
• Stop work if you smell gas

Gas Testers should:

• Understand which tests the Work Permit
requires and how often

• Use certified equipment for the tests

8-Jun-18
Reasons for GasTesting

• Gas testing assists in;

• Identifying, Assessing, Controlling and or Recovering from the
following Hazards,
• Oxygen Deficiency
• Oxygen Enrichment
• Toxic Gas
• Flammable Gas
• Inert Gas

8-Jun-18
Reasons for GasTesting

• Correct use of gas Detection Equipment can let us

know if …
• It is Safe to carry out Hot Work
• It is Safe to enter a Confined Space
• It is Safe to enter a potentially Hazardous area
• It is Time to leave a potentially Hazardous area
• There are any Gas leaks,
And
• The level of PPE or safety equipment that may be
required

8-Jun-18
Atmosphere Testing

Gas testing is mandatory for Hot Work and Confined

Space/Vessel Entry Permits. Only personnel trained
and certified as Authorized Gas Testers, shall carry
out gas testing.
Gas testing may also be required for vehicle or
combustion driven equipment entry to the Facility.

8-Jun-18
Atmosphere Testing

Confined Spaces Entry

8-Jun-18
Atmosphere Testing

Hot work of any type where heat is used or generated, eg. by

welding, flame cutting, grinding, etc.

8-Jun-18
Atmosphere Testing

Work which may cause an uncontrolled release of hydrocarbons,

other flammable or toxic materials.
8-Jun-18
Atmosphere Testing

Gas alarm investigation

8-Jun-18
CONFINED SPACES
A “confined space” is any enclosed or partially
enclosed space that:
• Is large enough for any person to bodily enter it and
perform assigned work
• Has limited or restricted means of entry or exit
• Has unfavourable natural ventilation
• Is not designed for continuous occupancy
• Has the potential to present hazards that may
result in physical injury to personnel within the
confined space through changes in atmosphere
Common examples of confined spaces are:
Process vessels, including columns, column
skirts, large pipes, flare stacks, boilers, storage
tanks, sewage pits and associated tunnels,
trenches, wells,
Other types of confined space are less obvious, for
example: Rooms that are inadequately ventilated;
Rooms that become confined because of the type of
work being undertaken, e.g. spray painting;
Open top tanks or Excavations (typically more than
1.2 meters).
Partially enclosed areas such as pits, excavations and
tank roofs are considered to be confined spaces when
they are deep enough for the breathing zone to be
inside the pit
Confined space entry means either complete body
entry or inserting a head into a confined space
Hot Works
 Hot Works category 1

• Any work that provided a positive source of

ignition ( eg welding, burning, cutting …)
 Hot Works category 2

• Any work that provided a potential source of

ignition ( eg combustion engines, battery
operated equipments, Use on non IS electrical
equipments, Opening junction boxes in
hazardous area … )
Atmospheric Hazards

8-Jun-18
Hazardous Atmosphere - Definition

Hazardous atmosphere is an atmosphere that may expose a

worker to the risk of death or incapacitation, or prevent a
worker from getting out of the confined space because of an
injury or critical illness. Such an atmosphere can be explosive,
flammable, poisonous, corrosive, oxidizing, irritating, oxygen
deficient, toxic, or otherwise harmful which can result in death,
illness, or injury.

8-Jun-18
Hazardous Atmosphere - Oxygen Hazards

Oxygen levels in a confined space may become enriched

(>21.5%) or decreased (<20%) causing potentially hazardous
situations.

Oxygen enrichment can cause ordinarily material to catch fire

easily.
Oxygen deficiency can be the result of consumption (Fire,
Bacteria, Chemical reaction ) or displaced by other gases.

8-Jun-18
Lack of Oxygen

• May be caused by:

• Too many people breathing

• Oxidisation (Fire, Rust)
• Poor Ventilation
• Displaced by other Gas

8-Jun-18
Lack of Oxygen

• Best Controlled by;

• Gas Testing
• Ventilation
–Forced
–Natural

8-Jun-18
Oxygen Enrichment

• May be caused by;

• Leaking Cylinder
–Welding
–Medical
• Chemical reaction
• Chemical release

8-Jun-18
Oxygen Enrichment

• Best Controlled by;

• Gas Testing
• Ventilation
–Forced
–Natural
• Storing Cylinders Outside Confined
Spaces / areas
• Referring to MSDS

8-Jun-18
8-Jun-18 HSE Induction - Day2
Hazardous Atmosphere - Flammable Gases

Flammable atmospheres may develop when combustible

gases or vapors accumulate.
Welding in a confined space is a major cause of explosions in
areas that contain combustible gas.

8-Jun-18
Flammable Gases

Oxygen Heat

Fuel

8-Jun-18
 Flammable Envelop

• Lower Explosive Limit (LEL)

– Lowest concentration of gas that can ignite
– Below this level the mixture of gas in air is too lean
– The maximum range used in most gas meters
• Upper Explosive Limit (UEL)
– The highest concentration of gas that can ignite
– Above this limit the mixture of gas in air is too rich
• Between these limits, hydrocarbon gas is explosive

8-Jun-18
 UEL LEL

Too Rich Too Lean

Gas
Source

H2S
45.5% 4.3%

Gasoline
7.6% 1.3%
LPG
10% 1.5%
Methanol
36% 6%
80% Acetylene 2.5%
8-Jun-18 HSE Induction - Day2
 Explosive Envelop

8-Jun-18
Hazardous Atmosphere - Flammable Gases

• May be caused by;

• Leaking Product
• Introduced Product
• Residual Product
• Chemical Reaction
• Oxygen Enriched

8-Jun-18
Hazardous Atmosphere - Flammable Gases

• Best Controlled by;

• Gas Testing
• Ventilation
–Forced
–Natural
• Isolations
• Control of Ignition sources

8-Jun-18
• Reduced Oxygen level Reduces explosive envelop, at around
8% oxygen flammability drops to zero

• During purging operations look for 6% Oxygen prior to

admitting hydrocarbons
8-Jun-18
 Toxic Gases

8-Jun-18
Common Toxic Gases

• H2S Hydrogen Sulphide

• CO Carbon Monoxide

• CO2 Carbon Dioxide

• NH3 Ammonia
• Cl2 Chlorine
• SO2 Sulphur Dioxide

8-Jun-18
 CO
Carbon Monoxide

• an odorless, colorless gas that is formed by

burning carbon based fuels (gas, wood).
Carbon monoxide inhibits the bodies ability to
transport oxygen to all parts of the body.

8-Jun-18
 CO2
Carbon Dioxide

•Asphyxiate Gas , results from complete cycle of

oxidation
•Colorless in atmospheric pressure
•Has refreshing odor / flavour
•Inert gas
•may build up in a confined space and subsequently
displace the oxygen

8-Jun-18
 H2S

•Produced in nature by decomposition of organic

materials by bacteria
•May develop in low oxygen areas - swamps, polluted
water
•Can be found in unstabilised crude oil and gas
streams

8-Jun-18
Key Properties of H2S

Highly Toxic

Flamable & Explosive

At very low concentrations has a rotten egg odor

Highly soluble - in drilling and formation fluid

Corrosive - to certain metals & elastomer seals

and causes Sulfide Stress Cracking

Heavier than air and will accumulate in low-lying

areas
8-Jun-18
Key Properties of H2S continued-

Density: 1.189 (Air=1)

Molecular weight: 34.08 g/mol
Solubility: 437 ml\100 ml of water
Auto-ignition temperature:500 F (260 0C)
Flash point: -115 F (-82 0C)
LEL: 4.3 %
UEL: 46 %

8-Jun-18
 Solvents

Many solvents, such as kerosene, gasoline, paint strippers, degreasers,

etc. are not only flammable, but if inhaled at high concentrations can
cause central nervous system (CNS) effects. CNS effect can include
dizziness, drowsiness, lack of concentration, confusion, headaches,
coma and death.

8-Jun-18
Nitrogen Safety:

Precautions when using ‘Nitrogen include:-

• Ensuring systems are not over-pressurised

• Providing sufficient ventilation or using appropriate PPE
(nitrogen asphyxiates)
• Venting any nitrogen safely
• Preventing spillage of liquid nitrogen
( causes stress cracking on steel)
• Using barriers and PPE to prevent
freeze burns to personnel from
liquid nitrogen
8-Jun-18
Toxic Gases

TWA : Time Weighted Average ;

The average exposure to a contaminant or condition (such as gas) to which
workers may be exposed without adverse effect over a period such as in an
8-hour day or 40-hour week.

STEL: Short Term Exposure Limit ;

A short-term exposure limit (STEL) is the acceptable average exposure
over a short period of time, usually 15 minutes as long as the Time
weighted average is not exceeded.
8-Jun-18
Toxic Gases

Carbon Monoxide Hydrogen Sulphide

– STEL - 200 ppm – STEL – 10 ppm
– TWA - 30 ppm – TWA – 5 ppm

Chlorine Benzene
–STEL – 1.0 ppm –STEL - None
–TWA – 0.5 ppm –TWA – 1.0ppm

8-Jun-18
 Risk Assessment & Safety Systems of Work

8-Jun-18
 Work with a valid work permit when required

You should…

• Understand the Work Permit

and
follow it

• Confirm that the Work permit

is valid

• Confirm with the Supervisor

or the Person in Charge of the
work that it is
safe to start work

8-Jun-18
•The work permit forms are the core of the Permit to Work system

The work permit is the master written statement signed by the appropriate,
authorized persons, allowing work to be performed on or around MFD
facilities under a stated set of precautions and controls. There are 5 types
of Work Permit:

Hot work 1
Hot work 2
Cold work
Breaking containment
Confined space entry certificate
Hot work category 1

This permit covers work involving hot work with a positive source of
ignition (such as welding, burning, grinding etc), as well as work
covered by hot work 2 and cold work permits.
Hot work 1 permits have a red border.
14 days validity
Hot work category 2

This permit covers work involving hot work with a potential source of
ignition (such as combustion engines, battery operated equipment) The
permit can also be used for cold work if only one part of the scope is hot
work (I.E opening live Junction box in Haz 2 area but the main scope is
running and tying in the cable)
Hot work 2 permits have a yellow border and is valid for 14 days
14 days validity
Hot work in a Hazardous area

• It is not allowed to carry out Hot Work category 1 (positive source of ignition)
in Hazardous Zone 0 or 1 area.
• Diesel engines in Hazardous zone 2 must have full Hazard Zone 2 rating.
•This shall include spark arrestors, water cooled exhaust manifolds and turbo
chargers, certified electrical components and fitted with a fuel solenoid to cut
off fuel supply on high LEL gas detection.
•Note: road going diesel engine driven vehicles, cranes etc that are NOT rated
for Hazardous Zone 2 areas and if required in the area must be positioned at
least 5 meters from the potential leak source, a route plan submitted with the
permit and a Flag man with a gas testing certification in his HSE passport
allocated.

•Hot work Cat 1 may be carried out in a Haz zone 1 only with the permission
of the Field Manager as per the hot work matrix (fig 2) . Only one issued
permit per area at any one time.
•This can only be granted after all alternatives to hot work are explored and
exhausted.
•Where dispensation is granted it should be accompanied by a Job Hazard
Analysis (JHA). The JHA should highlight potential threats, the precautions
and what to do if a problem arises.

Note:
•Continuous Gas monitoring is mandatory

•Precautions as outlined in HOT WORK hazardous check sheet plus the

following to be considered:

• Depressurise the hydrocarbon system

• Minimise Number of persons in the Hazardous area

• Practice Emergency Drill before starting work

• Gas bottles to be outside Hazardous area

A Hot Work Hazard Checklist shall
be filled out and attached to all Hot
Work Permits Cat 1 & Cat 2
Cold work permit

• This permit covers cold work activities.

•Cold work permits have a blue border.

•The permit is valid for 28 days ( non High risk )

A Cold Work Hazard Checklist
shall be filled out and attached to
all Cold Work Permits
Breaking containment
•This permit covers the breaking of containment in systems /
equipment of the production process containing hydrocarbons / high
pressure / high temperature / toxic / corrosive / flammable liquids eg
oil, gas, water injection, chemical injection, glycol etc.
•This permit is also used for spading or de spading of .systems or
equipment containing hydrocarbons / high pressure / high
temperature / toxic / corrosive / flammable liquids eg oil, gas, water
injection, chemical injection, glycol etc.
14 days validity
•This Certificate is a stand alone document that must accompany a Permit it
only authorises entry into a confined space and the work task and Description
with all the Authorisations must accompany it on the correct permit for the
task to be undertaken.

•Confined Space Entry permits have a green border And the validity is 14
days
Title of Presentation | 00 Month Year
High Risk Work:
Defined as any work with a high risk of escalation or with an increased potential to
harm staff.
These jobs require a formal written Job Hazard Analysis (JHA) which requires review
and approval of the Operations Lead and Field Manager who may delegate review of
the JHA depending on the nature of the work to be undertaken and the available
expertise.
Work that falls under high risk work is:
Breaking of hydrocarbon lines.
Confined Space Entry.
Hot Work Cat 1 in Hazardous areas.
Complex or Concurrent Activities.
Lifting Operations over live process plant.
Working in well cellars & deep excavations (below 1.2 meters).
Working at height (above 1.8metres) without scaffold.
Work in H2S high risk zones.
The Operations Lead will ensure that there is sufficient supervision and emergency
response capabilities to cover the number of high risk permits being issued / worked at
any time at each facility.
Hazardous Work:

The nature of this work is such that it must be approved by the Operations Lead.
It shall include but not be limited to;
Pressure / Hydro testing,
Major equipment plant outage,
Well Services, (shall include Xmas tree change out and acid work/stimulation).

These jobs require a formal written Job Hazard Analysis (JHA) which requires
review and approval of the Operations Lead and Field Manager.
Requirements for Continuous Gas Monitoring

• Entry in Confined Space

• Hot Work Cat 1 in Hazardous Area
• Hot Work Cat 2 in Hazardous Area
• Breaking Hydrocarbon containement
• Working in High risk H2S area
 Verify isolation before work begins and use the specified life
protecting equipment

You should…

• Understand the isolations that

protect you from danger

• Confirm with the Supervisor or

the Person in Charge of the
work that isolations are in
place

• Confirm with the Supervisor or

the Person in Charge of the
work that it is safe to start work

8-Jun-18
 The implication of Organizational & Statutory
requirements in Gas Testing

8-Jun-18
 Health and Safety at Work Act 1974

Employers' responsibilities
The Act places a general duty to 'ensure so far as is reasonably practicable the
health, safety and welfare at work of all their employees'.
They must provide and maintain safety equipment and safe systems of work
ensure materials used are properly stored, handled, used and transported
provide information, training, instruction and supervision - ensure staff are
aware of instructions provided by manufacturers and suppliers of equipment
provide a safe working environment
provide a written safety policy/risk assessment
An employer is forbidden to charge his or her employees for any measures
which he or she is required to provide in the interests of health and safety (for
example, personal protective equipment).

Employees’ responsibilities
take care of their own health and safety and that of other persons
co-operate with their employers
not interfere with anything provided in the interest of health and safety
• Control of Substances Hazardous to Health Regulations 2002
COSHH :
is a United Kingdom Statutory Instrument that states general
requirements on employers to protect employees and other
persons from the hazards of substances used at work by risk
assessesment, control of exposure, health surveillance and
incident planning. There are also duties on employees' to take
care of their own exposure to hazardous substances and
prohibitions on the import of certain substances into
the European Economic Area.
The Confined Space Regulations 1997

Apply where the assessment identifies risks of serious injury from

work in confined spaces.
These regulations contain the following key duties:
avoid entry to confined spaces, e.g. by doing the work from the
outside;
if entry to a confined space is unavoidable, follow a safe system of
work; and put in place adequate emergency arrangements before
the work start
Pesonal Protective Equipments

Minimum PPE required for:

• Head
• Eyes and Face
• Hearing
• Body and limbs
• Hands
• Feet
8-Jun-18
Respiratory Protective Equipments
They Provide filtration, absorption of
atmospheric contaminants or an independent
source of breathable air.
• Breathing apparatus
– Self Contained Breathing Apparatus (SCBA)
– Air line breathing apparatus
– Or a combination

8-Jun-18
•Breathing apparatus
– Self Contained Breathing Apparatus (SCBA)
– Air line breathing apparatus
–Or a combination

8-Jun-18
Air Filters Provides filtration or absorption
of atmospheric contaminants
– Filter mask
– Filter and cartridge
– Canister type

Not designed for IDHL environment

8-Jun-18
 Atmosphere measuring and monitoring
equipments Hands on Activity

8-Jun-18
Selecting gas testing-detection equipment depends on:

purpose of test
concentrations of gas
levels of toxicity
% lower explosive limit
oxygen content
location of work
number and frequency of tests
other equipment in use

8-Jun-18
Portable Electronic monitors

Used to test/monitor atmospheres of tanks, vessels

and other work areas.

Usually battery operated with audible and visible

alarm functions.

have multiple sensing capabilities for ambiant air

intrinsically safe

They are usually sensitive to water and shock.

They need frequent calibration.

8-Jun-18
Portable Electronic monitors

Drager X-am 5000

1 to 5-gas detector reliably measures combustible

gases and vapours as well as oxygen and harmful
concentrations of CO, H2S, CO2, Cl2, HCN, NH3,
NO2, PH3 and SO2.

Four alarm levels: Low, High, TWA and STEL

8-Jun-18
Using the Catalytic Ex sensors , 36 months life time
Catalytic sensors

Disadvantages:
• May be contaminated by:-
– Silicones
– Sulphur compounds
– Welding fumes
– Chlorine
– High levels of hydrocarbons
‘Catalytic’ Gas Detectors
must have at least 16% Oxygen
present in the atmosphere to be measured before
hydrocarbon gas concentrations can be accurately
detected.
8-Jun-18
EXTERNAL PUMP

The optional external pump, which operates

with a hose up to 30 (98 feet) meters long,
makes it possible to use the detector for
pre-entry measurements into confined
spaces such as tanks, shafts, etc. The
pump starts automatically when the detector
is inserted.

8-Jun-18
 Crowcon
‘Detective’
Gas Monitor

8-Jun-18
Inspecting Multi Gas Detection Equipment

visual inspection
periodic calibration
equipment and accessories are intact
undamaged and operational
battery check
function check

8-Jun-18
Fresh Air Calibration & Bump test of Drager X am
5000

8-Jun-18
 Gas Testing In Confined Spaces

8-Jun-18
 Obtain authorization before entering a confined spac

You should…
• Confirm with the Supervisor or the Person
in Charge of the work that it is safe to
start work

• Confirm with the Attendant that you can

enter a confined space
• Follow the requirements of the Work
Permit

Attendants should:
• Approve and control access to a confined
space
• Have means of communication with
people in the confined space

8-Jun-18
8-Jun-18
• ‘Light end’ hydrocarbons consist
of four gases :-
– Methane, (chemical formulae; C1H4)
– Ethane, (C2H6)
– Propane, (C3H8)
– Butane, (C4H10)

8-Jun-18
• MOL weight of ‘Air’ is 28.9
• Methane (C1H4) therefore, is lighter than ‘air’
• Methane will rise if it escapes into the atmosphere
• It can become trapped against
roofs and ceilings

8-Jun-18 HSE Induction - Day2

• Only enter a vessel if all other options
have been ruled out
• Carry out gas testing from outside the vessel if possible
• Everyone involved must be competent to do the work
• All sources of energy affecting the space must have been isolated
• Atmospheric gas testing must have taken place and tests repeated
as often as defined in he risk assessment
• A standby person with clearly defined duties is stationed
• Unauthorised entry is prevented

8-Jun-18
 Gas Testing In Confined Spaces

• Barriers and signs to prevent unauthorised entry

• Good communications system (internal and external)
• Consider internal hazards; Scale, radiation from instruments, COSHH
requirements, loose equipment, slippery surfaces.
• Additional, properly rated lighting
• Good access / egress
• No pressurised cylinders within vessel (With the exception of BA)
• External risks considered (drains,vents etc)
• Air moving equipment (consider earthing to prevent static)

8-Jun-18
Always test the
air at various levels
to be sure that the
entire space is safe. Good Air

Poor Air
Good air near the
opening does NOT
mean there is good
air at the bottom!

Deadly Air

8-Jun-18
 Gas Testing In Confined Spaces

8-Jun-18
Continuous gas monitoring required for all Hot Work involving
Confined Space Entries

For each test required on the permit, you

must allow enough time for the air from the
space to be drawn into the equipment and
for the sensor (or other detection device) to
react to the chemical if it is present. This is
considered the “minimum response time”
Be aware that you will need to add time to
this "minimum response time" if you have
attached hosing or a probe extension to the
inlet

8-Jun-18
 Gas Testing In Hot Work

8-Jun-18
Hydrocarbons: Solid, Liquid or Gas form

• Solids
– The most dense phase of an element
– Visible
– Molecules have insufficient energy to move
around freely
– Solid hydrocarbons can be waxes or asphaltene.
Gas detection equipment will not detect a solid

8-Jun-18
Hydrocarbons: Solid, Liquid or Gas form

• Liquids
– Less dense than solids
– They take the form of the container in which they are
placed
– Can normally be seen, but some hydrocarbons may be
clear
– Liquid hydrocarbons can also contain a complex
variety of molecules and may be quite dark in colour
– Some change into a gas more readily than others.
However:- Gas detection equipment will not detect
a liquid

8-Jun-18
Hydrocarbons: Solid, Liquid or Gas form

• Gases
– Gas molecules are relatively far apart
– Have neither definite shape nor volume
– Will occupy all of the volume available
to them
– Can be sensed by automatic and manual
gas detection equipment

8-Jun-18
Gas Testing In Hot Work

• Check at all levels of the worksite in the area

specified by the work permit
– High for methane
– Low for heavier hydrocarbons
• Select the type of gas on the meter or apply a
correction factor
• With a vessel, approach from upwind, testing
all the time
• Never expose yourself to unknown gas
concentrations
8-Jun-18
 In all cases for Hot Work with positive ignition sources inside
vessels or outside in the open air the measured Flammable
gasses must be zero % LEL. Hydrogen Sulphide (H2S) to be
less than 5 ppm
Continuous gas monitoring is required for all Hot Work Cat 1
& Cat 2 in hazardous areas

8-Jun-18
 Interpreting & Documenting the results

8-Jun-18
Atmosphere Testing

MFD Gas Test Certificate shall

be raised by an Authorised
Person, the results entered by
the Authorised Gas Tester,
cross-referenced to the Permit,
registered, and attached to the
permit

8-Jun-18
 Atmosphere Testing

For all Hot Work and Confined

Space/Vessel Entry Work
Permits. The Gas Test
Certificate is the
record of the Tester, location, the
frequency of testing, the
gases tested for, and their
concentrations.

8-Jun-18
 AUTHORIZED GAS TESTER
Written Assessment

8-Jun-18
 AUTHORIZED GAS TESTER
Preparation for practical assessment & Briefing

8-Jun-18
 AUTHORIZED GAS TESTER
Practical assessment & de-briefing

8-Jun-18
 AUTHORIZED GAS TESTER
Session closure

8-Jun-18