PR-1154 - Gas Testing Procedure

Petroleum Development Oman L.L.C.
Document Title: Gas Testing
Document ID PR-1154
Document Type Procedure
Security Unrestricted
Discipline Engineering and Operations
Owner UOP Operations Function Team Leader
Issue Date October 2014
Version 4.1
Revision: 4.1
Petroleum Development Oman LLC Effective: Oct-14
This page was intentionally left blank
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.
Page 2 PR-1154 Gas Testing Printed 07/10/17

The controlled version of this CMF Document resides online in Livelink. Printed copies are UNCONTROLLED.
Revision: 4.1
i Document Authorisation
Authorised For Issue October 2010

Revision: 4.1
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
iii Related Business Processes

Code Business Process (EPBM 4.0)
EP.71.02 Operate Wells and Facilities
iv Related Corporate Management Frame Work (CMF)

Documents
The related CMF Documents can be retrieved from the CMF Business Control Portal.
Refer to Appendix 6 for Reference Material

Revision: 4.1
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......................................................................................................................... 10
3.1 Scope............................................................................................................................ 10
3.2 Potential Hazards.......................................................................................................... 10
3.2.1 Oxygen Enriched Atmosphere.....................................................................10
3.2.2 Oxygen Depleted Atmosphere.....................................................................10
3.2.3 Flammable or Explosive Atmosphere..........................................................10
3.2.4 Toxic Atmosphere......................................................................................... 11
3.2.5 Hydrocarbon Enriched Atmosphere.............................................................11
3.3 Gas Test Requirements.................................................................................................. 11
3.3.1 Breaking Containment..................................................................................11
3.3.2 Hot Work in a Process or Hydrocarbon Area................................................11
3.3.3 Gas Freeing and Purging.............................................................................12
3.3.4 Confined Space Entry / Work within a Confined Space...............................12
3.3.5 Checking for Suspected Gas Leaks.............................................................12
3.3.6 Providing Clearance for Work Activities......................................................12
3.3.7 Use of Diesel Engines in a Process / Hydrocarbon Area.............................12
3.3.8 Vehicle Entry to a Process / Hydrocarbon Area...........................................12
3.4 Testing Instruments....................................................................................................... 12
3.4.1 Multigas Monitors......................................................................................... 13
3.4.2 Explosimeter Monitors.................................................................................13
3.4.3 Detector Tubes.............................................................................................13
3.5 Gas Tester..................................................................................................................... 13
3.6 Pre-User Checks........................................................................................................... 13
3.7 Gas Testing Process...................................................................................................... 15

Revision: 4.1
Appendix 1 Atmospheric Testing.............................................................................................17

Appendix 2 Oxygen Content Testing.......................................................................................18
Appendix 3 Flammable Gas Testing.......................................................................................20
Appendix 4 - Toxic Gas Testing.................................................................................................. 22
Appendix 5 Hydrocarbon Vapour Narcotic Effect....................................................................24
Appendix 5 Abbreviations........................................................................................................ 25
Appendix 6 Reference Material...............................................................................................26
Appendix 7 User Feedback Page............................................................................................27

Revision: 4.1
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 Permit to Work or a 3rd 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.
1.3 Distribution / Target Audience

This procedure is intended to be referenced by PDO Operations and Engineering staff
and Contractors undertaking work authorised by PDO.
1.4 Changes to the Document

Responsibility for the upkeep of the Document shall be with the Functional Production
Team Leader UOP, the Owner. Changes to this document shall only be authorised and
approved by the Owner.
Users of the Document who identify inaccuracy or ambiguity can notify the Custodian
or his/her delegate and request changes be initiated. The Requests shall be forwarded
to the Custodian using the User Feedback Page provided in this Document.
The Document Owner and the Document Custodian should ensure review and re-
verification of this procedure every 3 years.

Revision: 4.1
1.5 Step-out Approval

This procedure is mandatory and shall be complied with at all times. Should
compliance with the procedure be considered inappropriate or the intended activity
cannot be effectively completed or safely performed, then step out approval must be
obtained in accordance with PR-1001e Operations Procedure Temporary Variance.
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

Revision: 4.1
2 Roles and Responsibilities

All affected personnel shall read this procedure. If they do not understand something within the
procedure they shall ask their line supervisor or The Operating Integrity Coordinator (Interior) to
explain it. It is the line Supervisors Responsibility to ensure that all his subordinates have read
and understood this procedure. When the procedure is read and understood they shall sign the
Record of Procedure Understanding Form.
Role Responsibility
Permit Applicant Define the gas testing requirements for the work
Prepare the Job Safety Plan and indicate the frequency of gas
testing
Complete the appropriate section for gas testing on the PTW
Indicate the special gas detection equipment is required e.g.
hydrocarbons in inert
Responsible Supervisor Agree requirements of gas testing with the Permit Applicant
Authorises relaxation of rules for 1st Gas Test on Class A permits
where appropriate
Agree the Job HSE Plan
Ensure all technicians under his supervision read and
understand the procedures and sign the Record of Procedure
Understanding Form
Ensure that the Record of Procedure Understanding Form is
correctly completed and retained in a central location within
each area.
Area Authority Tick the gases to be tested for on PTW.
Indicate how often the test shall be repeated on
PTW.
State if continuous monitoring for gas is required
during the work.
For Class A permits performs the 1st 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

Revision: 4.1
activity
Maintenance Staff Comply with this procedure
Ensure the procedures are read and understood and they sign
the Record of Procedure Understanding Form

Revision: 4.1
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.
3.2 Potential Hazards

Generally the potential hazards addressed by gas testing are;
Oxygen enriched atmosphere
Oxygen depleted atmosphere
Flammable or explosive atmosphere
Toxic atmosphere
Hydrocarbon enriched atmosphere (narcotic effect)
Each of the above shall be addressed with a more detailed description in the Appendix.
3.2.1 Oxygen Enriched Atmosphere

Atmospheres containing more than 21.5 % vol. oxygen shall be treated as oxygen
enriched. Generally oxygen enrichment does not occur often as the source of the extra
oxygen shall have to be introduced. Oxygen enriched atmospheres when mixed with
hydrocarbons can result in explosive mixtures quicker than would be the case with
normal air (20.8%).
3.2.2 Oxygen Depleted Atmosphere

Atmospheres containing less that 20% vol. oxygen shall be treated as oxygen depleted.
Such atmospheres can occur when gas freeing of purging has been carried out to
remove hydrocarbons / toxics or air. The oxygen in the atmosphere shall have been
normally replaced / diluted with an inert gas i.e. nitrogen.
3.2.3 Flammable or Explosive Atmosphere

Flammable or explosive atmospheres are those that contain mixtures when exposed to
an ignition source will or may ignite and burn. Such atmospheres can be created when
opening pipework or equipment that contains or has contained hydrocarbons.

Revision: 4.1
3.2.4 Toxic Atmosphere

Toxic atmospheres are those that contain concentrations of vapours that shall cause
injury or death to humans. Such atmospheres may have sufficient oxygen to support
life and insufficient flammable concentrations to cause explosions or fire, but may
contain sufficient concentrations of the toxic to harm personnel. An example would be
H2S or mercury.
3.2.5 Hydrocarbon Enriched Atmosphere

Hydrocarbon enriched atmospheres are those where the concentrations of hydrocarbon
vapours are sufficient to induce a narcotic effect on personnel inside the atmosphere.
3.3 Gas Test Requirements

PR-1172 Permit to Work System Section 3.5 shall be referenced to determine the
frequency of gas testing and the specific work it is required for.
In general gas testing is required for the following types of work;
Breaking containment
Hot work in a process or hydrocarbon area
Gas freeing and purging
Confined space entry / work within a confined space
Checking for suspected gas leaks
Providing clearance for work activities
Use of diesel engines in a process / hydrocarbon area
Vehicle entry to a process / hydrocarbon area
3.3.1 Breaking Containment

Gas testing shall be required when containment is broken on any system containing
hydrocarbon or toxic liquids / solids / vapours. Appropriate PPE and safety equipment
i.e. SCBA, masks, face visors etc, shall be worn as necessary.
The type of gas tested for shall be indicated on the PTW by the Area Authority in
addition to the frequency of testing. Types of gas can include one or all of the following;
Hydrocarbons
H2S
Mercury (refer to PR-1515 Onsite mercury Management)
NORM (refer to SP-1170 - HSE Specification - Naturally Occurring Radioactive
Materials (NORM)
3.3.2 Hot Work in a Process or Hydrocarbon Area

Hot work carried out in an area where hydrocarbons are present or can be present must
be preceded by a gas test of the work site and adjacent areas to address the risk of fire
and explosion caused by concentrations within the Lower Explosive Limits.
The gas test shall be primarily for hydrocarbons and carried out in accordance with PR-
1172 Permit to Work System Section 3.5 and 6.2.4

Revision: 4.1
3.3.3 Gas Freeing and Purging

Gas freeing of pipework and equipment shall be carried out prior to work being
undertaken on hydrocarbon or toxic system. The normal medium for gas freeing is an
inert, nitrogen or water.
Gas testing of the pipework or equipment shall be carried out in accordance with PR-
1172 Permit to Work System Section 3.5 and PR-1073 Gas Freeing, Purging and
Leak Testing of Process Equipment.
During gas freeing processes using nitrogen the gas testing shall be to detect
hydrocarbons in an inert and requires the appropriate testing equipment to be used.
3.3.4 Confined Space Entry / Work within a Confined Space

Spaces or vessels requiring entry by personnel to inspect or carryout work shall require
to be tested prior to and during the work.
Gas testing shall be undertaken in accordance with PR-1172 Permit to Work System
Section 3.5 and PR-1148 - Entry into a Confined Space Procedure
Confined space gas testing shall be to determine whether the atmosphere within the
space can safely support life. Tests shall be for oxygen content and hydrocarbons /
toxics.
3.3.5 Checking for Suspected Gas Leaks

Small gas leaks in and around pipework and equipment may be detected using
portable gas testing equipment.
3.3.6 Providing Clearance for Work Activities

Work activities in hazardous area shall require that the atmosphere at the work site and
in the surrounding areas is safe before permission is given to carryout the work activity.
3.3.7 Use of Diesel Engines in a Process / Hydrocarbon Area

The use of internal combustion engines (diesel driven) within a process or hydrocarbon
area shall be subject to authorisation and require gas testing in accordance with PR-
1172 Permit to Work System Section 3.5.
Diesel driven plant i.e. mobile cranes, air compressors etc, shall be subject to
continuous gas monitoring while in use. The units shall also be subject to a gas test
prior to starting.
The gas test shall primarily be to check for hydrocarbons.
3.3.8 Vehicle Entry to a Process / Hydrocarbon Area

Vehicles shall only be allowed into a process area if covered by a PTW. A PTW is not
required for a hazardous area but gas testing is mandatory for both.
Vehicles shall be subject to continuous gas monitoring while inside the area.
The gas test shall be to check for an explosive or flammable atmosphere
3.4 Testing Instruments

Gas testing shall only be carried out by authorised gas testing personnel who have
completed the necessary training. These personnel shall be registered in PDO.
Testing can be carried out using approved instruments. The following types are in use
by PDO:

Revision: 4.1
Multigas monitors (indication usually in %LEL or %Vol or ppm dependant on

the gas being monitored)
Explosimeters (indication usually in %LEL)
Detector tubes (indication usually in ppm or volume)
NOTE: When testing for mercury, NORM or hydrocarbons in an inert atmosphere
specialist meters are required and the user shall be trained in its use.
3.4.1 Multigas Monitors

Multigas monitors are capable of measuring a number of gases simultaneously. The
gases monitored and displayed can include Flammable, Oxygen, Carbon Monoxide,
Hydrogen Sulphide, Sulphur Dioxide, Chlorine, Nitrogen Dioxide, Ammonia, and
Carbon Dioxide. The results are displayed continuously.
The multigas meter is provided with a sample pump allowing for deep penetration
testing of confined spaces and well cellars from a safe location.
Audible and visual alarm is provided making the monitors suitable for deployment in
the confined space or as perimeter guard for protection and warning.
3.4.2 Explosimeter Monitors

Explosimeter are provided to measure only flammable gases. The monitor will provide
a measurement of the immediate area from which the sample is taken, which can be
remote if sample lines and probes are used. The reading is displayed on a meter by
needle deflection. The sensitivity of the instrument is set by the control knob. The
instrument shall only be used by personnel who have undertaken the appropriate
course.
3.4.3 Detector Tubes

Detector tubes are single spot check devices for detection of gases in the direct
vicinity of where the sample is taken. Different detector tubes are provided for different
gases, the selection of the detection tube being dependant on the gas being detected.
A fixed volume 1 sample is drawn through the detector tube by a hand pump. The
detector tubes are calibrated and the change in colour observed will indicate the
concentration of the gas present.
In PDO the typical gas sampled for using detector tubes is H 2S and CO2.
3.5 Gas Tester

An Authorised Gas Tester (AGT) is a person who has passed the Gas Testing Course
and holds a current Gas Testers Card, and has passed either a Permit to Work
Signatories or Holders Course.
For further details refer to PR-1172 Permit to Work System Section 5.9.
3.6 Pre-User Checks

Before using a portable gas detector (with exception of detector tubes) the following
shall be observed:
Ensure that the gas detector test is in date. Do not use a gas detector that is
out of test
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.
Revision: 4.1
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:
Tell the Permit Holder to stop any current work.

Tell the Permit Holder and Area Authority that it is not safe to work, and why, so
that the problem can be dealt with.
The remainder of this page is Intentionally Blank

Revision: 4.1
3.7 Gas Testing Process
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
Revision: 4.1
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

Revision: 4.1
Appendix 1 Atmospheric Testing
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.

Revision: 4.1
Appendix 2 Oxygen Content Testing
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 persons
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.;
Leaving a vessel completely closed for some time, since the process of rust 2
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
Revision: 4.1
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.

Revision: 4.1
Appendix 3 Flammable Gas Testing
Flammable gas testing shall be carried out to detect accumulations of flammable

vapours, fumes or dust which could ignite in the presence of a source of ignition.
Flammable vapours or fumes typically result from:
Materials previously processed or stored in the vessel or tank;
Sludge or other deposits disturbed during cleaning;
Material left under scale, even after cleaning;
Material leaking through the tank floors;
Material leaking from behind vessel linings (lagging, refractory etc.) or from
vessel fittings such as tank floating roof pontoons and legs, instrument
connections or pipes;
Materials leaking from flanges or vents on process pipes running through the
confined space, e.g. process tubes in a furnace combustion chamber;
Vapour entering the confined space from nearby process plant that has not
been effectively isolated or from nearby work that is not well controlled;
Solvents brought into the space for cleaning, painting, dye penetration tests or
in adhesives;
Gases brought into the space / area for welding or gas cutting, including
leakage from cylinders, valves and hoses;
Contaminated firewater / process water used to wash the confined space and
introduced by hoses;
Vapour or fumes that build up in sewers, manholes, contaminated ground or
excavations.
A source of ignition can be any heat source having enough energy to ignite a
flammable vapour air mixture, or to raise the temperature above the auto-ignition
temperature. Possible ignition sources include:
Open flames and sparks resulting from welding, gas cutting and grinding;
Sparks or arcs produced by electrical equipment, lightning and electrostatic
charges;
Hot pipes or exhausts that can raise the flammable mixture above the auto-
ignition temperature;
Heat of friction during drilling, sawing or other cutting activities;
Pyrophoric materials, e.g. iron sulphide in scale;
Thermite reactions from aluminium or other alloy tools striking against rusted
iron or steel;
Any highly reactive material capable of producing sufficient heat for
combustion, for example:
- Strong oxidising substances, such as hydrogen peroxide used in waste
treatment facilities;
- Chemicals that undergo self-accelerating exothermic reactions when a
critical temperature is reached, such as ethylene oxide.

Revision: 4.1
The recommended approach to controlling flammable vapours in confined spaces or

where hot work is being undertaken is to eliminate all flammable materials from area
before the work is undertaken. The objective should be no detectable flammable
vapour, i.e. an explosimeter reading less than 1% LEL.
WARNING: Confined space entry shall not be allowed into spaces where the
flammable concentration is greater than 10% LFL.

Revision: 4.1
Appendix 4 - Toxic Gas Testing
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 (H 2S).
Allowable concentrations are related to the Threshold Limit Value (TLV) which

Revision: 4.1
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 H 2S is 15 ppm and is the concentration of
H2S gas in air above which protective equipment must be used.

Revision: 4.1
Appendix 5 Hydrocarbon Vapour Narcotic Effect
Extra Reading - HSE Offshore Safety Notice 4/2004 Hydrocarbon Releases
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.

Revision: 4.1
Appendix 5 Abbreviations
AGT Authorised Gas Tester

ALARP As Low As Reasonably Practicable
HRA Health Risk Assessment
IDHL Immediately Dangerous to Life or Health
JHA Job Hazard Analysis
LEL Lower Explosive Limit
MSDS Material Safety Data Sheet
NORM Naturally Occurring Radioactive Materials
O&M Operations and Maintenance
OEL Occupational Exposure Limit
PPE Personal Protection Equipment
PTW Permit to Work
SCBA Self Contained Breathing Apparatus
SHOC Safe Handling Of Chemical Cards
STEL Short Term Exposure Limit
TLV Threshold Limit Value
TRIC Toolbox Talk Risk Identification Card

Revision: 4.1
Appendix 6 Reference Material
The following documents are related to this procedure

PDO Code of Practice
CP-115 Operate Surface Product Flow Assets CoP
PDO Specifications
SP-1170 Naturally Occurring Radioactive Materials (NORM)
SP-2087 Specification for Onsite Mercury Management
PDO Procedures
PR-1073 Gas Freeing and Purging of Process Equipment (Exc. Tanks)
PR-1078 Hydrogen Sulphide Management
PR-1079 Gas Freeing and Purging of Tanks
PR-1081 The Buddy System
PR-1148 Confined Space Entry
PR-1172 Permit to Work System
PR-1515 Onsite Mercury Management
External Documents
HSE Offshore Safety Notice 4/2004 Hydrocarbon Releases

Revision: 4.1
Appendix 7 User Feedback Page
PR-1154 Gas Testing User Feedback Page
Any user who identifies an inaccuracy, error or ambiguity is requested to notify

the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID Date:
Page Ref: Brief Description of Change Required and Reasons
UOP7
Custodian of Document Date:


PR-1154 - Gas Testing Procedure

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PR-1154 - Gas Testing Procedure

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Petroleum Development Oman L.L.C.

Document Title: Gas Testing

Document Type Procedure

Discipline Engineering and Operations

Owner UOP Operations Function Team Leader

Issue Date October 2014

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iii Related Business Processes

iv Related Corporate Management Frame Work (CMF)

Refer to Appendix 6 for Reference Material

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Appendix 1 Atmospheric Testing.............................................................................................17

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1.3 Distribution / Target Audience

1.4 Changes to the Document

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1.5 Step-out Approval

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2 Roles and Responsibilities

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3.2 Potential Hazards

3.2.1 Oxygen Enriched Atmosphere

3.2.2 Oxygen Depleted Atmosphere

3.2.3 Flammable or Explosive Atmosphere

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3.2.4 Toxic Atmosphere

3.2.5 Hydrocarbon Enriched Atmosphere

3.3 Gas Test Requirements

3.3.1 Breaking Containment

3.3.2 Hot Work in a Process or Hydrocarbon Area

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3.3.3 Gas Freeing and Purging

3.3.4 Confined Space Entry / Work within a Confined Space

3.3.5 Checking for Suspected Gas Leaks

3.3.6 Providing Clearance for Work Activities

3.3.7 Use of Diesel Engines in a Process / Hydrocarbon Area

3.3.8 Vehicle Entry to a Process / Hydrocarbon Area

3.4 Testing Instruments

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Multigas monitors (indication usually in %LEL or %Vol or ppm dependant on

3.4.1 Multigas Monitors

3.4.2 Explosimeter Monitors

3.4.3 Detector Tubes

3.5 Gas Tester

3.6 Pre-User Checks

Tell the Permit Holder to stop any current work.

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3.7 Gas Testing Process

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Appendix 1 Atmospheric Testing

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Appendix 2 Oxygen Content Testing

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Appendix 3 Flammable Gas Testing

Flammable gas testing shall be carried out to detect accumulations of flammable

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The recommended approach to controlling flammable vapours in confined spaces or

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Appendix 4 - Toxic Gas Testing