Professional Documents
Culture Documents
Approved
CONTENT
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 REQUIREMENTS
SUPPLEMENTS:
1.0 PURPOSE
The purpose of this general Instruction (GI) is to provide information regarding performing atmospheric gas tests
using portable gas monitors (Industrial Scientific [ISC] models MX4 and MX6) as required by GI 2.100, Work
Permit System. Tests for hydrogen sulfide (H2S), oxygen concentration, combustible gases, and/or any other toxic
substances (e.g., carbon monoxide [CO]) shall be performed before issuing work permits and either continuously or
periodically during work activities, as necessary. The Saudi Aramco-approved gas monitoring equipment and their
accessories are used to continuously and simultaneously monitor the presence of combustible gases or vapors, toxic
substances and oxygen concentration in air.
2.0 SCOPE
2.1 This instruction applies to all gas testing activities during construction, commissioning, start-up, operation,
maintenance, decommissioning and demolition at Saudi Aramco (SA) facilities and SA project sites in
accordance with GI 2.100.
2.2 This instruction is not a manual of how to operate portable gasmonitors.
2.3 The equipment manufacturer's instruction manuals shall be consulted and utilized where applicable when
operating, calibrating or function testing portable gas monitoring instruments.
2.4 Any conflict with this instruction and other applicable engineering standards (SAES),engineering procedures
(SAEPs), or codes used by Saudi Aramco shall be referred to the appropriate standards committee chairman
for resolution.
3.0 REFERENCES
4.0 DEFINITIONS
4.1 Alarm Set Point: The selected gas concentration level at which an alarm is activated.
4.2 Asphyxiant: A vapor or gas which can cause unconsciousness or death by suffocation (lack of oxygen).
4.3 Atmosphere-Supplying Respirator: A respirator that provides breathing air from a source independent of the
surrounding atmosphere. These include supplied air (airline) breathing apparatus (SABA) and self-contained
breathing apparatus (SCBA).
4.4 Asset Task Tracking System (ATTS): A corporate solution in SAP plant maintenance, which can be used to
track the calibration of portable gas monitors and issue a notification to asset owners when the periodic
calibration is due.
4.5 Calibration Gas: A gas of known concentration(s) used to set the instrument span or alarm level(s).
4.6 Confined Space: Any space that:
Has limited or restricted means of entry or exit.
Is not designed for human occupancy.
Contains or has the potential to contain a hazardous atmosphere.
Contains any other recognized serious safety or health hazard(s).
Examples of confined spaces include tanks, vessels, vessel skirts, vaults, manholes, sewers, valve boxes,
lift stations, and structures or excavations 1.2 m (4 ft.) deep or deeper. Areas above floating roof tanks
where the top of the roof is more than 1.2 m (4 ft.) below the rim of the tank are also considered confined
spaces.
4.7 Flammable Mixture: Hydrocarbon mixtures composed of various volatile compounds. Flammable materials
contain vapors or gases which are potentially explosive and can ignite when exposed to an open flame or
ignition source.
4.8 Function Test: A function test, or bump test, involves exposing the instrument’s sensors to a known gas
concentration to indicate that the instrument will respond accordingly and that all alarms operate as they were
designed and calibrated.
4.9 Gas Test: Analysis, using a company-approved gas monitoring instrument, of an atmospheric sample to
determine the concentration of oxygen, and presence of combustible or toxic gases.
4.10 Hazardous Atmosphere: An atmosphere in which workers are exposed to the risk of death, injury,
incapacitation or illness.
4.11 Immediately Dangerous to Life and Health (IDLH): An atmospheric concentration of any toxic, corrosive or
asphyxiant substance that poses an immediate threat to life or would cause irreversible or delayed adverse
health effects or would interfere with an individual's ability to escape from a dangerous atmosphere.
4.12 Lower Explosive Limit (LEL): The lower vapor concentration boundary for a specific compound or material
of interest at which the vapor-air mixture will propagate a flame (i.e., explode) if ignited. When testing for
combustible gas using gas monitoring instruments, the amount of combustible gas present is specified in
terms of % LEL: 0% LEL being a combustible gas-free atmosphere and 100% LEL being an atmosphere in
5.0 RESPONSIBILITIES
5.1.9 Verify that each instrument is properly calibratedevery three months, at a minimum.
5.1.10 Ensure that each instrument calibration is trackedthrough ATTS. Guidance information on how to
add portable gas monitors to ATTS can be found on the LPD intranet site
(http://lp.aramco.com.sa/site/education/publications/special).
5.1.11 Immediately notify the vendor andarrange for any defective or damagedMX4 and MX6 instruments
and any key accessories (such as the Docking Station, charging units, etc.) to be sent to the vendor’s
service center for necessary repairs.
6.0 REQUIREMENTS
6.1 Only personnel having a valid gas testing certificate issued by T&D and signed by the gas testers’ division
head may perform gas tests in accordance with the requirements of GI 2.100 and use the ISC MX4 and/or
MX6 devices to monitor atmospheric conditions.
6.2 Gas testing personnel shall be trained, tested and re-certified everytwo years in the correct use of gas testing
equipment. Training includes the curriculum offered by T&D (BET #40069981, Gas Testing Program).
6.3 Gas testers shall carry a valid certificate issued by T&D and signed by the gas testers’ respective division
head.
6.4 Atmospheric gas testing is required at all locations where injury to personnel or damage to property could
occur due to the presence of combustible gases, toxic gases, or oxygen enriched/deficient atmospheres.
Atmospheric gas testing shall be performed, but not be limited to the following work activities/situations:
6.4.1 Oxygen (O2) testing shall be conducted for:
a) All confined space entry activities.
b) All areas which may have a potential for an oxygen deficient or enriched atmosphere.
6.4.2 Combustible gas testing (i.e., LEL) shall be conducted for:
a) All confined space entry activities.
b) All hot work in restricted areas, as defined in GI 2.100.
c) All work locations where combustible gases are or may be present.
6.4.3 Hydrogen sulfide (H2S) gas testing shall be conducted for:
a) All confined space entry activities where H2S may be present.
b) Jobs in areas where sour crude/gas is produced, transported, stored or processed and where
proponent organizations determine that H2S gas testing is necessary.
c) Jobs in close proximity to sewage treatment plants and sewer lift stations.
d) All work locations where H2S monitoring is required for work or operational purposes.
6.4.4 Carbon monoxide (CO) gas testing shall be conducted for all confined space entry activities.
6.5 Other toxic gas testing should be conducted for all work locations where other toxic gas(es) or vapor(s) is
(are) or may be present. Examples of other toxic gases include carbon dioxide (CO 2), sulfur dioxide (SO2),
chlorine (Cl2), ammonia (NH3), hydrogen chloride (HCl), and mercury vapor (Hg). The Saudi Aramco Loss
Prevention Department should be consulted when questions arise regarding other toxic gas testing.
6.6 The work permit issuer must determine when periodic, frequent or continuous gas monitoring is required,
specify the requirement on the associated work permit, and make arrangements to have a certified gas tester
available to perform required tests.
6.7 The person conducting gas tests in an atmosphere known or suspected of being potentially hazardous should
enter the area only after donning adequate personal protective equipment, including but not limited to
appropriate atmosphere-supplying respirator equipment, (e.g., self-contained breathing apparatus [SCBA]).
Refer to GI 1780.001 for details.
6.8 Hot work is not permitted if the atmosphere is above 0% of the lower explosive limit (LEL).
6.9 Work is not permitted if the atmosphere has an O2 concentration above 23.5%.
6.10 Work is not permitted in areas where the atmosphere is at or above 10% LEL, H2S concentration is at or
above 100 ppm or CO concentration is at or above 1000 ppm even if atmosphere-supplying respirator
equipment is used.
6.11 An atmosphere-supplying respirator shall beused if any of the following atmosphericconditions exist:
6.11.1 O2 concentration is less than 20.0%.
6.11.2 Flammable/combustible mixtures are at or above 5% and less than 10% of the LEL.
6.11.3 H2S concentration is at or above 10 ppm and less than 100 ppm.
6.11.4 CO concentration is at or above 35 ppm and less than 1000 ppm.
* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION X
Saudi Aramco: Company General Use
SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. No. Approved
6.23 Users of portable gas monitors shall conduct dailyinspection & function testand pre-use checks. Resultsof
the daily inspection & function test shall be recorded on a daily log sheet (see Supplement 2.709-4).
6.23.1 The daily inspection and function test shall include the following:
a) Visual inspection
b) Pump leak test
c) Function test
d) Zeroing
e) Clearing the peaks
6.23.2 The pre-use instrument checks shall include the following:
a) Visual inspection
b) Zeroing
c) Clearing the peaks
d) Pump leak test if air-sample accessories tobe used (e.g., sample tubing, probe)
6.24 Function tests shall be conducted per the manufacturer’s instructions. Instructions for co
nducting function
tests are found on the respective portable gas monitor operating instructions.
Note: The purpose of the daily function test is to check for sensor and alarm functionality. The installed
sensors are briefly exposed to expected concentrat ions of calibration gases that are greater than the sensors’
alarm set points. When one or more sensors “pass” the test, they are “functional” and the unit will alarm. For
the unit to pass the function (bump) test, all sensors shall “pass” the test. The nction
fu test is not the same as
a calibration test and does not measure for sensor accuracy.
6.25 If a portable gas monitor instrument does not successfully pass the pre-use instrument checks, it shall
be
removed immediately from service and repaired/calibrated accordingly.
6.26 The useful life of function test gas canister is designated byexpiration date on canister. Any expired or spent
canisters are to be disposed of by sending them to the nearest Storehouse Operations Reclamation facility.
Completion of Saudi Aramco Form 112 (Material Disposal Form) is required to request this service.
1.0 The following conditions are required prior to entry into or work inside a confined space:
1.3 Confined space entry is not permitted if the atmosphere is at or above 10% LEL, H2S concentration is at or
above 100 ppm, CO concentration is at or above 1,000 ppm, O 2 concentration is above 23.5%, or other
potential toxic gas concentrations are above their IDLH level.
Permitted without
an atmosphere- At or above 20%
and less than or Less than 5% Less than 35 ppm Less than 10 ppm
supplying equal to 23.5%
respirator
Permitted only
while continuously At or above 35 ppm At or above 10
At or above 5% and less
wearing an Less than 20% and less than 1000 ppm and less than
than 10%
atmosphere- ppm 100 ppm
supplying
respirator
No entry permitted Above 23.5% At or above 10% At or above 1000 At or above 100
ppm ppm
1.0 The following alarm set points have been established for Saudi Aramco portable gas monitoring instruments
(i.e., ISC MX4 and MX6):
1.0 The Industrial Scientific(ISC) models MX4 and MX6 have certain limitations which must be adhered to in order
SUPPLEMENT 2.709-4
Date Visual Leak Test Gas Function Zeroing Clearing the Checked by Remarks
Inspection Test Peaks
P F P F P F P F Yes No
__________________________
Supervising Operator
Note: Conduct an inspection and function test at the beginning of each day or prior to use in accordance with GI 2.709,
Section 6.23. The results of the daily inspection & function test are recorded on the above Daily Inspection and
Function Test Log. Remarks should reflect failure of any pre-use checks or function tests.
P = Pass F = Fail (Check P or F)