Document ID No: MSSM-1-SF-001

Power & Water Utility Company for

Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13. GAS TESTING

Reference Standards:
SASO 315
GS 209/1987-3.6.2.2
OSHA – 29 CFR 1910.146

INTRODUCTION

Of all the dangers inherent to works inside confined spaces or on or near gas systems, the invisible
threat of atmospheric hazards pose greatest risks to employees. Dangerous conditions involving
unsafe oxygen levels, as well as toxic and combustible gases, have caused the most accidents.

Atmospheric hazards are not visible and accurately detectable through any of the human senses.
Even relying on vision and smell can be deadly dangerous. For these reasons, carrying out gas tests
and ensuring that atmosphere is safe is essential before entering confined space or locations.

Atmospheric conditions while working also can change rapidly, adding an element of unpredictability
and elevating the level of danger. In this case it is also required frequent or continuous monitoring of
the atmosphere to alert personnel to evacuate the areas and move to a safer place.

Possessing an approved gas detector is not enough to ensure safe working conditions. Lives of
persons working in hazardous atmosphere depend on i) evaluation of hazards, 2) interpretation of
results and 3) judging for safe conditions by Authorized Gas Tester before allowing entry in confined
spaces or areas with flammable or toxic gas systems.

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13.1 GAS TESTING REQUIREMENTS

Authorized Permit Issuer should determine the requirement of the gas
test

Authorized Permit Controller should specify the frequency of gas

testing

Authorized Gas Tester should carry out gas testing prior to Issuing
Permit to Work Certificate for:-

 Working in areas where there are chances of: -

i) Flammable / explosive gases such as methane, acetylene,

propane, etc.
ii) toxic gases such as carbon monoxide, hydrogen
sulphide, chlorine, ammonia, etc. and
iii) Oxygen deficiency.

 Entry inside confined spaces,

 Working on or near gas / oil systems / lines,
 Working inside or nearby sewers or
 Working in trenches of narrow widths and depth more than 1.3
meters and likely to have contaminated atmosphere from
emissions of petrol engine driven machines or leakage of sewer
or flammable gas lines

Time interval between gas testing and issue of PTWC should not
exceed two hours.

Gas test should be repeated if:-

 Specified by Authorized Permit Controller for the next day or

frequently to be conducted
 Work is continued for next following and if there is a suspect of
unpleasant atmosphere
 the work is interrupted due to atmospheric changes or
 the personnel working inside confined spaces raise concern of
discomfort and breathing difficulty
 the plant was re-started and run for short period of time for
i) urgent production need or
ii) checking performance on trial of repaired machinery

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13.2 AUTHORIZED GAS TESTER (AGT)

Authorized Gas Tester should:

 Trained and competent to carry out gas test. Training will be
provided by Marafiq Safety section.

 Possess a valid authorization card to perform GAS TEST

 Conduct gas test, interpret results and record them in Permit to

Work Certificate in section 3. (Refer Safety Procedure # 14 -
Permit to Work)

 Record the results of gas test in Gas Free Certificate in case of

frequent gas monitoring as specified by Authorized Permit
Controller.
 (Refer Safety Procedure # 14 - Permit to Work –Attachment 10 -
Gas Free Certificate)

 Provide a gas detector for continuous monitoring at the breathing

zone of personnel while carrying out works which can
contaminate the atmosphere inside confined space example:-hot
work, painting or abrasive cleaning, using chemicals, etc.

Inform occupants to evacuate the confined space immediately of, if any

alarm sounds.

 Act as standby man for critical jobs like

1. Hazardous gas line breaking

2. Performing work that could contaminate atmosphere

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13.3 GAS DETECTOR

Gas detectors should be:-

 approved by Marafiq Safety Section prior to raising purchase

requisition

 Used by Authorized Gas Tester only according to its compatibility.

 Tested and calibrated for proper operability prior to each use in fresh
open air.
 Regularly inspected, used, calibrated and maintained including
replacement of sensors / other spare parts as per manufacturer’s
instructions. Records should be maintained accordingly.

 Stopped from using if found defective, damaged malfunctioning

If the gas pipelines or systems or vessels are purged with inert gases
such as Nitrogen, then gas detector that will be used for carrying out gas
test should be suitable to be used in inert atmosphere.

Combustible gas detector or multi gas detector that is used in air, must
not be used to measure flammable / explosive gas concentration in
confined spaces or in gas lines which are purged with inert gases

13.4 GAS TESTING WITHOUT ENTRY INTO CONFINED SPACES

AGT should not enter confined space to conduct gas test. He should
make use of probe, aspirator and sample lines to carry out gas
testing.

Prior to gas testing, the confined space should be:

 Isolated, locked and tagged

 Drained and vented
 Flushed and Purged
 Ventilated effectively
 Ventilation must be stopped 15 minutes prior to conducting the
gas tests, to allow gas concentrations to stabilize.

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13.5 GAS TESTING WITH ENTRY INTO CONFINED SPACES

If an entry into a confined space for testing is a must and there

is no other alternative for carrying out gas test, AGT should:-
 Ensure safe access and egress including safe ladder and
scaffolding where required

 Wear fire suit if flammable atmosphere is suspected.

 Post a standby attendant at the entrance

 Wear self contained breathing apparatus (SCBA) or supplied air

respiratory protection, fall protection equipment, chemical clothing,
boots, gloves, etc.

 Ensure that emergency rescue equipment such as tripod winch or

a pulley with rescue personnel are available

 Obtain Permit to Work Certificate and ensure safe isolation

complete in all respects and proceed for entry,

13.6 GAS TESTING IN OPEN AREAS

Gas testing should be carried out in open areas such as natural gas
pressure reducing stations, sewers, narrow deep trenches, etc where
there is likelihood of flammable and / or toxic gases leak. Points such
as vents, bleeders, valves, flanged connections, etc. should be
considered for gas test

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13.7 Oxygen Concentration

Oxygen content level in confined space should be 21%. Oxygen Entry

level
If the confined space was purged with inert gas, then it should be 21% Allowed
ventilated to bring the level of oxygen content to 21% before allowing 20-21% Allowed if no
entry of personnel into the confined space. other toxic or
flammable
Allowable limit for oxygen should be between 20 to 21% provided no gases
toxic or flammable gases are present above their threshold limit Above Not allowed
values. All means of ventilation should be tried to raise the 21%
concentration to the ambient level i.e. 21% in air. No oxygen gas
should be introduced.

13.8 Flammability Testing

The concentration of flammable/combustible gas / vapors in the

suspected area should be measured as the percentage of the lower
flammability / explosive limit (%LEL) in air.

If the explosive meter indicates more than 1% LEL reading in a

confined space, where there are no chances of presence of
flammable gas, hot work should not be carried out and no person
should be allowed to enter a confined space. There may be
chances of ingress of flammable gas due to leak of flammable gas
cylinders taken inside which must not be taken or may be due to
leak from flammable gas hoses or other sources.

No one should enter the confined space unless the cause of

presence of flammable gas is identified, rectified and confirmed by
Authorized gas tester carrying out gas tests.

If atmosphere is purged with inert gas (nitrogen) for carrying out hot
work on combustible gas lines or systems on the surface, then gas
detector should be compatible for use in inert atmosphere. If the
gas detector which is compatible for using in air is used, it will get
damaged its sensors and other parts. The gas concentration should
not be more than 10% LEL and oxygen level should be 0% inside
the gas lines of systems prior to carrying out hot work .

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

13.9 TOXICITY TESTING

Gas testing should be carried out where there is a possibility of toxic

gases such as Carbon Monoxide, Hydrogen Sulphide or chlorine gas.
Toxic Gas Allowable Limit
Carbon Monoxide CO O to 25 ppm

Hydrogen Sulphide H2S 0 to 10 ppm

Chlorine Cl2 0 to 0.5 ppm

13.10 CALIBRATION CHECK

Following tests should be performed to check gas detector

calibration before carrying out gas test ::-

Function Test should be performed in the field before use in

open fresh air and not in suspected atmosphere by operating
the gas detector. It should read 21% for O2 and zero for other
gases

Exhalation test for Oxygen sensor should be performed by

:
breathing out into sampling tube it till alarm sounds at preset
level 20%

13.11 TESTING STRATIFIED ATMOSPHERE

Authorized gas tester should: -

 Use access ladder to climb or provide other means of access

 Prevent / protect him from falling. Use full body harness

 Slightly open cover on opposite side

 Use a probe and conduct test at opening. Record reading

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 Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010

MARAFIQ SAFETY MANUAL

 Use sampling pump and tube. Conduct test of stratified atmosphere at

different levels – top, bottom, midpoint and sides since gases

i. Heavier than air will fall to the bottom (example- hydrogen

sulphide, chlorine, etc),

ii. Of the same density as that of air will lie in the middle
(example) carbon monoxide) and

iii. Lighter than air will rise to the top (example – methane
natural gas).

13.12 TESTING FOR CHLORINE LEAK

Authorized gas tester should:-

 Use a probe to test atmosphere in chlorine contaminated room

from outside through any hole/ opening

 If not possible, enter the room using Breathing Apparatus and

PVC clothing and gloves

 Test atmosphere at all levels and inside sinks, trenches, drains,

underground tunnels

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