SAUDI ARABIAN OIL COMPANY (Saudi Aramco) GI NUMBER : 0002.

709
GENERAL INSTRUCTION MANUAL APPROVED
ISSUE DATE REPLACES
ISSUING ORG. LOSS PREVENTION DEPARTMENT 04/30/2020 02/07/2019
APPROVAL PAGE NO.
SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 1 OF 11

CONTENTS

1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 REQUIREMENTS
7.0 APPROVAL

SUPPLEMENTS
SUPPLEMENT 2.709-1, CONFINED SPACE ENTRY ATMOSPHERIC LIMITS
SUPPLEMENT 2.709-2, PORTABLE GAS MONITOR ALARM SET POINTS
SUPPLEMENT 2.709-3, PORTABLE GAS MONITOR LIMITATIONS AND PRECAUTIONS

1.0 PURPOSE

* The purpose of this General Instruction (GI) is to provide information regarding performing atmospheric gas tests
using portable gas monitors 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 gas monitors.
* 2.3 The equipment manufacturer's instruction manuals shall be consulted and utilized where applicable when
operating, calibrating or performing function checks of portable gas monitors.
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

GI 2.100, Work Permit System

GI 6.012, Isolation, Lockout and Use of Hold Tags
GI 1780.001, Atmosphere-Supplying Respirators

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SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 2 OF 11

Saudi Aramco Construction Safety Manual (CSM)

** Safety Management Guide (SMG) 06-004, Portable Gas Monitors (PGM)

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 monitor 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 Check: A function check, or bump test, involves exposing the monitor’s sensors to a known gas
concentration to indicate that the monitor will respond accordingly and that all alarms operate as they were
designed and calibrated.
* 4.9 Gas Test: Analysis, using a company-approved gas monitors, 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 monitors, 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 which
the gas is at its lower explosive limit.

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4.13 Oxygen Deficient: An atmosphere that contains less than 20.0% oxygen.
4.14 Oxygen Enriched: An atmosphere that contains more than 23.5% oxygen.
4.15 Parts Per Million (PPM): A unit of measurement used for small portions or concentrations. In gas
analysis, it expresses the volume of gas present in terms of its relationship to a whole of 1 million parts
of air. 1% = 10,000 ppm. 1% of volume = 10,000 ppm, 100% of volume=1,000,000 ppm.
4.16 Sensor: A sensor (also called detector) is a converter that measures a physical quantity and converts it into a
signal which can be read by an electronic instrument. A gas-detecting sensor converts the presence of a gas
or vapor into a measurable signal.
4.17 Threshold Limit Value (TLV): A time-weighted average concentration under which most people can work
consistently for 8 hours a day, day after day, with no harmful effects. A table of these values and
accompanying precautions is published annually by the American Conference of Governmental Industrial
Hygienists.

5.0 RESPONSIBILITIES

5.1 Proponent management shall:

5.1.1 Ensure employees involved in gas testing and using portable gas monitoring equipment are in
compliance with the procedures and requirements in this instruction.
5.1.2 Verify appropriate gas tests are conducted in accordance with GI 2.100 prior to issuing a work
permit (and during the course of work activities when necessary), and for all jobs where toxic gas,
combustible gas or oxygen deficiency/enrichment may exist.
5.1.3 Ensure that gas tester candidates have sufficient knowledge and experience, are capable of
recognizing hazards, and are competent in the requirements of GI 2.100 and this instruction, prior to
their enrollment in the applicable certification training.
5.1.4 Instruct employees to complete the gas testing e-Learning module available on the Training &
Development (T&D) intranet site (http://tdonline.aramco.com.sa) prior to enrollment for gas testing
certification in order to enhance their knowledge of gas testing techniques and requirements.
5.1.5 Ensure gas-testing personnel are trained, tested and certified every two years in the correct use of gas
testing equipment. Certified gas testers shall be informed of updates or changes to company and/or
department requirements regarding use of portable gas monitors.
5.1.6 Ensure that sufficient number and type of gas testing devices are provided to gas testing personnel.
5.1.7 Department/division heads shall authorize employees as certified gas testers and issue certificates
after successful completion of the gas testing training (in accordance with Section 6.2), and pass the
subsequent certification test. Individuals will be certified on the specific gas monitoring equipment
they have been trained on.
* 5.1.8 Ensure users gas monitors conduct daily inspection & function check and pre-use monitor checks in
accordance with Section 6.23.
* 5.1.9 Verify that each monitor is properly calibrated as recommended by the equipment’s manufacturer.
* 5.1.10 Ensure that each monitor calibration is tracked through ATTS. Guidance information on how to add
portable gas monitors to ATTS can be found on the LPD intranet site
(https://sharek.aramco.com.sa/orgs/30001886/GIref/GI_2.709/Adding_Gas_Monitors_ATTS.pdf).

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SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 4 OF 11

5.1.11 Immediately notify the vendor and arrange for any defective or damaged monitors and any key
*
accessories (such as the Docking Station, charging units, etc.) to be sent to the vendor’s service
center for necessary repairs.

5.2 Training & Development shall:

5.2.1 Conduct gas tester classes and administer certification and re-certification tests so that the proponent
division head can certify and maintain successful candidates as department/division gas testers.
5.2.2 Maintain a record of current certified gas testers.
5.2.3 Administer re-certification test to candidates that have successfully completed the gas tester e-
Learning course.
5.2.4 Administer e-certificates to proponent organizations for successful candidates.

5.3 Certified Gas Testers shall:

5.3.1 Ensure they maintain and carry a valid gas testing certificate signed by their respective division head.
* 5.3.2 Utilize only a monitor, which bears a valid calibration-due-date sticker or indicates a valid
calibration date in the system’s memory, has the correct sensors for the gases to be detected, and
which passes daily inspection & function check and the pre-use checks per Section 6.23.
5.3.3 Use only portable gas monitors for which they have been trained and certified.
* 5.3.4 Conduct daily inspection & function check and pre-use checks for the portable gas monitors in
accordance with the manufacturer’s instructions. Results of the daily inspection & function check
shall be recorded on a daily log sheet.
5.3.5 Conduct required gas tests for combustible atmospheres, toxic atmospheres (e.g., H2S, CO), oxygen
concentration and additional air contaminants (as required) in accordance with GI 2.100
requirements and this instruction. Gas test limits shall meet the requirements of Section 6 to
determine if safe working conditions exist, before a work permit is issued.
5.3.6 Enter the gas test results on the respective work permit and sign the corresponding gas testers section
(i.e., Section 3 of the work permit).

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 using approved monitors to
monitor atmospheric conditions.

6.2 Gas testing personnel shall be trained, tested and re-certified every two 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.

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SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 5 OF 11

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 hot work in restricted areas, as defined in GI 2.100.
c) 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 (CO2), 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 wearing 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 be used if any of the following atmospheric conditions exist:
6.11.1 O2 concentration is less than 20.0%.

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SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 6 OF 11

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.

6.12 The proponent organization division head must sign applicable work permits when H2S concentration is at or
above 10 ppm and below 100 ppm, or O2 concentration is below 20.0%, per GI 2.100.

6.13 Atmospheric conditions prior to entry or during work inside a confined space shall meet the requirements as
specified in Supplement 2.709-1, Confined Space Atmospheric Limits.

6.14 Atmospheric gas tests for a confined space shall be performed and immediately recorded:
6.14.1 Prior to entry.
6.14.2 After breaks or interruptions in the work.
6.14.3 Changes to the conditions inside the confined space.
6.14.4 At periodic intervals specified on the permit (e.g., every 2 hours) or continuously as necessary to
determine whether acceptable atmospheric conditions are being maintained during the course of the
confined space entry.

6.15 Initial gas testing prior to entering a confined space shall be performed with all mechanical ventilation shut
down at least 15 minutes prior to testing. Additional testing (e.g., after breaks) shall be conducted with the
ventilation system turned on to ensure that contaminants are being removed and that the ventilation system is
not the source of contamination.

6.16 Confined space entry is not permitted if the atmosphere is at or above 10% LEL, H2S concentration is at or
above 100 ppm, carbon monoxide (CO) concentration is at or above 1,000 ppm or oxygen (O2) concentration
is above 23.5%.

6.17 Whenever testing of the atmosphere results in a gas monitor alarm condition (see Supplement 2.709-2,
Portable Gas Monitor Alarm Set Points), work shall be stopped until proper controls are implemented, which
may include establishing appropriate work procedures and complying with work permit requirements per GI
2.100.

* 6.18 SA-approved portable gas monitoring equipment and their accessories (e.g., Docking Station, calibration gas
cylinder) are available via B2B. The appropriate material numbers for these items are listed on the LPD
intranet site: (https://sharek.aramco.com.sa/orgs/30001886/GIref/GI_2.709/Gas_Detectors_Catalog.pdf).

* 6.19 Operation of portable gas monitors shall follow manufacturer’s instructions. Guidance information on the
operation of approved portable gas monitors can be found on the LPD intranet site:
(https://sharek.aramco.com.sa/orgs/30001886/Portable%20Gas%20Monitoring%20PGM%20Equipment/For
ms/AllItems.aspx)

* 6.20 Portable gas monitors have certain limitations which must be adhered to per Supplement 2.709-3 in order to
avoid potentially dangerous consequences.

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* 6.21 Each portable gas monitor shall receive a full calibration of all sensors as specified by the original equipment
manufacturer.

* 6.22 Each portable gas monitor shall be calibrated either via the vendor’s service center or via the on-site Docking
Station. The location of installing Docking Station devices shall be decided by the proponent.

* 6.23 Users of portable gas monitors shall conduct daily inspection & function check and pre-use checks. Results
of the daily inspection & function check shall be recorded on a daily log sheet.
* 6.23.1 The daily inspection and function check shall include the following:
a) Visual inspection
b) Pump leak test
c) Function check
d) Zeroing
e) Clearing the peaks
* 6.23.2 The pre-use monitor checks shall include the following:
a) Visual inspection
b) Zeroing
c) Clearing the peaks
d) Pump leak test if air-sample accessories to be used (e.g., sample tubing, probe)

* 6.24 Function checks shall be conducted per the manufacturer’s instructions. Instructions for conducting function
checks are found on the respective portable gas monitor operating instructions.
Note: The purpose of the daily function check is to check for sensor and alarm functionality. The installed
sensors are briefly exposed to expected concentrations 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) check, all sensors shall “pass” the test. The
function check is not the same as a calibration test and does not measure for sensor accuracy.

* 6.25 If a portable gas monitor does not successfully pass the pre-use monitor checks, it shall be removed
immediately from service and repaired/calibrated accordingly.

* 6.26 The useful life of function check gas canister is designated by expiration 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 SAP Form 112H (Material Disposal Form) is required to request this
service.

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SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 8 OF 11

7.0 APPROVAL

CONCURRED: _______________________________________ DATE: _________________

GENERAL MANAGER
Training & Development

APPROVED: _______________________________________ DATE: _________________

MANAGER
Loss Prevention Department

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SUBJECT GAS TESTING USING PORTABLE GAS MONITORS GGA 9 OF 11

SUPPLEMENT 2.709-1, CONFINED SPACE ENTRY ATMOSPHERIC LIMITS

1.0 The following conditions are required prior to entry into or work inside a confined space:

1.1 No atmosphere-supplying respirator is required if:

 Oxygen (O2) concentration is at or above 20.0% and less than or equal to 23.5%.
 Flammable/combustible mixtures are less than 5% of the LEL.
 Carbon Monoxide (CO) is less than 35 parts per million (ppm).
 Hydrogen sulfide (H2S) is less than 10 ppm.
 Other potential toxic gas concentrations are at or below their threshold limit value (TLV).

1.2 An atmosphere-supplying respirator shall be continuously worn if:

 O2 concentration is less than 20.0%.
 Flammable/combustible mixtures are at or above 5% and less than 10% of the LEL.
 CO concentration is at or above 35 ppm and less than 1000 ppm.
 H2S concentration is at or above 10 ppm and less than 100 ppm.
 Other potential toxic gas concentrations are above their designated TLV and at or below their IDLH
level.

1.3 Confined space entry is not permitted if the atmosphere is at or above 10% LEL, H 2S concentration is at or
above 100 ppm, CO concentration is at or above 1,000 ppm, O2 concentration is above 23.5%, or other
potential toxic gas concentrations are above their IDLH level.

1.4 These requirements are summarized in the following table.

Confined Flammable/combustible Carbon Hydrogen

Oxygen (O2)
Space Entry Mixtures Monoxide (CO) Sulfide (H2S)
Permitted At or above
without an 20% and less Less than 35 Less than 10
atmosphere- Less than 5%
than or equal ppm ppm
supplying to 23.5%
respirator
Permitted only
while
At or above 35 At or above 10
continuously Less than At or above 5% and less
ppm and less ppm and less
wearing an 20% than 10%
than 1000 ppm than 100 ppm
atmosphere-
supplying
respirator
No entry Above 23.5% At or above 10% At or above At or above
permitted 1000 ppm 100 ppm

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SUPPLEMENT 2.709-2, PORTABLE GAS MONITOR ALARM SET POINTS

* 1.0 The following alarm set points have been established for Saudi Aramco portable gas monitors:

1.1 Oxygen (O2):

 Low Alarm: 20.0%
 High Alarm: 23.5%
1.2 Lower Explosive Limit (LEL): 5%
1.3 Hydrogen sulfide (H2S): 10 ppm
1.4 Carbon monoxide (CO): 35 ppm
1.5 Sulfur dioxide (SO2): 2 ppm
1.6 Chlorine (Cl2): 0.5 ppm
1.7 Ammonia (NH3): 25 ppm

2.0 Alarm set points for substances/gases not covered under this GI will be established through consultation with LPD
and the Environmental Protection Department.

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SUPPLEMENT 2.709-3, PORTABLE GAS MONITOR LIMITATIONS AND PRECAUTIONS

* 1.0 Portable gas monitors have certain limitations which must be adhered to in order to avoid potentially dangerous
consequences.

* 2.0 Function check the monitor in a clean environment at the beginning of each day using a known concentration of
test gas. If the monitor does not pass the function (bump) check, a full calibration is required. Only use a portable
gas monitor with a valid calibration date.

* 3.0 Servicing the unit, replacing or recharging battery packs, or using the communications port must only be
performed in a nonhazardous environment.

4.0 Portable gas monitors are susceptible to poisoning of the sensors when exposed to vapors containing appreciable
concentration of contaminants such as:
4.1 Tetra Ethyl Lead (e.g., from leaded gasoline or associated sludge/residue).
4.2 Silicone vapors (e.g., from greases). Silicone compound vapors or other contaminants may affect the
combustible gas sensor and cause readings to be lower than actual gas concentrations.
* 4.3 The effects of these poisons are that they reduce sensitivity to respective sensors. Any monitor exposed to
such vapors without an appropriate filter in place to remove the contaminants must be function checked. If it
fails the test, the affected monitor must be sent for service prior to use.

* 5.0 To ensure combustible gas testing accuracy (i.e., LEL), the sampled atmospheres should contain at least 16%
oxygen by volume (unless the IR sensor is being used). Oxygen deficient atmospheres may cause combustible gas
readings to be lower than actual concentrations.

6.0 Oxygen enriched atmospheres (i.e., O2 greater than 23.5%) may cause combustible gas readings to be higher than
actual concentrations.

7.0 Obstructions of the sensor openings and/or contamination of the water barriers may cause readings to be lower
than actual gas concentrations.

* 8.0 Portable gas monitors must be used in accordance with the Class and Zone for hazardous locations within the
ambient temperature range as specified by the manufacturer.

9.0 Minimize prolonged exposure to high temperature environments.

10.0 High over-range conditions may indicate explosive gas concentrations.

* 11.0 Physical abuse such as crushing or drowning the monitor, using unapproved materials, or performing service or
repairs by an unauthorized provider will nullify the manufacturer’s warranty.

* 12.0 For maximum safety and operations performance, read and understand the respective operations manuals for each
portable gas monitor issued by the manufacturer.

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