Gas Testing Procedures PDF

Gas Testing Procedures UKCS-SSW-004
Contents
Authorisation for Issue

Amendment Record
Amendment Summary
Distribution List
Preface
Paragraph Page
1 Introduction 1
1.1 What is Gas Testing? 1
1.2 Why is Gas Testing Carried Out? 1
1.3 Who Carries Out Gas Testing? 1
1.4 When is Gas Testing Carried Out? 2
2 Flammable Gases 2
2.1 The Chemistry of Fire 2
2.2 Explosive Range 4
2.3 Common Gases 5
2.4 Flashpoint 5
2.5 Narcotic Effects of Hydrocarbon Vapours 5
3 Toxic Gases and Vapours 6

3.1 Asphyxiants 6
3.2 Measuring Toxic Gases 7
3.3 Hydrogen Sulphide 7
4 Properties of Gases 9
4.1 Gas Cloud Movement 9
4.2 Gas Behaviour 9
4.3 Physical Properties 9
4.4 Dispersion 10
4.5 Outdoor Areas and Open Structures 10
July 2004 Issue 1/AM03 i

UKCS-SSW-004 Gas Testing Procedures
Contents (cont’d)
Paragraph Page
5 Confined Space Entry 11

5.1 What are Confined Spaces? 11
5.2 Buildup of Gases in Confined Spaces 11
5.3 Testing Confined Spaces 11
5.4 Further Considerations 12
6 Portable Gas Detection Equipment 13

6.1 Introduction 13
6.2 Types of Portable Gas Detectors 13
6.3 Pre-use Check 13
6.4 Temperature Effects 14
6.5 Limitations of Portable Gas Detectors 14
6.6 Erratic Indications 15
6.7 Defective Equipment 15
6.8 Environments that Affect Readings 15
6.9 Off-scale Readings 15
6.10 Aspirated Detector Tubes 15
6.11 Photoionisation Detectors 16
6.12 Warning Systems 16
7 Gas Testing Procedures 17

7.1 Process Plant 17
7.2 Hazardous Areas 17
7.3 Gas Testing in Support of Work Activities 18
7.4 The Safe System of Work 18
7.5 Continuous Gas Monitoring 18
7.6 Practical Gas Testing 19
7.7 Air Movement 19
7.8 Evaluation 20
7.9 HVAC Flowpaths 20
7.10 Main Points of Gas Testing 20
7.11 Investigating Leaks 21
ii July 2004 Issue 1/AM03

Contents (cont’d)
Paragraph Page
8 Case Studies 21
8.1 The Wrong Way to do it 21
8.2 The Right Way to do it 22
Addendum 1 Glossary
Addendum 2 Guidance for Trainers who are Providing Practical
Training Following Completion of the CBT Package
for Gas Testing Level 1 or Level 2
Addendum 3 Guidance for Confined Space Entry Gas Testing
Addendum 4 Terms of Reference and Audit Protocol
January 2005 Issue 1/AM04 iii/iv

Authorisation for Issue
Technical Authority
Name: Alan Lindsay
Signature: _______________________________________________
Date: _______________________________________________
Position: Offshore Operations Engineer, Magnus
August 2003 Issue 1/AM02 v/vi

Amendment Record
For Audit Use

Amendment Incorporated By
Checked
Number
Name Signature Date Signature Date
AMOSAF.171
September 2001 Issue 1 vii/viii

Amendment Summary
Issue No Date Description
Issue 1 September 2001 First issue.

Issue 1/AM01 March 2002 H2S limits updated throughout document (and in
particular Section 3 Paragraph 3.2) to reflect
changed exposure limits, in line with the Health
and Safety Executive Environmental Health Series
EH40 2002.
Distribution List updated.
Issue 1/AM02 August 2003 Two new Appendices have been added: the first
provides guidance for practical training for Level
One and Level Two Gas Testers, and is intended
for use following completion of the CBT training
package; the second is an aide-memoir for
Authorised Gas Testers who are carrying out
confined space entry gas testing.
Issue 1/AM03 July 2004 Flammable gases, portable gas detection
equipment and gas testing procedures amended
with regard to narcotic effects of hydrocarbon
vapours.
document August 2004 Distribution List updated.
control action
Issue 1/AM04 January 2005 Clarification of gas testing and timing of issue of
WCCs under ISSOW. Minor changes to
requirements for calibration and servicing.
Clarification of refresher training intervals and
guidance for lighting for initial gas tests.
document September 2006 Terms of Reference and Audit Protocol added as
control action Addendum 4.
January 2005 Issue 1/AM04 ix/x

Distribution List
Holders of Controlled Hard Copy
Copy Copyholder Location
01 Data Control Centre (DCC) ODL, Aberdeen
Virtual Copyholders
Copy Copyholder
01 Document Technical Authority

02 G ABZ SMS Notifications
July 2004 Issue 1/AM03 xi/xii

Preface
Gas Testing Levels of Competency

This document and the computer-based training package that accompanies it define two levels
of Authorised Gas Tester.
These are:
• Level Two
Level Two Gas Testers are deemed competent to be able to carry out gas monitoring prior to
and during naked flame and spark potential work. Subject to any local rules, they are
authorised to enter the results of gas tests onto spark potential and naked flame
work permits.
• Level One
In addition to the competencies of the Level Two Gas Tester defined above, Level One Gas
Testers are deemed competent to carry out monitoring prior to work involving confined
space entry. Subject to any local rules, they are authorised to enter the results of gas tests
onto Entry Certificates.
Sentry Monitoring
Performing Authorities engaged in carrying out spark potential work in hazardous areas may be
required to use a portable gas monitor for sentry monitoring. Where practicable, such personnel
should be trained to Level Two. If such training has not been carried out, then the Area
Authority should be satisfied that the Performing Authority understands the basic operation of
the gas monitor, including the alarm signals, low battery signal, how and where to locate the
monitor, and the actions required should the monitor go into alarm.
At least one Performing Authority in a squad engaged in naked flame work in hazardous areas
shall be trained to Level Two.
Review and Update

This document will be subject to 12-monthly review and update, when document holders will
have the opportunity to express opinions and suggest improvements.
However, the document control system allows for continuous update of this document. As
such, any user may at any time identify an error or suggest an improvement using an
Amendment Proposal proforma which is available electronically on the UK Upstream SMS
website, from the Data Control Centre (DCC) Supervisor or from the Technical Authority.
All holders of this document are registered so that they can be sent updates and be kept
informed of changes or reviews.
September 2001 Issue 1 xiii

Responsibility of Copyholders
It is the responsibility of the registered copyholder of controlled hard copy versions to
maintain the accuracy of the document by ensuring that all updates are promptly
incorporated and acknowledged.
Furthermore, the registered copyholder of controlled hard copy versions must at all times
maintain custody of this document unless prior approval is given by the relevant
Technical Authority.
The roles and responsibilities of copyholders and ‘virtual’ copyholders are detailed in Section 1
of the Document Control Procedure (UKCS-DCM-001).
xiv September 2001 Issue 1

1 Introduction
This document is intended to support the Authorised Gas Testing Computer-based
Training Course and provides an easy reference to the requirements for gas testing and
defines some of the key terms and abbreviations used.
1.1 What is Gas Testing?

Gas testing involves testing for toxic and flammable gases using portable gas detection
equipment, and is an integral part of establishing a safe system of work in the oil and
gas industry.
Gas tests are performed to confirm that the working environment is safe from the
hazards of combustible or toxic gases, and to confirm that oxygen levels are within
specified tolerances and safe to breath.
Flammable and combustible are similar words, meaning ‘capable of igniting and burning’.
1.2 Why is Gas Testing Carried Out?

Oil and gas production by its very nature presents many hazards, including the release of
flammable or toxic gases. It is the aim of BP to ensure that gas testing is carried out by
competent personnel to enable an area to be declared free from toxic or flammable
gases, therefore reducing the risk of fire, explosion or asphyxiation of personnel.
1.3 Who Carries Out Gas Testing?

Authorised Gas Testers (AGTs) are responsible for carrying out gas testing duties in
liaison with the other supervisory roles and in accordance with specified precautions.
An AGT must have completed the necessary training, have been certified as competent
and be:
• Able to demonstrate the ability to survey potentially hazardous areas using the
detection equipment available and be familiar with plant and process areas
• Aware of the capabilities and limitation of gas testing equipment
• Aware of and demonstrate knowledge of, the requirements of the Permit to Work
Procedure, relating to gas testing
March 2002 Issue 1/AM01 1

1.4 When is Gas Testing Carried Out?

Gas testing should be carried out wherever there is a risk of flammable or toxic gases
being present or when oxygen enrichment or deficiency is a likely hazard. Typical
circumstances requiring gas testing are:
• Hot work of any type where heat is used or generated, for example welding, flame
cutting, grinding etc
• Work which may generate sparks or other sources of ignition
• Work which may cause an uncontrolled release of hydrocarbons, other flammable or
toxic materials
• Entry into confined spaces
• Gas alarm investigation
• Monitoring purging operations
2 Flammable Gases
2.1 The Chemistry of Fire
For a fire or explosion to occur, three components must be present:
• Fuel
• Oxygen
• Ignition source/heat
If any of these components are not present then fire is impossible. The components are
often represented as the sides of a triangle and this is known as the ‘fire triangle’.
OX
EL
YG
FU
EN
IGNITION
UKCSSSW004.004
2 September 2001 Issue 1

2.1.1 Fuel
As any fire burns it consumes fuel and converts this into heat energy and other
by-products such as smoke. Almost any substance can be considered as fuel and burn
under the right conditions. Common fuels in the oil and gas industry are methane, oil and
solid waste.
When a fire consumes all of its fuel or the fuel is removed it is called ‘starving’ the fire.
All fuel gases and vapours are characterised by explosive limits between which the gas
or vapour mixed with air is capable of sustaining the spread of flame. These can be
referred to as explosive or flammable limits. While these two terms are interchangeable,
within this document the term explosive limits will be used.
2.1.2 Oxygen
Oxygen in air normally represents 20.9%.
To prevent the risk of fire or explosion it is important to minimise the opportunities for
flammable gases and oxygen (air) being present in such proportions that they can be
ignited, this can be achieved by:
• Controlling the presence of combustible substances and ignition sources
• Minimising air entry into production equipment
2.1.3 Ignition Source/Heat

The basis for ignition can come from many different sources. Though far from
exhaustive, some examples are: the discharge of static electricity, switching of electrical
contacts, pump bearings running hot or diesel engines taking in gas through their
air intakes. They all have the potential to produce enough heat energy to ignite a
surrounding gas. Care must be taken to eliminate or protect all potential sources of
ignition from coming into contact with a fuel oxygen mix.
A fire can be extinguished by applying a coolant to reduce and maintain its temperature
below its ignition temperature.
September 2001 Issue 1 3

2.2 Explosive Range

The region between the LEL and the UEL is known as the flammable or explosive range.
2.2.1 Lower Explosive Limit

The Lower Explosive Limit (LEL) refers to the lowest concentration of a gas in the
atmosphere that results in a flammable mixture. For example, the LEL of methane is
5% by volume. This means that if there is less than 5% by volume of methane in air,
the mixture is too lean (weak) to support combustion.
0% 100% LEL
METHANE 5%
= TOO LEAN TO SUPPORT COMBUSTION
= WILL SUPPORT COMBUSTION
= TOO RICH TO SUPPORT COMBUSTION UKCSSSW004.001
2.2.2 Upper Explosive Limit

The Upper Explosive Limit (UEL) refers to the highest concentration of a gas in the
atmosphere, which results in a flammable mixture. For example, the UEL of methane in
air is 15% by volume. This means that if there is more than 15% by volume of methane
in air, then the mixture is too rich (concentrated) to support combustion.
A rich gas mixture would typically occur in a confined area such as an oil storage tank
where the methane cannot disperse. From the table shown, we can see that
concentrations of methane in air between 5 and 15% are combustible.
0% 100% LEL UEL
METHANE 5% 15%
4 September 2001 Issue 1

2.3 Common Gases

The LEL and UEL of some common gases found in the oil and gas industry are shown in
the table.
0% 100% LEL UEL
ACETYLENE 2.4% 88.0%
BUTANE 1.5% 8.5%
ETHANE 3.0% 15.5%
ETHYLENE 2.7% 34.0%
HYDROGEN 4.0% 75.6%
METHANE 5.0% 15.0%
PROPANE 2.0% 9.5%
PROPYLENE 2.0% 11.0%
For most practical gas testing purposes it is the LEL which is significant. The Authorised
Gas Tester is responsible for recording the percentage of LEL for the specific flammable
gas being tested.
2.4 Flashpoint
The flashpoint for a liquid is the lowest temperature that it produces sufficient vapour to
form an ignitable mixture with air. This means that the concentration of flammable
vapour above the liquid is close to the LEL.
2.5 Narcotic Effects of Hydrocarbon Vapours

Inhalation of volatile hydrocarbon vapours such as from condensates can cause narcotic
effects, eg drowsiness, dizziness, confusion and inability to make rational decisions.
Such effects will be apparent after three to four breaths (equally, full recovery will be
achieved after three to four breaths of uncontaminated air).
July 2004 Issue 1/AM03 5

The physical effects experienced when breathing a hydrocarbon vapour, for different
concentration levels, are shown below:
Narcotic Effects of Hydrocarbons
Narcotic Effects vs Portable Monitor Reading
Corresponds to approx 50%

general anaesthetic dose
100%
Failure to respond to required for surgical
verbal commands operations
% Lower Explosive Limit
80%
Hyper-excitation, loss 60%

of ability to take
rational decision
40%
Likely there is no
impairment of
functionality
20%
No impairment
of functionality 10%
UKCSSSW004_005.ai
Note: The concentration levels are expressed as a percentage of the LEL of the vapour,
not the concentration by percentage volume. One hundred percent LEL is about
5% methane in air by volume.
The calibration against LEL enables personnel with portable hydrocarbon gas monitors to
be aware of the presence of a potential narcotic atmosphere in good time, and take
appropriate action to evacuate to a safe place.
3 Toxic Gases and Vapours

Many gases in the oil and gas industry may not be flammable but may still present a
health hazard due to their toxicity, however, you should be aware that many gases may
be both flammable and toxic.
As previously stated, flammable gases are expressed as the LEL percent by volume.
The concentration of toxic gases is expressed in parts per million (ppm), where 1% by
volume equals 10,000ppm. Many toxic gases present health hazards in concentrations of
less than 100ppm.
3.1 Asphyxiants
Gases such as nitrogen, hydrogen, methane etc all act simply by diluting the air and so
reducing the level of oxygen available. These gases are known as simple asphyxiants.
Substances that affect the body’s assimilation of inspired oxygen, such as carbon
monoxide, prevent the uptake of oxygen in the blood. These gases are known as
chemical asphyxiants.
More toxic asphyxiants, such as hydrogen sulphide (H2S) directly affect the respiratory
centre of the brain, causing breathing to stop.
6 July 2004 Issue 1/AM03

3.2 Measuring Toxic Gases

A wide variety of instruments, including portable and fixed detectors, exist for the
measurement of toxic gases. Ranging from simple chemical filled detector tubes to
complicated electrochemical systems, they are relatively specific to individual gases or
families of gases.
3.2.1 Occupational Exposure Limits

Under COSHH there are two types of Occupational Exposure Limits (OELS): Maximum
Exposure Limits (MELs) and Occupational Exposure Standards (OESs). OELs are set to
help protect the health of workers. Both types of limit are the concentration of hazardous
substances in the air, averaged over a specified period of time; referred to as a Time
Weighted Average (TWA). Two time periods are used: Long-term (8 hrs) and short-term
(15 mins). Short-term Exposure Limits (STELs) are set to help prevent effects which may
occur quickly.
MEL is set for substances with the most serious health effects, (such as cancer or
occupational asthma) and for which ‘safe’ levels of exposure cannot be determined.
OES is set at a level at which (based on current scientific knowledge) there is no
indication of risk to the health of workers exposed by inhalation day after day.
3.3 Hydrogen Sulphide

When testing for toxic gases at the Installations, our primary concern is H2S.
H2S is one of the most dangerous gases found in the oil and gas industry. It is possible
that a field can start producing H2S at any time, therefore caution must be exercised at
all times, particularly in confined spaces.
3.3.1 Characteristics of H2S

H2S is often referred to as sour gas. The characteristics of H2S are:
• Has a distinct odour of rotten eggs at low concentrations (under 10ppm). Less than
1ppm can detected by this odour
• Can deaden sense of smell at higher concentrations. The concentration will vary from
individual to individual but will usually be greater than 10ppm
• Is a colourless, flammable gas which may be liquefied under pressure
• Is soluble in water, crude oil or petroleum fractions
• Extremely corrosive
• Burns with a blue flame producing sulphur dioxide (also a toxic gas)
• Slightly heavier than air and may accumulate in low lying areas and confined spaces
• Easily dispersed by wind movements or air currents
• Extremely hazardous to health – deadly

3.3.2 Exposure Limits

The Health and Safety Executive Occupational Exposure Limits (EH40) establishes
occupational exposure limits, for H2S as follows:
• Long-term exposure limit of 5ppm (0.005% by volume) over an 8-hour
reference period
• Short-term exposure limit of 10ppm (0.001% by volume) over a 15-minute
reference period
3.3.3 Measurement of H2S

Toxic gas detectors are calibrated to measure H2S in ppm of H2S in air, by volume ratio.
3.3.4 Concentrations of H2S

There is a significant difference between H2S concentration in air and H2S in liquid.
The actual concentration measured in air by volume ratio can be 10 to 100 times higher
than the equivalent measurement in liquid by weight ratio.
For example, crude oil being discharged into a storage tank may contain only 70ppm H2S
in the liquid by weight. However, the concentration of H2S in the vapour space above the
crude oil could exceed 7000ppm by volume.
3.3.5 Effects of H2S on Personnel

When H2S is inhaled by an individual it passes directly through the lungs into the
bloodstream. To protect itself the body ‘oxidises’ (breaks down) the gases as rapidly as
possible into a harmless compound.
If the individual breathes in so much H2S that the body cannot oxidise it all, it builds up
almost instantly in the blood and the individual is quickly overcome.
The areas of the brain which control breathing become paralysed; the lungs stop working
and the person is asphyxiated.
The way in which H2S affects a person depends on the following:
• Intensity – the concentration of exposure
• Duration – the length of time the individual is exposed
• Frequency – how often the individual has been exposed
• Susceptibility – the individual’s physiological make-up
3.3.6 Effects of H2S on Equipment

H2S is highly corrosive to steel and at high stress levels extreme metal embrittlement
may occur in a very short time.
Equipment that may be subject to exposure should be specified accordingly and an
appropriate schedule maintained to ensure detection of metal deterioration.

4 Properties of Gases
4.1 Gas Cloud Movement
Vapours in air move from place to place under two influences:
• Gravity, where gases are heavier than air they flow in a similar way to that of liquids
• Normal turbulence and ventilation, where gases are lighter than air
4.2 Gas Behaviour

In the event of a leak, combinations of gases remain mixed until each component is
separated. This separation can take several hours and may be caused by many factors
including condensation, gravity or air movement, depending on local ambient conditions.
Hydrocarbon gases are often at high pressure, and have constituents that are both
lighter and heavier than air. When gas is under pressure a relatively small leak can result
in very rapid and large gas concentrations forming. These are referred to as plumes.
Plant, equipment, pipework and vessels, from which gas could leak, may be situated
outside in well-ventilated spaces, inside louvered modules or in enclosed areas where
there is forced ventilation. An appreciation of gas cloud movement is therefore critical.
4.3 Physical Properties

To anticipate gas cloud movement and behaviour, it is necessary to have a basic
understanding of the physical properties of gases.
Relative Density
The ratio of the density of a gas compared to that of air is know as the relative density.
Gases that have a low relative density are lighter than air, for example, methane under
normal conditions will rise. They will tend to collect beneath objects or surfaces, which
prevent them from rising upwards.
Gases that have a high relative density such as hydrogen sulphide or pentane will fall to
the ground and tend to gather in low lying areas or in drains.
In practice other factors such as temperature and pressure can affect relative density.
Velocity
The velocity of a gas is the speed at which it travels. The velocity of a gas escape or leak
into the surrounding air will lead to a disturbance called turbulence, which causes the
gas to mix with the surrounding air and increases the potential for an explosive mixture
to develop.

Temperature
In general, heating of gases will lead to a reduction in density causing the gas to rise.
Cooling will have the opposite effect, resulting in an increase in density and a tendency
for the gas to condense and fall.
The main point to note is that a rise in temperature can alter the nature of the hazards
posed by flammable gases and vapours. Usually the dangers are increased when the
temperature rises.
Pressure
Some gases are kept in a liquid state by being pressurised, such as liquefied petroleum
gases containing butane and propane. As a pressurised liquefied gas escapes into the
surrounding atmosphere, its pressure decreases and its temperature drops. This causes
its relative density to increase and the gas to fall.
Evaporation
Liquefied Petroleum Gas (LPG) contains propane and butane, which will evaporate when
exposed to the atmosphere. As liquids evaporate their temperature drops, this causes
their density to increase. The cold and therefore heavy gas released during evaporation
behaves like a ‘slow-motion’ liquid and will flow at a low level along floors.
The reverse effect can occur with hot, heavier than air gases, which may be buoyant for
several minutes after release.
4.4 Dispersion
The nature of the initial dispersion will affect the behaviour of the escaping gas. In the
absence of air movement or any confining structure, the dispersion of gas from a source
of release will initially be determined by the momentum of the released gas, its density
relative to air, or both.
Gas escaping with high velocity, for instance a leak from a pressurised line or container,
will behave initially as a jet directed away from the source of release. As the distance
from the source of release increases, the momentum of the jet will decay until,
eventually, the dispersion of the gas will be controlled by buoyancy effects.
4.5 Outdoor Areas and Open Structures

In outdoor areas or on open structures, wind speed and direction will affect the
dispersion of gas following a release.
In open areas, the spread of gas upwind of the release will be reduced, whilst downwind
of the release it will be increased. This effect will be greater at high wind speeds.
More complex airflow patterns will occur around items of plant and other structures.
Low lying areas, partially enclosed spaces of areas with restricted air movement may
have a significant effect on gas movement and dispersion.

5 Confined Space Entry

5.1 What are Confined Spaces?
The term ‘confined space’ is widely used throughout the industry, but is also sometimes
misunderstood. The following definition is recognised by various companies:
‘Any area which has limited access/egress or which is sufficiently confined to permit the
accumulation of flammable/toxic gases or vapours, or where an oxygen deficiency or
enrichment could occur.’
or:
‘Any enclosure where the presence of air contaminants may be harmful to personnel
and prevent their ability to escape unaided.’
Refer to UKCS-SSW-001 Paragraph 5.1.
5.2 Buildup of Gases in Confined Spaces

Hazardous concentrations of gases or vapours can arise from sources both inside and
outside confined spaces. For example:
• From a process which has previously been carried out in the confined space
• From adjoining plant due to ineffective isolation
• From migration from another area
• From sludge deposits that are disturbed during inspection/cleaning
• From an operation performed inside the confined space, eg welding
• From oxygen enrichment of the atmosphere caused by leaks of oxygen into the
confined space
5.3 Testing Confined Spaces

Gas testing of a confined space must be carried out before it is certified as being safe
to enter, or before safety precautions to be taken upon entry are implemented.
Tests should check for the presence of gas or toxic fumes, and the adequacy of oxygen
and air supply. An acceptable result must be obtained before work in any area proceeds.
Where possible, all tests should be conducted from outside the vessel or confined
space. When this is impractical the following basic rules should be adhered to when
entering the confined space to carry out gas testing:
• Wear approved breathing apparatus
• Know what type of gas or vapours are to be expected
• Ensure all isolations to the confined space have been implemented
• Provide ready exit/entry routes for rescue team (side openings or manholes should be
used in preference to top openings)

• Wear an approved safety harness, with lifeline attached, before entering a

confined space
• Ensure there is at least one standby person on the outside, ready to raise the alarm in
the event of an emergency
• The standby man should always be in sight and call of the Authorised Gas Tester
5.4 Further Considerations

Other considerations that the Authorised Gas Tester should be aware of are the
oxidation process caused by rust that may reduce the content of oxygen present in the
atmosphere, or chimney stacks that may still contain flue gases.
Where purging activities have been carried out, the atmosphere in the vessel may still
contain inert gases that have displaced the original contents and the atmosphere within
could be oxygen deficient.
Remember that the gas may not be uniform inside a confined space and may be present
in different concentrations at various levels, with the heaviest gases falling to the lowest
point and the lightest gases collecting at the highest point. Gas may also collect behind
obstructions such as baffle plates or bulkheads, or may be trapped in sludge deposits in
the vessel.
H2S can arise from stagnant water or sludge, distributing such water or sludge may
cause H2S to be emitted.
After any test, the Authorised Gas Tester should record the maximum and minimum
readings on the Entry Certificate.
5.4.1 Oxygen
Oxygen is a non-toxic gas which represents 20.9% of the air we breathe. However,
if the oxygen content of the atmosphere falls below or rises above this level, as may be
the case in a storage tank or vessel, the human body will suffer from oxygen starvation
or intoxication.
Oxygen – Too Little

Too little oxygen could result from purging with inert gas to remove flammable or toxic
gas or vapour, or the formation of oxidant products such as rust on the inside surface of
a vessel.
Oxygen – Too Much

Too much oxygen has a poisonous effect on the body as well as representing an
increased fire hazard. This could, for example, occur in the vicinity of leaking gas
welding equipment.

5.4.2 Work Involving Air or Gas Lines

It is important to isolate and remove all air/gas lines that are not being used, for example
oxy-acetylene lines, to reduce potential leakage of gases into the confined space.
Note: No gas/air cylinders other than Breathing Apparatus (BA) sets are allowed in
confined spaces.
6 Portable Gas Detection Equipment

6.1 Introduction
Portable gas detectors are a convenient means of detecting the presence of flammable
or toxic gases and vapours and ensuring that oxygen levels in the atmosphere are safe.
They have the advantage that they can be taken to the site where the sampling is to take
place and will give a clearly defined reading or signal.
6.2 Types of Portable Gas Detectors

Types of detector commonly used in the oil and gas industry are:
• Combustible – catalytic, thermal conductivity or electronic
• Toxic (H2S) – electrochemical
• Oxygen – electrochemical
Manufacturers supply electronic instruments to customer requirements; they may
detect one specific gas or a combination of gases.
Although the manufacturer and model may vary from site to site, all combination
detectors are designed to measure oxygen, toxic (H2S) and flammable gases.
6.3 Pre-use Check

Before using any gas detector, Authorised Gas Testers must ensure that they are fully
conversant with their operation and are responsible for completing a number of
pre-use checks.
Pre-user checks, include the following:
• Select the correct gas detector for the job
• Check that the detector is within the next calibration date
• Ensure that the detector is in a good state of repair, and that the casing is
not damaged
• Check that the battery life is sufficient for the job
• Check that the sensor head membranes are clean and not blocked

• Check that the detector zeros in a clean air environment as follows:

- % LEL = 0%
- ppm hydrogen sulphide = 0
- % oxygen = 20.9%
- If using an aspirator, check that the aspirator is in a good condition and leak free
- If required test the detector with a sample gas of known concentration
It is important that care is exercised with portable detectors, not only to ensure that they
are properly used, but also to ensure that the correct interpretation is made of the
readings and that their limitations are realised.
Gas meters shall be checked and calibrated by a Competent Person, at the intervals
specified by the manufacturer. Experience may indicate that more frequent checks are
appropriate, eg if in frequent use or if used in a dirty environment.
In areas being surveyed with portable gas detection equipment, where gases or vapours
may be stratified rather than uniformly mixed, spot checks should be made at different
levels using an extension probe and aspirator (if required).
When sampling vapour above a liquid, care should be taken to avoid the sample line or
sensor from coming into contact with the liquid, since this may block the entry of gas or
vapour to the apparatus.
Only sample lines or sensors recommended by the manufacturer should be used with
the detector.
6.4 Temperature Effects

When taking portable gas detection equipment from a warm to a cool environment, it is
important to allow the equipment temperature to stabilise to avoid condensation
(the formation of vapour) which may otherwise interfere with the operation of the
gas detector.
6.5 Limitations of Portable Gas Detectors

Gas detection equipment may not be sensitive to a specific gas, for example H2S
detectors may not detect methane and furthermore, adverse readings may be generated
by the presence of gases other than those for which the detector is calibrated.
It is important to note that some substances such as solvents or silicones may also
adversely affect detectors and you should check the manufacturer’s specifications
before use.
If contamination is suspected the detector must be returned for checking and
recalibration.
Flammable gas detectors are not sensitive to low levels of hydrocarbon vapours below
the LEL range. Where there is concern over the presence of hydrocarbon vapours in the
ppm range, other monitoring equipment should be selected, eg Photoionisation
Detections (PIDs), detector tubes.
14 January 2005 Issue 1/AM04

6.6 Erratic Indications

Erratic indications on detection equipment may point to contamination, an equipment
malfunction or some atmospheric disturbance.
In such cases, carry out the test again.
Where there are doubts, a check should be made with another gas detector of the same
type. Suspect equipment should be returned for checking and recalibration.
6.7 Defective Equipment

Erratic indications may point to equipment malfunction or some atmospheric
disturbance. Where doubt exists a check should be made with another gas detector of
the same type and/or the suspect equipment should be checked under controlled
conditions before its continued use.
6.8 Environments that Affect Readings

The presence of very low concentrations of combustible gas can produce indications
that may be mistaken for ‘zero drift’. In such circumstances the equipment should be
removed to a clean air environment and rechecked.
Dust or saturated steam may physically block the flame arresters of certain types of
gas detection equipment, rendering them inoperative, and care should be exercised
accordingly.
6.9 Off-scale Readings

Where ‘off-scale’ indications occur (in either direction), this may indicate the presence of
a potentially explosive atmosphere. It will then be necessary to flush the detection
equipment with clean air and to cross-check for the presence of gas by taking the
reading again, or by using another type of gas detection apparatus.
Under such circumstances, assume the presence of a potentially explosive atmosphere
until otherwise proven.
When using portable gas detection equipment, it is necessary to be aware that some
flammable gases and vapours are also toxic.
6.10 Aspirated Detector Tubes

In addition to electronic gas detectors, aspirated detector tubes may be used.
These consist of either a manual or battery-operated suction pump. The inlet of which is
fixed to a reactive chemical tube. The tube and its chemical contents are selected to
detect a known type of gas.
Tubes exist for detecting a variety of gases, such as petroleum hydrocarbons, benzene,
carbon monoxide, hydrogen, chlorine, H2S etc. Each type of tube is supplied with
instructions. These must be checked to determine the tube limitations and precautions
for use.

The pump draws in a metered amount of the atmosphere to be tested through the
chemical tube. The tube is normally calibrated such that, in the event of gas being
present, the reaction between gas and chemical shows up as a distinct colour on the
scale, indicating the concentration of gas present.
6.11 Photoionisation Detectors

Due to the harmful nature of hydrocarbon vapours, PIDs may be necessary when
detecting and measuring Volatile Organic Compounds (VOCs), including hydrocarbon
vapours at the ppm level, typically in the range 0.1 to 2000ppm. PIDs can be used to
detect VOCs during any breaking of containment activities or where there is concern of
personal exposures. PIDs are available, as both hand-held and personal monitors, and
can be set to alarm and to data log exposure levels if required.
PIDs do not respond to methane therefore should not be used for LEL judgements if
methane approaching LEL levels may be present.
6.12 Warning Systems

All types of portable gas detectors, except chemical tubes, have a visual and/or audible
warnings to alert the operator to the presence of unwanted gases.
The equipment must provide a method by which the quantity and type of gas can be
determined, and at pre-determined levels initiate alarms on the portable gas detector.
6.12.1 Gas Alarm Limits – Flammable

Portable gas detectors are set to alarm at a percentage of the LEL based on calibration
flammable gas. For example, the alarm may be set at 5% of the LEL for methane,
and this would equate to 0.25% of methane by volume in air.
6.12.2 Gas Alarm Limits – Toxic

The occupational exposure limit of H2S is 5ppm and it is at this point that portable gas
detector alarms are set.
6.12.3 Gas Alarm Limits – Oxygen

The atmosphere normally contains approximately 20.9% oxygen and the portable
detector is calibrated at this figure.
The detector incorporates high and low oxygen alarms.
6.12.4 Gas Alarm Limits – Flammable

It is recommended that portable gas detectors alarms are set at 10% LEL in order to
provide adequate warning of short-term health inhalation effects.
Portable total hydrocarbon vapour detectors (PID-type) should be set to alarm at 100ppm
for total hydrocarbons in order to protect against health effects.

7 Gas Testing Procedures

7.1 Process Plant
A very large number and variety of different types of connections occur in a process
plant and it is possible that at some time hydrocarbon gases will leak from these.
Particular attention must be given to flanges, screwed connections, gaskets, drains and
vents, valve glands and pump seals when performing tests.
The Authorised Gas Tester should be aware of the types of fluid that run through the
process equipment, or are adjacent to the proposed area of work.
7.2 Hazardous Areas

A hazardous area is an area in which explosive gas/air mixtures are, or could be,
expected to be present in quantities. These areas require special precautions to limit the
sparking potential of electrical equipment. This can be achieved by design considerations
for the equipment or pressurising the area to exclude the hazardous atmosphere.
Hazardous areas are classified into ‘Zones’ as follows:
7.2.1 Zone 0
An area in which an explosive gas/air mixture is continuously present or present for
long periods.
It is the most potentially hazardous area of any plant and is usually restricted to very
small areas of the plant, eg within the void space of tanks containing volatile
flammable liquids.
7.2.2 Zone 1
An area in which an explosive gas/air mixture is likely to occur in normal operation,
eg where gas may be vented to atmosphere.
7.2.3 Zone 2
An area in which an explosive gas/air mixture is not likely to occur in normal operation
but if it does occur it will be for a short duration.
It must be realised that ventilation, specifically natural ventilation, may cause these
potentially dangerous gas/air mixtures to migrate into adjacent ‘safe’ areas, ie those not
pressurised.
Therefore, the Authorised Gas Tester must be aware of this and should consider testing
these adjacent areas.
In general the majoritory of the total area of an Installation will be designated Zone 2.

7.3 Gas Testing in Support of Work Activities

The function of gas testing is to ensure that the site is clear of toxic/flammable gases
and to reduce the risks associated with work activities.
In any potentially flammable or toxic area or whenever a gas risk may exist at the
worksite, the applicable signatory in accordance with the Permit to Work System will
indicate that gas testing is required.
7.4 The Safe System of Work

The applicable signatory will advise a nominated Authorised Gas Tester on the Work
Control Certificate (WCC) where a gas test is required.
In some cases before a WCC is issued an initial gas test must be made at the worksite.
This test must be carried out by an Authorised Gas Tester. The results of this gas test
must be recorded on the WCC or Entry Certificate. The Authorised Gas Tester will sign
to signify that all gas tests made are within specified limits.
Subsequent gas tests may be required at intervals after the initial gas tests.
The applicable signatory will identify any additional requirements related to the frequency
of the gas tests. The results of these tests are also recorded on the WCC or
Entry Certificate.
Gas tests where specified, must be repeated at the time of WCC revalidation and when
the site is reoccupied after a major work break.
Where gas testing is required by the work permit, the test may be carried out by the
Performing Authority subject to the discretion of the Area Authority, and provided that
the Performing Authority is an Authorised Gas Tester of the required standard.
In some cases, the spark potential component of a task may not commence until some
time after the initial issue of the permit. In such cases, the Area Authority may choose
one of the following three options:
• Add a condition to the permit requiring a gas test prior to commencement or
recommencement of spark potential work
• Separate the components of the task into cold work and spark potential work, and
issue two permits accordingly
• If the Performing Authority is a Level 2 Authorised Gas Tester, a condition can be
added to the permit requiring the Performing Authority to carry out their own gas test
prior to commencement or recommencement of spark potential work
Note: The above does not apply to naked flame work, where a gas test shall always be
carried out immediately prior to issue of the permit.
The Area Authority has discretion to issue a spark potential permit without a gas test.
Normally this will be done in non-hazardous areas such as the accommodation module or
pressurised switchrooms.

7.5 Continuous Gas Monitoring

The normal requirement following the initial gas test will be monitoring during the
work activity.
These tests are additional to the requirements for initial, revalidation and subsequent gas
tests involving an Authorised Gas Tester.
Where continuous monitoring is required, this shall be carried out using a portable or
personal gas detector positioned adjacent to the job.
These detectors will normally be left with the person in charge of the worksite, who may
appoint a competent person to continuously check the gas detector readings during
the work.
7.6 Practical Gas Testing

The area for gas testing must be as wide as is necessary to identify any possible
hydrocarbons or other process gases that may be present. Take as many readings from
as many places as possible until confidence is achieved that the samples taken are truly
representative of the whole area. When evaluating the conditions for gas testing the
Authorised Gas Tester needs to be aware of the hazardous area conditions, which may
prevail during normal operations.
Guidance for practical training for Authorised Gas Testers can be found in Addendum 2.
An aide-memoir for confined space entry gas testing can be found in Addendum 3.
The Authorised Gas Tester should also be aware of the effects caused by the following:
• Open doors to the module
• Temperature/heat barriers at roof level
• Stagnant or flowing air patterns around the worksite
• Movement of sands or sludge which may contain trapped pockets of gas
In any area containing a potential source of release, fixed and portable detectors should,
as a minimum, monitor work locations that are detailed on the work permit.
The Authorised Gas Tester should also consider testing the following areas:
• In spaces near walls and large vessels
• In spaces where circulating air currents can pick up gas
• Close to potential sources of gas release for example, near vessels, hydrocarbon
systems, voids and vents
• At the end of exhausts, in flues and service ducts
• Near drains and liquid surfaces
• Where air movements may be negligible and gas could collect in clouds, for example
in very congested areas
January 2005 Issue 1/AM04 19

7.7 Air Movement

In any process module there may be stagnant areas of little or no air movement and
the Authorised Gas Tester should be aware that build up of gas in these areas
may be possible.
When carrying out gas testing, the Authorised Gas Tester should commence tests
upwind of the work area to a minimum radius of 5m from the worksite, working in
towards the risk spot and around all potential sources of release.
This test pattern will account for air movements around the area caused by a Heating,
Ventilation and Air Conditioning (HVAC) system, any prevailing wind etc. A thorough gas
test of the complete area will involve testing above head height and at floor level to give
the best possible chance of detecting gases with different relative densities.
7.8 Evaluation
Awareness of the hazardous area conditions which may prevail during normal operations
assists the Authorised Gas Tester in pre-test site evaluation.
The Authorised Gas Tester should also be aware of the effects caused by:
• Open doors to modules
• Temperature/heat barriers at roof level
• Stagnant or flowing air patterns around the worksite
7.9 HVAC Flowpaths

Openings from modules may provide differing air patterns from the HVAC flowpaths and
may give the impression of positive pressure within a module.
The Authorised Gas Tester must be aware of air movement around the area of any
potential gas hazard and ensure worksite precautions specified and implemented
address potential gas hazards.
Within roof void areas and at roof level, a heat barrier is created which can prevent
migration of gas or vapours to the fixed gas detectors at that level.
The Authorised Gas Tester should also be aware that no alarm signals from these
detectors does not necessarily indicate a no gas situation.
If the HVAC system is operating correctly, detectors at roof level may not reach alarm
situation due to dilution and dispersion of any release gas plumes.

7.10 Main Points of Gas Testing

The main points of gas testing are as follows:
• Test area – 5m radius around worksite
• Commence upwind of worksite
• Take nothing for granted
• If in doubt restart test
• Identify potential hazards within the area and inform the applicable signatory of
these hazards
• Never sign the authorised paperwork until you are 100% certain of full compliance
with work permit requirements
• Always look, listen, advise and report
• Where any indication of gas is detected, do not assume it is harmless just because it
is within the acceptable limit, check further
• Consider other operations in the area, especially any involving entry into a confined
space
7.11 Investigating Leaks

When investigating a known leak or breaching a hydrocarbon envelope, a monitor should
be used to monitor the breathable atmosphere (ie not the atmosphere around the leak
itself). This should be an ongoing process.
If a hydrocarbon leak is observed, do not intervene unless a gas monitor is available to
test the atmosphere, ie if necessary evacuate the site and return with a gas monitor(s).
In any situation, if levels of hydrocarbons in the atmosphere reach 10% LEL, evacuate to
a safe area to assess risks.
8 Case Studies
8.1 The Wrong Way to do it
A tank that had contained light hydrocarbons was to be worked on. It had not been
properly cleaned before work started. It had been filled with water and then emptied.
Some hydrocarbons remained in the crevices. The result was as follows:
• No tests were made for combustible gas
• A Welder working near the vent accidentally ignited the vapour
• Six people were killed and 29 injured
The correct procedures for tank cleaning were not in place or had not been followed.
The Permit to Work Procedure should have initiated gas testing before welding started.
Continuous gas monitoring should have occurred around the tank outlets (vents).
This accident was totally avoidable.
January 2005 Issue 1/AM04 21

8.2 The Right Way to do it

An old gas line had been out of use for 12 years. It had to be modified for reuse. For the
previous 2 years it had been blanked at one end and open at the other. A flange was
welded on the open end without incident.
The next job was to fit a 1 in branch 60m from the open end. A hole was drilled in the
pipe and a gas test proved negative.
A few hours later, immediately before welding, a repeat gas check indicated the
presence of flammable gas. It is believed that the gas was in the pipe for 12 years and
started migrating when the hot work caused a rise in temperature.
It may seem reasonable to assume that a line, redundant for 12 years, would not require
a gas test. Fortunately the people involved here took a different view.
They followed a procedure applying to all pipes. They assumed nothing – hence the
repeat gas test after the delay.
Note: You should also be aware of other risks, which may be present. For instance you
should be aware of Low Specific Activity (LSA) scale and/or pyrophoric scale in
susceptible areas.
REMEMBER: NEVER MAKE ASSUMPTIONS – ALWAYS CHECK IF IN DOUBT –
THEN CHECK AGAIN.

Addendum 1
Glossary
Gas A fluid substance, which is neither a solid nor a liquid at ordinary temperatures,
and has the tendency to disperse when not contained.
Liquid Any substance with the tendency to flow which is neither a gas nor a solid.
Vapour Gaseous form of a normally liquid or solid substance (above boiling point).
Glossary
September 2001 Issue 1 Add 1-1/2
Addendum 2
Guidance for Trainers who are Providing
Practical Training Following Completion
of the CBT Package for Gas Testing
Level 1 or Level 2
Paragraph Page
1 Introduction 1
2 Classroom Training 1
2.1 Gas Testing – Levels 1 and 2 1
2.2 Interpretation of Readings – Levels 1 and 2 2
2.3 Interpretation of Readings – Level 1 Only 2
2.4 Other Contaminants – Level 1 Only 2
2.5 General 2
3 Site Training – Level 2 3
4 Site Training – Level 1 3
Guidance for Trainers who are Providing Practical Training

August 2003 Issue 1/AM02 Add 2-i/ii
1 Introduction
The following is a list of points that should be covered during practical gas testing
training. This assumes that the candidate has successfully completed the Level 1 or
Level 2 Computer-based Training (CBT) package.
Training should be provided by someone who has a sound level of experience with
Level 1 and Level 2 gas testing, and who in the opinion of the Offshore Installation
Manager (OIM) or Site Controller is competent to do so.
The level of experience of Gas Testers should suit the type of testing that they are
required to undertake and it should be recognised that some gas tests are more complex
than others. For example, it is advised that someone with no previous experience of gas
testing who has just finished the Level 1 CBT package and practical training, should not
be expected to conduct unsupervised a difficult gas test such as the initial entry into a
separator vessel.
Refresher training shall be carried out at 2-year intervals. This will include both CBT and
practical training. At their discretion, OIMs or Site Controllers may allow experienced gas
testers who have exceeded the 2-year period to continue to carry out gas testing
pending refresher training.
2 Classroom Training
Enquire if there are any questions following completion of the CBT.
2.1 Gas Testing – Levels 1 and 2

• Review of type(s) of meters in use at the site
• Battery checks and duration between recharging
• Checking of general condition of meter, looking for damage, fouling of sample
ports etc
• Check of calibration date
• Meter should be checked for zero in fresh air before going to do gas test
• Correct method of fitting aspirator
• Checking aspirator for leaks
• Checking of internal pump (if fitted)
• Required number of aspirations per ft of tube (generally 1 per ft) for manual aspirators
• Awareness that meter will not detect anything if aspirator fitted unless pumping
• Use of meter as sentry monitor without aspirator fitted
• Extension probes and their use

January 2005 Issue 1/AM04 Add 2-1
2.2 Interpretation of Readings – Levels 1 and 2

• Difference between Lower Explosive Limit (LEL) and percentage by volume
• Under most circumstances, the only acceptable LEL reading before commencing
naked flame or spark potential work is zero
• Alarm settings
• Awareness of time lag between inspiring sample and indication showing on meter
• H2S and its effects at various concentrations
• Reminder that the acceptable H2S long-term, maximum exposure limit for an 8-hour
shift is now 5ppm, long-term, maximum exposure limit recently changed from 10ppm
• Under most circumstances, the only acceptable H2S reading before commencing
naked flame or spark potential work is zero
• Reminder that the nose is very much more sensitive to H2S than the typical gas
meter, therefore you may smell H2S although there is nothing registering on the
meter. Also that H2S may deaden the sense of smell
• Reminder that H2S is heavier than air and may collect in low points
2.3 Interpretation of Readings – Level 1 Only

• Oxygen level should be 20.9% before commencing vessel entry
• Review of physiological effects of high or low oxygen levels
• Implications of high oxygen levels, spontaneous combustion
• Review of factors that can affect oxygen levels:
- Corrosion leading to oxygen deficiency
- Damage to welder's oxygen hose leading to high oxygen
- Inadequate ventilation following nitrogen purging
- The presence of hydrocarbons or other containments
2.4 Other Contaminants – Level 1 Only

Discuss other toxins that may be encountered onsite during confined space entry,
eg chemical fumes, dusts. Discuss means of sampling, eg Draeger tubes or similar.
2.5 General
• Risks from pipework systems during naked flame works, checking of positive
isolations
• Possibility of vapours being released as a result of heat from naked flame work

Add 2-2 August 2003 Issue 1/AM02
3 Site Training – Level 2

Site training should, where possible, include testing at several locations where naked
flame or spark potential work is likely to be carried out. The training should be in an area
where the candidate is likely to conduct gas tests in the future, eg drilling areas for
drilling personnel, production areas for process personnel etc.
The candidate should conduct testing in these areas and would be expected to
demonstrate:
• Testing drains and the risk of sucking liquid into the aspirator
• Awareness/testing of atmospheric vents
• Consideration of wind speed and direction
• Migration of gas under insulation
• Weepage from control valve glands – a small amount is acceptable
• Testing of void spaces
• Consideration of areas above, below and adjacent to the worksite, and testing in
these areas where appropriate
• Suitable location for sentry gas monitors during the proposed work, taking wind
direction and location of biggest hazards into account
• Local hazards or conditions that are specific to your site
• Consideration of things that might change, eg wind, adjacent work, plant conditions
such as Emergency Shutdown (ESD) or blowdown
• Consideration of the nature of the work to be carried out
It must be emphasised throughout that conducting a gas test involves more than simply
looking at a meter. The Gas Tester is an additional set of eyes and ears (and a nose) to
help the Area Authority to control work. Gas Testers should view the proposed worksite
as a whole, and consider a wide range of hazards, in particular plant conditions or other
activities that may give rise to gas in the area at a later time.
4 Site Training – Level 1

Level 1 site training should, if possible, include a visit to a vessel or confined space that
is available for entry, and the training should involve conducting a gas test appropriate to
the task.
Level 1 Authorised Gas Testers must also be trained in the use of self-contained
breathing apparatus.
The responsibility for control of vessel entry rests with the Area Authority. However, the
Authorised Gas Tester can provide useful assistance and advice beyond simply
presenting a set of readings.

Safe Isolation and Reinstatement of Plant (UKCS-SSW-001) Paragraph 5 provides indepth

detail about the precautions relating to confined space entry. It should be referred to
as part of Level 1 practical assessment and it defines the procedures for confined
space entry.
Addendum 3 lists the precautions and checks that should be carried out during the three
stages of confined space entry: planning for entry, initial entry and subsequent entry.
This Addendum should be used as the basis for Level 1 practical training. Although some
of the areas covered are the responsibility of the Area Authority, it is important that the
Authorised Gas Tester is aware of them and there may be a certain amount of overlap
between their duties.

Add 2-4 August 2003 Issue 1/AM02
Addendum 3
Guidance for Confined Space Entry Gas Testing
Paragraph Page
1 Introduction 1
2 Before Entry 1
3 Initial Entry 2
4 Subsequent Entries 2

August 2003 Issue 1/AM02 Add 3-i/ii
1 Introduction
Safe Isolation and Reinstatement of Plant (UKCS-SSW-001) Paragraph 5 provides indepth
detail about the precautions relating to confined space entry. It should be referred to as
part of Level 1 gas testing practical assessment and for any confined space entry work.
The following is intended as condensed guidance for Authorised Gas Testers, both
during initial training and assessment, and as an aide-memoir for subsequent testing.
2 Before Entry
• Level 2 Risk Assessment – Entry Certificate prepared
• Emergency response/rescue plan in place. This includes provision for rescuing the
Authorised Gas Tester
• The Medic should be advised that the entry is about to take place
• Suitable access provided to reach manway
• Toolbox Talk with those involved in the work
• Lighting available – including a backup torch. Where any risk of residual hydrocarbons
exists, lighting should be rated Zone 0, for further guidance on rating of lighting refer
to Paragraph 5.8 of Safe Isolation and Reinstatement of Plant (UKCS-SSW-001)
• Communications tested
• Air movers in use – where used, an air mover should be in use sucking out from a
point remote from the manway, thus ensuring that the entry attendant is safe from
fumes or mists within the vessel. Air movers should be left on at all times. Sentry gas
testing should be carried out at the exhaust of the air mover duct. Ensure that air
drawn into the vessel comes from a location where contamination cannot take place
• Confirm positive isolations in place
• Confirm isolation of internal equipment eg agitators, paddles, pumps, heaters
• Confirm withdrawal of nucleonic sources
• Standby man fully briefed about his duties, as defined in Safe Isolation and
Reinstatement of Plant (UKCS-SSW-001) Paragraph 5.3.1
• Personal Protective Equipment (PPE) appropriate for the task available
• Consider need to test for pyrophoric scale
• Check security of shoring for excavations
• Confirm that Authorised Gas Tester is competent to use breathing apparatus

3 Initial Entry
• Test the meter using test gas to confirm that it is working okay. Alternatively take a
second meter as backup
• Look around outside of vessel for signs of possible problems inside, eg vessel boots,
nozzles on the bottom of the vessel, thermowells protruding into the vessel
• Look around outside of vessel for things that could give rise to fumes or vapours,
eg drains, vents, adjacent works
• As far as possible the initial test should be carried out from outside the vessel.
The Authorised Gas Tester will wear breathing apparatus for initial entry unless it is
possible to test all parts of the vessel from outside, and if there is no evidence of
sludge or other contaminants that may give rise to fumes if disturbed
• Harness should be worn, lifeline attached if this can be done without danger of
fouling. For top-entry vessels a retrieval aid should be set up
• Be aware that fixed ladders inside vessel may not be secure
• The mini-monitor or similar meters for Low Specific Activity (LSA) are not intrinsically
safe and should under no circumstances ever be taken near a vessel that has been
opened up for inspection. A sample of sludge or scale may be taken from the vessel
to an area remote from the vessel for LSA testing
• Test as much as possible from outwith the vessel using extension probes
• Test all parts of the vessel, including behind baffles, low points, sumps etc
• Note any hazards that may be recorded on the entry certificate for the benefit of
subsequent entrants, eg slip/trip hazards, access problems, obstacles, depth of
sludge
Although Safe Isolation and Reinstatement of Plant (UKCS-SSW-001) Table 2 defines
acceptable limits for entry, it must be emphasised that entry into a vessel containing
anything other than 20.9% oxygen and zero flammable and H2S should be the subject of
serious assessment. These limits should be regarded as maximums and can only be
tolerated where there is no practicable means of reducing the levels further.
Entry will continue to be under breathing apparatus until all traces of contaminant,
sludge etc have been removed from the vessel.
4 Subsequent Entries
Retest at minimum 12-hourly intervals. If entry without breathing apparatus has been
continuous during this time, then breathing apparatus need not be worn for the retest.
However, if there has been a break in the entry, then breathing apparatus should be
worn for the retest.
Review the rescue plan if the nature of the work or the configuration of vessel internals
change.

Add 3-2 January 2005 Issue 1/AM04
Addendum 4
Terms of Reference and Audit Protocol
Paragraph Page
1 Terms of Reference 1
1.1 Context 1
1.2 Objectives 1
2 Audit Protocol 2

January 2005 Issue 1/AM04 Add 4-i/ii
1 Terms of Reference
It is proposed to conduct an internal assurance audit of the implementation and
compliance of the Regional Safety Management System (SMS) for this document.
Findings from this audit will be communicated to the Offshore Installation Manager
(OIM), Terminal Manager or equivalent.
1.1 Context
The Regional SMS was developed to standardise Health, Safety and Environment (HSE)
processes and procedures across all of UK Exploration and Production assets.
The requirement for local assurance audits of local implementation and compliance with
Strategic Performance Unit (SPU) regional SMS is defined in Procedure for Assessment
Assurance and Improvement (UKCS-AL-001). These requirements in turn are designed to
meet the specific requirement set in GHSER Expectation 13.10.
The frequency of these audits will be determined by the audit programme developed by
the PU or function as laid out in UKCS-AL-001.
The attached protocol will be used as the minimum standard, however this may be
added to as deemed suitable by the PU, function or Site.
1.2 Objectives
• To ensure that the procedures laid out in this document are embedded and
understood at the location, by the appropriate people
• To ensure that the procedures laid out in this document are followed at the site
• Ensure Level 4 documents are aligned with the Regional SMS
• Provide assurance to site/PU management that this document is correctly gap
analysed and implemented
• Provide assurance on the quality of this protocol for self-assessment of the
effectiveness of processes and procedures to meet the requirements of the
document

2
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Gas Testing Procedures
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UKCS-SSW-004
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Gas Testing Procedures UKCS-SSW-004

Authorisation for Issue

3 Toxic Gases and Vapours 6

July 2004 Issue 1/AM03 i

5 Confined Space Entry 11

6 Portable Gas Detection Equipment 13

7 Gas Testing Procedures 17

ii July 2004 Issue 1/AM03

January 2005 Issue 1/AM04 iii/iv

Authorisation for Issue

Position: Offshore Operations Engineer, Magnus

August 2003 Issue 1/AM02 v/vi

For Audit Use

September 2001 Issue 1 vii/viii

Issue No Date Description

Issue 1 September 2001 First issue.

January 2005 Issue 1/AM04 ix/x

Holders of Controlled Hard Copy

Copy Copyholder Location

01 Data Control Centre (DCC) ODL, Aberdeen

01 Document Technical Authority

July 2004 Issue 1/AM03 xi/xii

Gas Testing Levels of Competency

Review and Update

September 2001 Issue 1 xiii

xiv September 2001 Issue 1

1.1 What is Gas Testing?

1.2 Why is Gas Testing Carried Out?

1.3 Who Carries Out Gas Testing?

March 2002 Issue 1/AM01 1

1.4 When is Gas Testing Carried Out?

2 September 2001 Issue 1

2.1.3 Ignition Source/Heat

September 2001 Issue 1 3

2.2 Explosive Range

2.2.1 Lower Explosive Limit

= TOO LEAN TO SUPPORT COMBUSTION

= WILL SUPPORT COMBUSTION

= TOO RICH TO SUPPORT COMBUSTION UKCSSSW004.001

2.2.2 Upper Explosive Limit

0% 100% LEL UEL

= TOO LEAN TO SUPPORT COMBUSTION

= WILL SUPPORT COMBUSTION

= TOO RICH TO SUPPORT COMBUSTION UKCSSSW004.002

4 September 2001 Issue 1

2.3 Common Gases

ACETYLENE 2.4% 88.0%

BUTANE 1.5% 8.5%

ETHANE 3.0% 15.5%

ETHYLENE 2.7% 34.0%

HYDROGEN 4.0% 75.6%

METHANE 5.0% 15.0%

PROPANE 2.0% 9.5%

PROPYLENE 2.0% 11.0%

= TOO LEAN TO SUPPORT COMBUSTION

= WILL SUPPORT COMBUSTION

= TOO RICH TO SUPPORT COMBUSTION UKCSSSW004.003

2.5 Narcotic Effects of Hydrocarbon Vapours

July 2004 Issue 1/AM03 5

Corresponds to approx 50%

Hyper-excitation, loss 60%

3 Toxic Gases and Vapours

6 July 2004 Issue 1/AM03

3.2 Measuring Toxic Gases