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Gas Testing Procedures PDF
Gas Testing Procedures PDF
Contents
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
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
Contents (cont’d)
Paragraph Page
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
Technical Authority
Name: Alan Lindsay
Signature: _______________________________________________
Date: _______________________________________________
Amendment Record
AMOSAF.171
Amendment Summary
Distribution List
Virtual Copyholders
Copy Copyholder
Preface
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.
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).
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.
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
2.1.1 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
METHANE 5%
METHANE 5% 15%
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.
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
80%
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.
3.1 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.
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
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.
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.
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.
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.
7.8 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
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.
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
Gas Testing Procedures UKCS-SSW-004
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
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.
2.5 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
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
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.
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
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
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Terms of Reference and Audit Protocol