Portable Gas Detector Procedure

HSE-SAF-PRO-00-0008
SAFETY
Rev. 6
PORTABLE GAS DETECTOR 26-Apr-2016

PROCEDURE Page 1 of 24
TABLE OF CONTENTS
1. INTRODUCTION........................................................................................................... 2
2. SCOPE & PURPOSE ................................................................................................... 2
3. DEFINITIONS ............................................................................................................... 2
4. PROCEDURE ............................................................................................................... 3
5. RESPONSIBILITIES ................................................................................................... 13
6. REFERENCES............................................................................................................ 14
7. ATTACHMENTS ......................................................................................................... 14
8. APPENDICES ............................................................................................................. 14
9. REVISION HISTORY .................................................................................................. 24
LIFE-CRITICAL PROCEDURE
Always conduct accurate gas detection as required.
Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

Lloyd G Askham
Chintan R Dalal
Moustafa S El-
Hamad
Carl Poldrack
 Added Q-Chem experience on cross Rajagopal S
Roehl Bartolome
sensitivity to gases (4.6, (ix)) Kumar
Saleh Abdulla
 Changed procedure review frequency from Boppana Saibabu
Syed N Shah
two years to the three years. ( 4.12) Yerramilli
6 26-Apr-16 Amit Parikh Abdulla S Al-
Namgala
 Added bump station location in Appendix D. Robin T Ulrich
Khulaifi
 Revised sensor cross interference table Dirk Perrin
Zakarya Y Al-
(Appendix B). Abdulla S Al-
Shareef
Zoubi
Mohammed H Al-
Amayreh
Ibrahim Al-
Hashemi
Next Scheduled Periodic Review: April/2019
HSE-SAF-PRO-00-0008 Page 1 of 24
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

1. INTRODUCTION
This document provides instructions on the procurement, routine care, use, maintenance and
calibration of portable gas detectors.
Portable direct reading gas detectors are an important tool used daily throughout the Plant to
detect and monitor atmospheres for safe work. The concentration of gases or vapors can be
measured by direct reading instruments, which perform both sampling and measurement.
2. SCOPE & PURPOSE
This procedure is applicable to the use of any portable multi-gas detection instruments within
Company. Company in this procedure refers to Q-Chem, Q-Chem II and RLOC facilities.
The purpose of this procedure is to establish and communicate the system that addresses the
management (procurement, routine care, use, maintenance and calibration) of portable gas
detectors.
3. DEFINITIONS
 Authorized Gas Tester: A Q-Chem employee (Direct Hire or Secondee) who has
successfully completed the Q-Chem Gas Detection and Monitoring training and is certified by
the Training Department.
 Bump Gas: A controlled mixture of gas for the purpose of instantaneously checking the
accuracy of sensors of a portable direct reading gas detector.
 Bump Station: A facility on site where a gas detector can be bump tested.
 Bump Test: A verification test of the gas detectors calibration using a test gas of known
concentration to “bump” the sensors into alarm states.
 Calibration: The adjustment of the gas detectors reading to coincide with a known
concentration (generally a certified standard) of test gas.
 Continuous Gas Monitoring: Gas testing conducted continuously at the location where the
task is in progress.
 Dilution Tube: A specialized device/accessory attached to the inlet port of a multi-gas
meter fitted with a catalytic diffusion sensor to allow the instrument to accurately detect
combustible gas concentrations in atmospheres containing less than 10% oxygen by volume.
 Explosive Limit (also known as Flammable Limit): The range of concentrations of
flammable vapor-in-air (gas-in-air), between the lower explosive limit (LEL) and the upper
explosive limit (UEL) that will propagate flame if ignited.
 Gas Test: A atmospheric test using a direct reading instrument to detect the concentration of
target gases in the atmosphere.
 Hazardous Atmosphere: A atmosphere where:
 Oxygen concentration is below 19.5% or greater than 23.5%, and/or
 Flammable gases are present in excess of 10% LEL ,and/or
 Toxic gases are present in excess of their occupational exposure limits (OSHA’s PEL or
ACGIH’s TLV).
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NOTE 1
This shall be determined without the use of mechanical or forced
ventilation.
 Immediately Dangerous to Life or Health (IDLH): An atmosphere that poses an immediate

threat to life, would cause irreversible adverse health effects, or would impair an individual’s
ability to escape from a hazardous atmosphere.
 Lower Explosive Limit (LEL): The minimum concentration (expressed as a volume
percentage) of a vapor-in-air mixture below which propagation of flame does not occur on
contact with an ignition source; generally considered to be “too lean to burn.”
 Multi-Gas Detector: A portable, direct reading gas detector that uses multiple sensors for
the detection of different gases.
 Occupational Exposure Limit (OEL): The maximum concentration of an air contaminant to
which a person can be safely exposed continuously over an eight hour period (over a normal
work life) without significant adverse health effects.
 Personal Gas Detector (e.g. H2S & SO2 detector): A generic reference to a small personal
badge type “clip-on” detector with an electrochemical sensor that alerts the wearer to the
presence of gas.
 Upper Explosive Limit (UEL): The maximum concentration (expressed as a volume
percentage) of a vapor-in-air above which propagation of flame does not occur upon contact
with an ignition source; generally considered “too rich to burn.”
 Zero Adjustment (Fresh Air Adjustment): Made by taking the instrument to a location that
does not contain combustible gases and drawing fresh air through the sensors to zero the
readings.
4. PROCEDURE
4.1. General Requirements

i. The Safety Section shall approve all portable gas detection equipment and accessories
used on site.
ii. Each production unit or end-user is responsible for:
a) Maintaining a minimum number of portable gas detectors based on self-assessed
needs.
b) Reporting any issues and concerns with these detectors to the safety section.
c) Keeping gas detectors in a state of readiness (e.g. charged, clean, calibrated and in
good repair).
d) Keeping gas detectors in a location that provides easy, safe access.
e) Keeping an accurate inventory of gas detectors in their care.
4.2. Types of Portable Gas Detectors
i. The Safety Section shall maintain a list of all approved gas detectors used on site.
ii. The Safety Section shall review the gas detector requirements every three years to
evaluate new products on the market as a means of ensuring Q-Chem personnel have
access to the latest technology best suited for the Company.
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a) Results from the review shall be published on the Safety Webpage.
4.3. Issuing of Portable Gas Detectors
i. Gas detectors and the necessary accessories are available as a stock item in the
Material Warehouse.
a) The end-user shall have access to the following accessories:

 Detector carry case,
 Dust Filter/Water Stop,
 Dilution tube,
 Extension sampling tube,
 Telescopic sampling probe.
b) Spares necessary for the maintenance and calibration of detectors shall only be
issued to the Fire & Gas group.
ii. Gas Detectors shall be issued to the end-user from the Materials Warehouse.
a) The end-user shall forward the detector along with a copy of the issuing document
to the Fire & Gas Group for registration, configuration and record keeping.
b) The issuing document shall include the detector manufacturer, serial number, the
receiving department and user information.
c) The Fire & Gas Group shall affix a unique serial number (indicating the owner’s
unit) to the instrument.
4.4. Instrument Configuration & Setup
i. Portable, multi-gas detectors used on the Q-Chem sites shall be configured by the Fire &
Gas group as follows (where applicable):
Instrument Alarm Settings

Gas Name Instant Hygiene
Low High TWA STEL
Oxygen (O2) 19.5% 23.5% N/A N/A
Combustibles (LEL) 10% 20% N/A N/A
Carbon Monoxide (CO) 25ppm 50ppm 25ppm 200ppm
Hydrogen Sulfide (H2S) 10ppm 20ppm 1ppm 5ppm
Sulfur Dioxide (SO2) 2ppm 4ppm 2ppm 5ppm
*Photo Ionisation Detector (PID) 100ppm 200ppm N/A N/A
(* This is applicable to RLOC only)
4.5. Operating Portable Gas Detectors

i. The Authorised Gas Tester shall ensure the portable gas detector is in proper working
condition before use.
a) User shall ensure meter passes self-check on start-up.
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 This shall be conducted in a “clean” atmosphere away from the potentially

hazardous atmosphere to be tested.
b) The calibration date shall be verified to ensure it’s still valid during instrument start-
up.
 Instruments out of calibration shall not be used until re-calibrated.
 See Section 4.8 for Calibration Details
c) Battery status shall be verified.
d) Zero the instrument.
e) The gas detector shall be bump tested at least once in a shift prior to use.
 Mesaieed Bump Testing Procedure (Refer to Appendix E)
 Ras Laffan Bump Testing Procedure (Refer to Appendix F)
f) Clear all peaks.
4.6. General Sampling Requirements
i. The maximum allowed sampling distance of gas detectors fitted with sampling pumps is
100 feet (30 meters).
a) This shall be achieved using either 1/8” or 3/16” urethane tubing only.
ii. The “2x2” sampling rule shall be followed when sampling:
a) 2 seconds sampling per foot of tubing used.
b) 2 minutes minimum sample time per location.
Example: 20 feet of tubing sample draw time would be 2 minutes and 40 seconds.
iii. For confined space sampling, sampling shall be conducted at the top, middle and bottom
of the space/vessel.
a) OSHA recommends 4 foot (1.2 meter) sampling intervals at a minimum.
iv. Any purging and venting (using mechanical ventilation) shall be stopped for at least 10
minutes prior to conducting gas testing.
a) Exception may be granted if slight purging is required to maintain a slight positive

pressure.
b) The Authorized Gas Tester may increase the stoppage time if necessary for larger
vessels or equipment.
v. Do not use gas detectors for measuring flammable gases in an atmosphere with steam.
vi. In locations of low oxygen atmospheres (less than 10% by volume), a dilution tube shall
be attached to the gas detector to obtain a more accurate reading for combustible gases.
a) The dilution tube shall be inserted into the sampling tube at the detector inlet.
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b) The dilution tube shall be inserted into the tubing with the directional arrow on the
tube pointing towards the detector.
 Installation of the dilution tube in the reverse direction shall cause erroneous
low readings.
c) The tube will draw a 1:1 ratio of ambient oxygen with the gas sample being drawn.
d) The action of the dilution tube will elevate the oxygen readings to a level suitable for
accurate combustible gas monitoring.
vii. The following criteria shall be adhered to when using dilution tubes:
a) Use to sample in atmospheres of less than 10% oxygen by volume.
b) Ambient oxygen readings must be between 20-23.5% by volume.
c) Sampling from a vessel/pipe containing a gas mixture exceeding 200% LEL may
damage the LEL sensor.
d) Instrument readings will be approximately equal to one half of all gas

concentrations being sampled.
 Displayed readings shall be multiplied by two (2) to obtain actual

concentrations.
e) Maximum sampling tube length of 10 feet (3 meters) can be used.
f) The area being sampled MUST be at atmospheric pressure:
 Do not use the dilution tube for sampling of positive pressure lines. Operation of
the dilution tube in this manner causes an imbalance in the 1:1 ratio thus
causing readings to be inaccurate.
 Sampling from a negative pressure area will produce a lower than actual
reading.
 Sampling from a positive pressure area will produce a higher than actual
reading.
g) Allow three (3) minutes before reading the concentration.
h) Avoid drawing oil, dust or steam into the dilution tube.
i) Do not clean the air intake hole or sample hole with wire or drill bits that may
enlarge the diameter of the holes.
j) Store the dilution tube in a sealed, clean and dust-free container when not in use.
viii. Some examples showing the use and effects of dilution tubes on gas detector readings:
Example 1: A 15% LEL reading on the meter display would actually be 30%.
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Example 2: A 10.5% Oxygen reading on the meter display would actually be 0% oxygen
(the 10.5% reading being due to the fresh air draw from the dilution tube).
ix. Electrochemical sensors, like many other sensors, are known to have cross-sensitivity to
gases other than its target gas. Depending on the nature of the reaction in the sensor,
the gas can either decrease the signal (negative cross-sensitivity) or increase the signal
(positive cross-sensitivity). The following sensor in Q-Chem experience cross
interference:
a) The Carbon Monoxide (CO) sensors on the portable multi-gas detectors experience
cross-interference from other substances, mainly Hydrogen and Ethylene gas. To
address cross-interferences from Hydrogen, the gas detectors have been fitted with
a hydrogen nullifying CO sensor that will reject the cross-interfering hydrogen gas
and yield a more accurate carbon monoxide reading. There is still however cross-
interference on the CO sensor to Ethylene. Refer to Appendix B for details.
4.7. Gas Detection Techniques
The items below describe the most common gas testing scenarios that may be
encountered on the Q-Chem facilities.
4.7.1. Confined Space Entry
i. Any purging and venting (using mechanical ventilation) shall be stopped for at least
10 minutes prior to conducting gas testing.
ii. Gas testing shall be conducted at the following intervals / frequencies for all confined
space entry jobs:
a) Prior to entry,
b) Prior to re-entry, and
c) Continuously.
iii. Initial gas testing shall be conducted from outside the vessel through an appropriate
opening, e.g. manway or hatch.
iv. Physical entry into the vessel/confined space is prohibited when performing the initial
gas testing of the atmosphere.
a) A sampling tube or telescopic probe of sufficient length shall be used to draw
the sample from the working space.
 A suitable opening such as a manway or hatch shall be used to insert the
tube or probe.
v. The atmosphere shall be sampled at selected points representing the entire vapor
space as the atmosphere may not be homogenous (e.g. release of fumes from sludge
or layering of inert gases).
a) Sampling shall be conducted at the top, middle and bottom of the space/vessel.
b) Adhere to OSHA’s 4 foot (1.2 meter) sampling intervals at a minimum.
c) Do not exceed the 100 foot (30 meter) sampling distance.
d) See Appendix A for a schematic diagram showing testing protocol.
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vi. When testing the confined space for atmospheric hazards, the hazardous atmosphere
shall be evaluated in the following order:
a) Oxygen content (%v/v)
b) Combustible gases and vapors (% LEL)
c) Toxic gases and vapors (ppm)
vii. Continuous gas testing shall be conducted within the vessel/confined space for all
confined space jobs.
a) Gas testing shall be at the locations where the work is conducted or occupants
are stationed.
4.7.2. Permit to Work (Other Than Confined Space)
i. Gas testing for flammables and toxics shall be conducted at the following positions:
a) Directly at potential source of ignition/area where work will be done.
b) Within a minimum radius of 15 meters (horizontal distance) from the potential
source of ignition/work area.
 This includes both inside and outside the firebox where open-flame hot work
is conducted.
 Within a minimum radius of 2 meters (vertical distance) from the potential
source of ignition/work area.
 See picture below for graphical representation.
ii. The Permit Issuer and Lead Worker shall ensure continuous monitoring for all Hot
Work Permits.
a) Monitoring shall be conducted at and around the closest position to the source
of ignition/work.
iii. The Permit Issuer and Lead Worker shall discuss and agree upon the monitoring
frequency of the gas testing requirements for General Work Permits.
NOTE 2
The 15 meter radius requirement is only applicable when conditions
within the test environment are normal/under control. No work shall
be authorized irrespective of gas monitoring results during periods
where workplace conditions are uncontrollable; e.g. when the
surrounding/ adjacent workplace atmosphere is over-range etc. In
such circumstances, special mitigation plans shall be required to
address work in these conditions.
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SAFETY
Rev. 6

2m vertical
gas testing
radius
15m horizontal gas

Potential ignition testing radius
source / work area
4.7.3. Process Equipment and Piping

i. Gas testing could be required for any of the following conditions / activities:
a) Blinding/De-blinding of equipment.
b) Opening of Equipment/Line Breaking.
c) Welding/Cutting of equipment/piping (containing or previously containing
hydrocarbons or inert gases).
ii. The internal atmosphere of the equipment shall be checked for flammables and toxic
gases.
a) Testing shall be conducted within the internal space wherever practicable.
b) See Figures 1 and 2 below for a graphical representation of testing scenarios/
positions.
iii. Continuous monitoring of the internal atmosphere is required due to the potential of a
rapid / sudden change of conditions.
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Flange cracked open slightly

to allow gas testing within
the internal space.
Figure 1: Diagram showing possible gas testing location on flange

iv. The atmosphere inside any container previously containing flammables, regardless of
size, shall be tested before authorizing any hot work involving grinding, cutting, or
welding on the outside surface and the atmosphere shall be continuously monitored
during the work.
a) Welding to the outside surface of a tank or container generates heat and sparks
near the weld area. The extreme temperatures and sparks will likely ignite
flammable materials present inside the equipment.
Gas testing of internal space

through open bleeder.
Figure 2: Diagram showing gas testing within piping from bleeder
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4.7.4. Leak Detection/Testing Unknown Atmospheres

i. Self-Contained Breathing Apparatus (SCBA) or supplied airline shall be worn while
searching for leaks/testing unknown atmospheres until the leak source/atmosphere is
verified using the direct reading instrument.
a) After the concentration is known, refer to the Respirator Selection Table (HSE-
SAF-TBL-00-0001) for choosing the appropriate respiratory protection to
conduct work.
ii. When checking for leaks, gas testing shall begin 10 – 15 meters downwind using the
gas detector to sample the perimeter atmosphere while slowly moving toward the
suspected source.
a) Do not proceed directly to the suspected source and begin gas testing.
4.7.5. Vehicle Entry Into Process Areas
i. Continuous gas monitoring shall be required for all vehicle entries into restricted
process areas. A portable multi-gas detector shall be used for such monitoring.
ii. Initial gas monitoring shall be conducted within a 10-15 meter radius of a stationary
vehicle while the engine is running, e.g. crane.
a) Once initial monitoring is completed; the gas monitor shall be mounted at the
vehicle in a suitable location to allow accurate and representative gas
monitoring.
iii. For moving vehicles; the gas detector shall be mounted in a position on the vehicle
that allows both accurate measurement and viewing of the detector by the equipment
operator.
4.8. Repair and Calibration
i. All portable, multi-gas detectors shall be calibrated at 30-day intervals.
a) Gas detectors can be calibrated at any of the authorized docking/calibration
stations by following the calibration procedure.
b) Gas detectors that fail the calibration test shall be handed over to the Fire and
Gas group for follow-up.
ii. Multi-gas detectors shall be calibrated using the following gas components / mixture:
Components Concentration
Pentane Gas (LEL) 25% LEL (0.35% vol.)
Carbon Monoxide (CO) 100 ppm
Hydrogen Sulfide (H2S) 25 ppm
Oxygen 18.0%
Sulfur Dioxide (SO2) 20 ppm
Nitrogen Balance
iii. Only the Fire & Gas group is authorized to carry out or attempt a repair on a portable gas
detector; including battery replacement.
a) Batteries that do not hold a charge shall be taken to the warehouse issue desk and
exchanged for new ones by the Fire & Gas group.
 Returned batteries shall be stored in a container dedicated for spent batteries in
the material warehouse.
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 The Environmental group shall arrange for battery disposal.

iv. Gas detectors shall be handed over/dropped off at the Fire & Gas section by the user for
any maintenance/repair.
a) The end user shall ensure that a tag is fixed to the detector with the following
information prior to handing over:
 Contact name
 Unit/Area identification
 Brief description of the problem.
b) The user shall also complete the entries in the logbook kept in the Fire & Gas
office.
v. The Fire & Gas group shall notify the end-user when instruments are ready for pick-up.
4.9. Personal Gas Detectors
i. Refer to Personal Gas Monitor Standard (HSE-SAF-STD-00-0045) for details.
4.10. Bump Stations
i. Bump stations are located at strategic locations throughout the Q-Chem facilities:
a) Refer to Appendix D for details.
ii. The Fire & Gas group shall maintain all bump stations.
a) The respective area owners shall report any problem with the bump station to the
Fire & Gas group.
iii. The Instrument & Electrical (Mesaieed) and Fire and Gas (RLOC) groups shall change
the bump gas cylinders when required.
iv. Gas cylinders, regulators and instrument tubing necessary to keep the bump stations
functional shall be maintained as stock item through min/max system.
4.11. Training
i. The Authorized Gas Tester shall complete “Gas Detection and Monitoring” training to
conduct the testing. The training shall include, at a minimum, the following:
a) Instrument features/operations (including hands-on use).
b) Sensor technology, applications and limitations.
c) Detector use and limitations.
d) Function test/bump test (practical).
e) Sampling rules & precautions.
f) Proper care & maintenance.
ii. Classroom-based refresher training shall be required every three (3) years for authorized
gas testers.
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Rev. 6

4.12. Procedure Review

i. This procedure shall be reviewed every three (3) years, with time between reviews not to
exceed 36 months.
ii. A change review team (CRT) comprising of affected stakeholders shall be formed to
conduct the reviews.
iii. The following items shall be addressed during the review process:
a) Records of any incidents or near misses involving gas detection deficiencies.
b) Lesson learned reports from other CPChem affiliate facilities.
c) Any audit findings since the previous review period.
d) Reviews of the “gas detection equipment market” for equipment improvements.
e) Review of the Authorized Gas Tester training program.
4.13. Portable Gas Detector Malfunctions
i. Refer to Appendix G for details.
5. RESPONSIBILITIES
5.1. Safety Department
i. Assists the Training Section in developing or modifying the “Gas Detection and
Monitoring” training package.
ii. Approves the gas detectors for use within Q-Chem.
5.2. Training Section
i. Schedules and conducts Gas Detection and monitoring training.

ii. Certifies and maintains records of all Authorized Gas Testers.
5.3. Fire & Gas Group
i. Configures all multi-gas detectors for use on the Q-Chem sites.

ii. Maintains an accurate database of all portable multi-gas detectors.
iii. Conducts any maintenance and repair of portable multi-gas detectors.
iv. Conduct monthly instrument calibrations if/when required.
v. Maintains the multi-gas detector maintenance contracts with the vendors.
vi. Despatches multi-gas detectors to third party vendors for repair when required.
vii. Maintains the bump stations on site.
viii. Replaces the bump gas cylinders at bump stations (Ras Laffan Only).
ix. Emptied calibration cylinders shall be handed over to Waste Management/Environment
team for the disposable.
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5.4. Instrument & Electrical Group (Maintenance – Mesaieed)
i. Replaces the bump gas cylinders at bump stations.
6. REFERENCES
6.1. Industrial Scientific Gas Detection Training Module – www.indsci.com

6.2. Title 29 of the Code of Federal Regulations, Section 1910.146, Permit-Required Confined
Spaces (OSHA).
6.3. Title 29 of the Code of Federal Regulations, Section 1910.119, Process Safety
Management of Highly Hazardous Chemicals, Sub-Section (k) ‘Hot Work Permits’.
6.4. Q-Chem Permit to Work (PTW) Procedure, HSE-SAF-PRO-00-0006
6.5. Personal Gas Monitor Standard - HSE-SAF-STD-00-0045
6.6. Portable Gas Detection Refresher Training Corse – HSE-SAF-CBT-00-0016
6.7. Authorized Gas Detector - HSE-SAF-PPT-00-0014
7. ATTACHMENTS
7.1. Respirator Selection Table - HSE-SAF-TBL-00-0001

7.2. Occupational Exposure Limits Table (OEL) - HSE-SAF-TBL-00-0002
8. APPENDICES
8.1. Appendix A – Confined Space Entry - Gas Testing Techniques

8.2. Appendix B – Sensor Cross-Interference Table
8.3. Appendix C – LEL Correlation Factors
8.4. Appendix D – Bump Station Locations
8.5. Appendix E – Bump Testing Procedure (Mesaieed)
8.6. Appendix F – Bump Testing Procedure (Ras Laffan)
8.7. Appendix G – Portable Gas Detector Malfunctions
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Rev. 6

Appendix A
CONFINED SPACE ENTRY – GAS TESTING TECHNIQUES
Only a Q-Chem Authorized Gas Tester shall be allowed to test the atmosphere of a confined
space before entry by any person into the confined space. Initial testing shall be done from
outside the confined space by inserting a sample probe and/or portable gas detection device at
appropriately selected access holes, nozzles and openings. Contaminants can settle at different
levels, thus each part of the confined space should be tested – side to side and top to bottom
1. Steps to be Followed When Testing Confined Spaces
i. Ensure that the gas testing instrument is within the calibration interval and bump tested.
ii. Check that the battery life of the instrument is adequate for the duration of the job.
iii. Ensure that the right and necessary accessories are used e.g. sampling tubes, probes and/or
dilution tubes.
iv. Determine if the atmosphere can be tested at all depths.
v. Ensure all depths are tested in the following sequence; start with oxygen, followed by
flammable gases and vapors and finally toxic gases and vapors.
Figure 1: Gas Testing Techniques for Confined Spaces
vi. It is critical for the test results to satisfy the following criteria before the entry permit can be
issued:
 Oxygen reading: ≥ 19.5 % Vol. to ≤ 23.5 % Vol.
 Flammable gases and vapors reading: ≤ 10% LEL
 Toxic gases and vapors reading: ≤ Occupational Exposure Limits
vii. Record all results and update this information on the entry permit document.
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

2. Additional Considerations Before Taking The Gas Test
i. Pre-inspect the accessories to ensure that they are of the right material and are functioning
properly.
ii. Conduct leak tests on the sampling hose and clean it by purging it with fresh air before each
gas test.
iii. The measurement values for each atmospheric hazard monitored shall be in accordance to
the response time of the gas detectors, i.e. a minimum sampling time of 2 minutes at each
sampling location plus 2 seconds per foot of tubing/probe length (2x2 sampling rule).
 Wait until the reading is stabilized before recording the readout display on the gas
detector instrument.
iv. Gas testers shall understand and take into account the geometry (vertical or horizontal
space, with or without compartments etc) of the confined space and the physical properties
(e.g. relative densities etc) of the gases to be monitored. These gases could be found
stratified at different levels or locations of the confined space (see Figure 1 above).
v. Do not exceed the 100 foot (30 meter) sampling rule. Testing shall be conducted through
multiple openings on vessels/equipment (e.g. Columns and Silos) where this rule could be
violated.
3. Frequency of Gas Testing
In addition to the continuous ventilation requirements for confined space entry, it is essential to
conduct the periodic retesting, taking the following factors into consideration:
i. The possibility or likelihood of a change in the space by the potential release of the
hazardous materials.
ii. When continuous occupation exceeds 6 hours.
iii. When a confined space is vacated for a significant period of time ≥ 60 min, without the space
being monitored continuously.
4. Continuous Gas Monitoring Requirements
Even when the confined space is tested and certified safe for any person to enter, at least one
person in a group working in the same vicinity shall be equipped with a suitable multi-gas
detector for measuring oxygen, combustible and the identified toxic contaminants (see Figure
2 below).
Figure 2: Portable Gas Detector Requirements for Confined Space Entry
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Appendix B
SENSOR CROSS INTERFERENCE TABLE
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Appendix C
LEL CORRELATION FACTORS
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Appendix D
BUMP STATION LOCATIONS
MESAIEED COMPLEX
1. North Control Room (NCR) SE Door
2. North Control Room (NCR) NW Door
3. North Product Warehouse West Wall of Bagging Lines
4. South Product Warehouse East Wall of Office Block
5. Utilities – North Offsites North BRM
6. Utilities – South Offsites South RIE
7. Utilities – New Waste Water Treatment Plant South FOC
8. Sulfur Unit FIC
9. Ethylene Unit FIC
10. Polyethylene / 1-Hexene Unit BRM
11. Polyethylene / 1-Hexene Unit Polyethylene FIC
12. Central Control Room (CCR) / Laboratory PE Lab
13. Central Control Room (CCR) West Side of the Building
RAS LAFFAN COMPLEX

1. Laboratory – Four Stations Room A-01
2. Fire Station – Fire Equipment Room Room 06
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

Appendix E
BUMP TESTING PROCEDURE (MESAIEED)
Step 1 Ensure cylinder valve is closed.
Step 2 Ensure pressure regulator is in fully counter-clockwise direction.
Step 3 Ensure instrument ball valve is closed.
Step 4 Open cylinder valve and ensure cylinder pressure.
Turn regulator knob slowly in clockwise direction until the output

Step 5
gauge shows 0.2 bar.
Connect the tubing onto the sample pump or calibration cup with the
Step 6
detector.
Open instrument ball valve and flow bump gas until detector
Step 7
readings stabilize.
Verify that all sensors go into alarm mode. If not, deliver gas detector
Step 8
to the Fire and Gas group for sensor calibration.
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

Close Cylinder valve and wait until regulator input and output gauges
Step 9 show 0 bar. Turn regulator knob fully counter-clockwise. Close
instrument ball valve. Remove detector from tubing.
Step 10 Clear peak values prior to using the gas detector.
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

Appendix F
BUMP TESTING PROCEDURE (RAS LAFFAN)
Step 1 Dock the instrument in the DS2 station.
DS2 will automatically perform a bump test or full calibration as per

Step 2
the docking station configuration.
Upon completion of the test “Green” LED light up on the DS2.

Step 3
Bump test result will be displayed during the test.
If DS2 “RED” LED lights up, return the instrument to Fire and Gas
Step 4
(Instrument will display the error code)
If the following error appeared return the instrument to Fire and

Gas for the correction and calibration.
 Unavailable gas
 Unavailable sensor
 If the device shows “CAL”
ERROR CODE
 If the device shows “CAL DUE”

 If the device shows “ERROR”
 If the device shows “Pump Failure”
 If the device shows “FAIL”
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

Appendix G
PORTABLE GAS DETECTOR MALFUNCTIONS
Gas Detection Failure Possible Cause/Reason Action to be taken by Gas Tester

1. Temperature and/or Humidity 1. Zeroing required in to fresh air at
changes on the sensor. same temperature of workplace.
Display negative reading of
H2S.
2. Sensor deviated from the 2. Hand over the instrument to
calibration and zeroing. F&G group.
Sensor Cross Interference with Considered measured value as
unknown gas (i.e. H2 may Presence of sensor cross real. (Refer Appendix B) If
interfere with CO sensor). interference gas. required then concern safety
department.
Display of CAL symbol.
CAL will appear when the
Hand over the instrument to
sensor deviated or it is required
F&G group.
calibration.
1. Hand over the instrument to
F&G group.
1. Pump failed to operate or failed
to draw workplace air.
2. Replace the internal/external
Display Pump Fault symbol.
filter and dock for the bump test
2. Possibility of internal/eternal
and check the operation of pump
filter clogging.
by blocking the intake.
Hand over the instrument to

Display Error Code symbol. Firmware failure of equipment. F&G group.
Immediate replace instrument

Display symbol of low battery. Battery drain/discharge. with fully charged equipment.
Display symbol of Hand over the instrument to

Due to physical damage of
Speaker Failed. F&G group.
equipment or hardware.
Mishandling (dropping the
equipment from height, not
Any Physical Damage of the
properly cared, Hand over the instrument to
Equipment.
removing/damaging the F&G group.
protection case, scratching over
the display).
Note:
1. Based on operation/maintenance experience of portable gas detector either during bump

test/calibration or workplace sampling above mentioned malfunction, possible cause/reason
and gas tester actions are defined on above table.
2. In case any other malfunction other than mentioned in above table shall be reported to HSE
Department by end user.
HSE-SAF-PRO-00-0008
SAFETY
Rev. 6

9. REVISION HISTORY
Rev. Date Amendment Description Prepared By Reviewed By Approved By
Roehl
5.2 09-Feb-15 Next revision date changed from Feb/2015. Amit Parikh Roehl Bartolome
Bartolome
5.1 16-Oct-14 Added the LCP Icon Box with notes (Page 1) Carl Poldrack Carl Poldrack Carl Poldrack
Lloyd G Askham
Chintan R Dalal
Moustafa S El-
Carl Poldrack
Change Category: Type-1 Hamad
Roehl Bartolome
Added PID alarm settings. (Section 4.4) Rajagopal S Kumar
Saleh Abdulla
Boppana Saibabu
Added portable gas detector malfunction. Abdulla S Al-
5 07-June-14 Amit D. Parikh Yerramilli Namgala
Khulaifi
(Section 4.13 and Appendix G) Robin T Ulrich
Updated bump station numbers into RLOC. Kevin C Kabell
Zakarya Y Al-
(Appendix D) Ali Al-Marri
Shareef
Mohammed H Al-
Amayreh
Mostafa A Mohamed
Updated definitions list. (Section 3)
Included details on instrument configuration and
setup. (Section 4.4)
Updated general sampling requirements;
including requirements for using dilution tubes
and the minimum sampling time. (Section 4.6)
Clarified the gas detection techniques for various
scenarios, including graphical and pictorial
illustrations. (Section 4.7)
Changed the calibration frequency from 90 days
to 30 days. (Section 4.8)
Included “Personal Gas Detector” standard. Lloyd G
4 01-Feb-13 Added this as attachment to procedure. (Section Amit D. Parikh Carl Poldrack
Askham
4.9)
Provided additional bump stations and their
locations. (Section 4.10)
Included a requirement for refresher training for
authorized gas testers at 3-yearly intervals.
(Section 4.11)
Included additional appendices to the document;
namely Confined Space Entry, Sensor cross-
interference table & LEL correlation factors.
(Appendix A, B and C)
Moved bump testing procedures for both sites to
appendix list. (Appendix E and F)
Bump test requirement changed to at least once
3 30-Nov-08 Faiz Ahmed Jarvis Olsen
in a shift prior to use. (Section 4.4)
Added LEL and UEL definition (Section 3)
Q-Chem standard meter changed from ITX to
iBRID MX6 and Dragger CMS to UltraRAE.
(Section 4.2)
2 15-Sept-08 Calibration & Maintenance responsibilities
changed from I&E (Maint.) to Fire & Gas Group
(Technical), (Section 5.4)
I&E (Maint.) will be responsible to change bump
station cylinder. (Section 5.5)
Bump Stations complete. Calibration Station on-
1 08-May-06
site. (Scott Sutherland)
0 22-Aug-05 First Release (Scott Sutherland)

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HSE-SAF-PRO-00-0008

PORTABLE GAS DETECTOR 26-Apr-2016

2. SCOPE & PURPOSE ................................................................................................... 2

9. REVISION HISTORY .................................................................................................. 24

Always conduct accurate gas detection as required.

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

PORTABLE GAS DETECTOR 26-Apr-2016

2. SCOPE & PURPOSE

PORTABLE GAS DETECTOR 26-Apr-2016

 Immediately Dangerous to Life or Health (IDLH): An atmosphere that poses an immediate

4.1. General Requirements

PORTABLE GAS DETECTOR 26-Apr-2016

a) Results from the review shall be published on the Safety Webpage.

4.3. Issuing of Portable Gas Detectors

a) The end-user shall have access to the following accessories:

Instrument Alarm Settings

4.5. Operating Portable Gas Detectors

PORTABLE GAS DETECTOR 26-Apr-2016

 This shall be conducted in a “clean” atmosphere away from the potentially

4.6. General Sampling Requirements

ii. The “2x2” sampling rule shall be followed when sampling:

a) 2 seconds sampling per foot of tubing used.

b) 2 minutes minimum sample time per location.

a) OSHA recommends 4 foot (1.2 meter) sampling intervals at a minimum.

a) Exception may be granted if slight purging is required to maintain a slight positive

PORTABLE GAS DETECTOR 26-Apr-2016

a) Use to sample in atmospheres of less than 10% oxygen by volume.

b) Ambient oxygen readings must be between 20-23.5% by volume.

d) Instrument readings will be approximately equal to one half of all gas

 Displayed readings shall be multiplied by two (2) to obtain actual

e) Maximum sampling tube length of 10 feet (3 meters) can be used.

f) The area being sampled MUST be at atmospheric pressure:

g) Allow three (3) minutes before reading the concentration.

h) Avoid drawing oil, dust or steam into the dilution tube.

PORTABLE GAS DETECTOR 26-Apr-2016

4.7. Gas Detection Techniques

4.7.1. Confined Space Entry

PORTABLE GAS DETECTOR 26-Apr-2016

PORTABLE GAS DETECTOR 26-Apr-2016

15m horizontal gas

4.7.3. Process Equipment and Piping

PORTABLE GAS DETECTOR 26-Apr-2016

Flange cracked open slightly

Figure 1: Diagram showing possible gas testing location on flange

Gas testing of internal space

Figure 2: Diagram showing gas testing within piping from bleeder

PORTABLE GAS DETECTOR 26-Apr-2016

4.7.4. Leak Detection/Testing Unknown Atmospheres

PORTABLE GAS DETECTOR 26-Apr-2016

 The Environmental group shall arrange for battery disposal.

4.9. Personal Gas Detectors

i. Refer to Personal Gas Monitor Standard (HSE-SAF-STD-00-0045) for details.

4.10. Bump Stations

PORTABLE GAS DETECTOR 26-Apr-2016

4.12. Procedure Review

4.13. Portable Gas Detector Malfunctions

i. Refer to Appendix G for details.

5.1. Safety Department

5.2. Training Section

i. Schedules and conducts Gas Detection and monitoring training.

5.3. Fire & Gas Group

i. Configures all multi-gas detectors for use on the Q-Chem sites.

PORTABLE GAS DETECTOR 26-Apr-2016

5.4. Instrument & Electrical Group (Maintenance – Mesaieed)