Autorized gas tester

Authorised Gas Testers are responsible for testing the atmosphere in a confined space
before any personnel are permitted to enter. They also test for gases periodically
throughout the job, as dangerous gases can build up.

But what is a confined space? A confined space is defined as any place, including any
chamber, tank, vat, silo, pit, trench, pipe, sewer, flue, well or other similar space in
which, because of its enclosed nature, there is a risk. This means that there are limited
openings for entry and exit and poor natural ventilation. Workers should not be inside
confined spaces for long periods of time.

Some confined spaces are easy to identify; others however, are not so obvious.
Examples of these are some excavations, open-topped tanks and closed, poorly
ventilated rooms.

Every confined space is unique and there may be multiple hazards present.
Some of the work that require testing for flammable and toxic gases include the
removal of flammable materials from tanks and pipes in preparation for entry; line
breaking, cleaning, or hot work such as welding; spraying and the spreading or coating
of items with paint, adhesives or other substances containing flammable solvents.

Inside a confined space, the presence of even a small amount of toxic vapour can
easily create a deadly environment. Therefore, entry into confined spaces containing
toxic vapours in dangerous concentrations is absolutely prohibited, even if wearing
breathing apparatus. The safety of workers is an absolute priority, so atmospheres
must be gas tested immediately prior to entry.

If flammable gases are present at a particular concentration, there is a great risk of fire
and explosion. Detection measures should be in place at locations where the presence
of these gases would present a risk to people, plant and equipment or the
environment.
The average oxygen content of the atmosphere is 20.9%; lower levels will not support
normal breathing.

If the level falls as low as 19.5%, the atmosphere is described as oxygen deficient.
Someone working in an oxygen deficient atmosphere would first experience tiredness,
quickly followed by unconsciousness and then ultimately death due to starvation of
oxygen.
Several factors may cause oxygen to be absorbed, causing deficiency in a confined
space.

The most common causes are:

Corrosion or rusting
Burning or welding
Bacterial growth, and
The presence of chemicals which absorb oxygen

Too much oxygen can also be dangerous. This is known as oxygen enrichment and
occurs when oxygen levels rise above 23.5% oxygen by volume. Not only can this be
toxic, causing breathing problems and disorientation, it can cause substances that
would normally be non-flammable to become flammable, and may ignite or explode if a
source of ignition is present.
Potentially toxic gases that may be present in or around confined spaces are hydrogen
sulphide, carbon monoxide, solvents and hydrocarbons.

Hydrogen sulphide, also known as H2S, or sour gas, is extremely hazardous to health,
even in small concentrations. It is one of the most dangerous gases to be found in the
oil and gas industry and can kill within a couple of breaths. The greatest risk from H2S
exists around sour oil and gas facilities.

When breathed in, carbon monoxide attaches to the red blood cells and stops the
blood from carrying oxygen around the body. In this way, carbon monoxide starves the
body of oxygen. If exposed to the gas for long enough, you would be killed.

Volatile hydrocarbons are substances that originate from crude oil and are gases at
reasonably low temperatures. Inhalation of these gases, such as condensates, can
cause narcotic effects. The effects develop from drowsiness to dizziness, to confusion
and the inability to make rational decisions after as little as three or four breaths.

Other gases, like nitrogen and argon are described as physiologically inert and will kill
or asphyxiate a person when breathed in because no oxygen is being passed into the
bloodstream.
The flammable gases associated with oil and gas production consist largely of
hydrocarbon gases. The most common of these is methane, otherwise known as C H
4, which typically makes up 70 to 90% of produced gas. Other common flammable
gases include butane, ethane, hydrogen and hydrogen sulphide.
All flammable gases and vapours are characterised by their explosive limits. The Lower
Explosive Limit or L E L refers to the lowest concentration of a gas in an atmosphere
that creates a flammable mixture. The upper explosive limit or U E L refers to the
highest concentration that can produce the same effect.

In a confined area, such as a tank, where the gas cannot disperse through the air, the
immediate danger may not be combustion if the atmosphere is too rich to support
combustion, but asphyxiation due to insufficient oxygen.

Another important value for flammable substances is the flashpoint. The flashpoint for
a liquid is the lowest temperature which produces enough vapour to form an ignitable
mixture. At this temperature, enough of the substance has evaporated to support
combustion which means this vapour is close to its L E L.

LEL =flashpoint
Metanol 5%

A suitable and sufficient assessment of the risks for all work activities must be carried
out before any testing activities and before entry to a confined space. Note that even
before an initial gas test is taken, a risk assessment must be carried out.
You must always follow the procedures that are in place for confined space entry as
this type of work will always require an entry certificate. For this reason, every confined
space entry job should be considered unique, and have its own risk assessment,
Permit and Confined Space Entry certificate.
If entry to a confined space cannot be avoided, all asphyxiates, flammable and toxic
hazards must be eliminated by positive isolation, thorough cleaning, gas purging and
ventilation. A high level of preparation is vital prior to a safe entry.
Gas tests are performed to ensure that the environment is safe from the hazards of
combustible or toxic gases, and that the worksite contains the right amount of oxygen.
For working in confined spaces, the hazards present must be identified, the risks
assessed, and controls determined. You can only enter a confined space once all
preparation requirements have been met and a manufa entry certificate has been
authorised and issued.
An entry certificate will detail the controls that are required. Some example controls
include an initial gas test, continuous gas monitoring, forced ventilation for a specified
time, breathing apparatus, oxygen monitors, radios, first aid kits and many more. There
must always be a rescue plan in place.

Your employer is required to ensure that even a confined space is a safe place of work.
To do this, a Safe sSystem of Work must be followed.

Isolation of all mechanical and electrical equipment is required to protect against all
sources of energy and potentially hazardous substances.
Before entering a confined space, entry permits and certificates should be
authorised and posted at the entrance.

Gas testing is an integral part of establishing a Safe System of Work in the oil and gas
industry. Before a Permit involving confined space entry is issued, an initial gas test
must be made at the worksite. This test must be carried out by an AGT and the results
recorded, typically on a Gas Test Certificate. Where continuous monitoring is required,
this is carried out using an appropriate portable gas detector.

An adequate communications system is required to enable effective communications

between the people inside and outside the confined space. You must also have a
formal rescue plan in place. It is at this point, that your communication system will
really make a difference.

There may be stagnant areas of little or no air movement where gases can build up, so
you must have adequate ventilation. Air movement fans can be placed in the space to
allow for air to be forced through, and out of the space.

One person, called the stand-by person is always required to be outside of the
confined space. Their responsibilities include monitoring activities inside and around
the confined space, and communicating and raising the alarm in the event of an
emergency.
The person on safety watch should always be able to maintain contact with the AGT
within the confined space without placing themselves at risk. If, during an initial gas
test, the AGT has to enter the confined space, another AGT must be stationed close to
the space to communicate with them.
It is the job of the person on safety watch to ensure that all safety and rescue
equipment works properly and is available, in accordance with the approved rescue
plan. It may be essential to notify the emergency services before entry.

----As an AGT you must have successfully completed training in all relevant control of
work procedures and safe systems of work. You must also be able to apply these
policies, procedures and instructions at the worksite where gas testing is to take place.
Your employer will have their own policies and procedures that you must make sure
you are familiar with. Ask your supervisor for assistance if you are unsure about
anything relating to these policies and procedures.
It is vital that you follow the procedures completely. Do not make up anything on your
own. Safety systems are designed to make sure that everyone knows that safety is the
priority and that it should not be compromised.
To be deemed competent and have the authority to work as an AGT, you must
demonstrate the ability to survey potentially hazardous areas using the detection
equipment available and be familiar with plant and process area.

As an AGT, you are likely to be exposed to a variety of hazardous environments. You

will therefore be required to wear suitable personal and respiratory protective
equipment.

It is the responsibility of your employer to provide you with all Personal Protective
Equipment (PPE) to use at work.

The PPE that you would typically expect to use for gas testing are a properly fitting
safety helmet; appropriate eye protection such as safety glasses or goggles; gloves;
flame retardant, long-sleeved coveralls; correctly fitted ear defenders; steel toe-capped
safety boots, where the steel is covered to avoid potential sparks and appropriate
breathing apparatus.

Other specialist equipment that may be required when working in a confined space
may include a body harness and a lifeline attached to the person entering the confined
space. Requirements such as these will be detailed on the risk assessment and the
Confined Space Entry certificate or Permit.

It is your responsibility to make sure that the equipment is used, maintained and stored
correctly. You must make sure you carry out a visual inspection before and after use.
When selecting respiratory protective equipment, or RPE, it is important to consider the
physical demands of the job and the impact of reduced visibility.

The three main groups of RPE that are used are:

respirators which filter substances from the air
self-contained breathing apparatus; and
cascade airlines

Respirators generally cover your nose and mouth, or your entire face or head. To be
effective, the respirator must fit you properly. The purpose of the respirator is to trap
chemical contaminants in a filter before they can be breathed in. Because they filter out
contaminants and do not supply oxygen, they must never be used in oxygen-deficient
atmospheres.
The choice of filter is also crucial, as different filters offer protection against different
contaminants. For example, a filter to remove hydrogen sulphide cannot be used to
remove volatile hydrocarbons, however there are combination filters available. The
packaging on the filter should state which substances it can be used for. Respirators
can make breathing difficult, particularly as the filter becomes increasingly clogged up
from use.
Manufacturers supply gas detectors either as individual units that monitor one of the
three gas personnel exffailure, or as combination units which are capable of monitoring
all three gas types.

Always refer to the manufacturer’s operating instructions for the detector you are using.
For example, the operational instructions for a personal H2S detector will be different
from a multi-gas detector, and different brands will also have different instructions.

All gas detectors are supplied with operational instructions. AGTs must familiarise
themselves with the instructions for whichever detector or detectors you are using.
We will now look at portable gas detectors in more detail, as this is the type of detector
you will most commonly use. These monitors are set to give readings at specified time
intervals and alarm when exposed to specific concentrations of gases.

Portable gas detectors can be used actively or passively. Active monitoring is normally
carried out using hand-held portable detectors. The instruments are carried around and
used to check the general area, the atmosphere within a confined space, or for leaks
from likely sources, for example drains or flanges.
When using the detector passively, you might position it temporarily in one place to
monitor the atmosphere for a period of hours or days.

Portable gas detection equipment should be checked to ensure that it is still within its
calibration validity period. Do not use any gas detector meter that reads less than it
should during set up and testing. Return it as faulty or to be re-charged.
Most portable gas detection equipment is certified as safe to use in hazardous areas
and is appropriately labelled with the codes shown on screen.
These Symbols are used together on the Certification Label of the Gas Detector.

As well as electronic gas detectors, aspirated chemical 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 particular detector tube and its chemical contents
are selected to detect a known type of gas.
These detector tubes are used to measure the concentration of a gas in a spot test by
drawing in a metered amount of the atmosphere through the chemical tube. There are
a variety of chemical tubes for testing different gases.
The tube is normally calibrated so that the reaction between gas and chemical shows
up as a distinct colour on the scale, indicating the approximate concentration of gas
present. Tubes exist for detecting a variety of gases, such as benzene, carbon
monoxide, hydrogen, sulphur dioxide or chlorine. Each type of tube is supplied with
instructions and you must refer to these before use.

Gas detectors that are properly charged, calibrated and looked after should be
effective for a whole shift, but remember that detectors will occasionally fail.
The two main reasons for failure are a flat battery or probe contamination; for example,
dipping the probe in liquid accidentally.

Battery Failure - Gas detectors should always be kept fully charged to prevent the
battery from failing, the alarm sounding and the need for emergency procedures.
Always refer to the manufacturer’s instructions for battery maintenance.

Liquid Ingress - Liquids such as water will damage the gas detector sensors. The
sensors are provided with a membrane to protect them from damp. However,
continuous exposure will cause permanent damage.

Rough Handling - Although most gas detectors are quite robust, they are electronic
instruments and should be handled with care. If provided, the meter should be kept in
its protective cover.

Sensor Poisoning - Contamination of the sensor will cause a detector to stop

functioning. Hydrocarbon gas sensors can be poisoned by exposure to substances
such as silicones, welding fumes, chlorine and high levels of hydrocarbons.

Zero Drift - This is where the reading at zero changes slightly over time. Slight zero drift
is normal and may be found just after switching on the meter if it has not had enough
time to warm up. It may also be caused by a change of operating environment.
Normally, this is easily fixed by either waiting for a few minutes to let the meter
acclimatise, or by zeroing the meter in fresh air.

It is important to check that a sufficient amount of sample is moving through the probe.
If not, there could be a leak. A leaking probe will give unusual and unreliable readings.

If your detection equipment is behaving erratically, this could point to equipment

malfunction or atmosphere disturbance. If in doubt, check with another gas detector of
the same type or check the suspect equipment under controlled conditions.
Before deciding on which detector to use, you should consider the strengths and
weaknesses of each particular detector.
The main strength of electronic detectors is that they can monitor a variety of gases
continuously.
However, they require frequent bump testing and calibration; and the sensor can be
easily contaminated by certain gases and vapours present in the atmosphere.
In comparison, chemical detector tubes require no calibration and they are very
straightforward to use.
However, they can only be used once, and therefore cannot be used for monitoring
purposes, only measuring or spot checks. Additionally, their accuracy is not as good as
ic detectors.
Chemical detector tubes are specific for a particular gas and concentration, so care
must be taken to ensure that the correct tube is used. These detectors have a limited
shelf life, so you should check the ‘use by date’ before use.

Detectors that incorporate an infra-red sensor are advantageous for testing

flammable gases because they can operate in inert atmospheres. This means that
there is no requirement for oxygen to be present.

These sensors are not damaged by exposure to high concentrations of gas or

contaminants and can function in a wider range of levels than most flammable gas
detectors.

Transportable gas detectors are excellent for continuous monitoring of a worksite for a
combustible gas atmosphere.

These are free-standing, self-powered units fitted with flammable gas and vapour
detectors. Using Infra-red sensors, the instrument is configured to detect combinations
of oxygen, toxic and flammable gas. However, they are not as effective in a large open
space.
When taking portable equipment from cool to warm conditions, allow the equipment
temperature to rise sufficiently to avoid condensation which may otherwise interfere
with the correct operation of the equipment.
A clear understanding of the behaviour and nature of gas releases is essential for
ensuring that effective and representative measurements are collected. You must
ensure that the entire area is sampled appropriately, not just one point.

A survey of the space should involve checking high and low points within the work
area. Thereafter, you need to ensure that the work location continues to be safe by
siting a detector very near the workers. You should also place the detector where it can
be seen and heard; avoid places where it could be easily broken.

Using the right type of gas detector for a particular gas is essential to carrying out a
successful gas test. Gas detectors are designed to be sensitive to a specific gas, so it
is important that you choose the correct detector. For example, H2S detectors will not
detect methane, and a detector calibrated for methane can significantly under-read
other gases such as propane or butane.

When deciding which gas detector to use, you should consider the following:
The substances potentially present
The properties and toxic effects of the substances
The levels they are present at
The Occupational Exposure Limit of the substances which is determined by company
policy
The concentration of oxygen in the work area; and
The need for emergency escape

Also be aware that the presence of gases, other than what is calibrated for, may affect
the outcome of the test.
Inert gases are not chemically reactive and an inert atmosphere containing these
gases will not support human life because there is a lack of oxygen. These
environments do not contain enough oxygen to support combustion either.

Nitrogen is a good example of an inert gas you may encounter. During purging with
nitrogen oxygen is removed from vessels and pipelines so that explosive mixtures
cannot form.
To measure hydrocarbons in inert environments, we can use infra-red, open path or
line of sight gas detectors.

Due to the seriousness of exposure to an inert atmosphere, confined spaces should be

tested from outside the space, using a long probe. The Authorised Gas Tester must
wear Cascade breathing apparatus with full face mask and positive pressure air
supply, even though they are outside the area.

It is always necessary to use the appropriate gas detector. Infra-red sensors cannot
detect hydrogen gas, so are unsuitable for use where hydrogen forms part of the
potential flammable risk.
Before using any gas detector, you first need to do a visual inspection. You should
firstly check for contamination and damage. Then check that all the sensor ports are
not obstructed or contaminated, that the tubes containing chemicals are within their
‘use by’ date, and the batteries.

When first switched on, nearly all detectors will go through a pre-programmed self-
check. This will check the function of the audible alarms, visible alarms and the display.

Switch on the detector and allow it to warm up in a clean atmosphere that is free of
contaminants and contains a normal oxygen concentration.

You should perform bump tests and checks to verify that sample quantities, in litres of
air per stroke, are within the manufacturer’s limits. This will ensure that an accurate
sample will be taken when the equipment is in use.
Test boundaries can vary dramatically depending on the task required. Testing the gas
contents of a condensate pump for example would only require testing the small
volume of gaseous space within the pump and associated pipework. Therefore, the
test boundary is small and localised.

On an FPSO, the cargo tanks are very large vessels and the test boundaries can be
very large area. In this case, as part of the job planning, the Area Authority would
specify that all levels of the tank must be tested and define how it is to be done.
Generally, once the positive isolations are in place, an entry would need to be done
using breathing apparatus to be able to access all levels of the cargo tank
All detectors over time will have a ‘drift’, which means that the reference point has
shifted. So, it is important that all instruments are calibrated to prevent inaccurate
readings. You should never make any unauthorised modifications or replace any parts
of a gas detector yourself.

A bump test must be performed before each shift use. This involves passing a gas of
known concentration over the sensor to ensure the detector is reading correctly. If the
instrument fails the bump test, it will need to be fully calibrated.

To ensure proper calibration of instruments, the company should always use the
manufacturer’s guidelines. Calibration of sensors must be performed with known
mixtures of gas and air at the manufacturer’s recommended flow rate.

As an Authorised Gas Tester, it is your responsibility to check the calibration certificate

and to ensure that the detector is within the calibration date.

You must keep a permanent record of all calibration checks and who makes them for
each instrument. A gas detector calibration and maintenance log should be used for
this purpose.

If the gas detector is not functioning correctly, it must be withdrawn from service for
maintenance and repair immediately.
If you find your equipment to be damaged or defective while completing initial checks,
you will need to return the equipment to the competent person in charge of the
equipment.

This competent person may vary from site to site; however they should replace your
damaged or defective equipment with a unit which is operating normally.
The competent person would be responsible for repairing or recalibrating the defective
equipment.
All types of gas detectors have some form of warning system; visual, audible or both
which alerts the operator to the presence of unwanted gases.

Suitable alarm systems are incorporated into each gas detector. The instrument might
detect only one gas type and display a single visual warning light, or it could be a
combination unit with a visual warning light and digital reading for each gas detected.

The alarm on the detector is triggered if a specified gas concentration or set point is
exceeded.
Many portable gas detectors display a digital reading for the gas or gases that they are
designed to test. An AGT will be expected to have an understanding of what the
readings represent.

Chemical tubes contain chemicals that change colour on exposure to a certain

concentration of toxic gas. Different detector tubes are used for different gases and are
ideal for carrying out spot tests. AGTs must be familiar with the colour change which
indicates that there has been a gas release.

The AGT must select appropriate detectors for the environment and be able to
recognise what would be considered normal and abnormal values.

Examples of test results. Oxygen targets should be 20.8% O2. Hydrocarbons

(Methane) is measured in Lower Explosive Limit (LEL) and should be zero for entry
purposes. Drager tubes are used extensively for Benzene and other cyclic
hydrocarbons
During the continuous monitoring of gases, you will need to test gas levels on a regular
basis.
A confined space entry certificate will detail the range and frequency of testing. Even if
continuous monitoring is not required, you should re-test every two hours.
All readings from gas detection must be recorded. This “log” is a vital record of what is
occurring in the atmosphere where personnel are carrying out their duties. Gas tests
are only valid for the duration of the test.

The person recording the levels must be a trained AGT and be able to recognise when
gas concentrations are changing or approaching unacceptable levels.

The AGT on safety watch duty must be aware of the implications of changes in gas
levels and when to initiate emergency procedures. Proper precautions should be taken
before entry to a potentially hazardous environment and emergency procedures must
be followed to ensure the safety of all personnel.

When gas is detected, the AGT on safety watch duty must immediately evacuate the
confined space and inform the Control of Work Centre. When it is appropriate, the AGT
must put on suitable breathing apparatus and then re-test the site.
Once the safety check is completed, all findings must be recorded .