GAS TESTING & MONITORING

HSES Training Center

OBJECTIVES

The objectives of this presentation are:

• To identify the causes of hazardous

atmospheres.

• To review the principles of gas testing.

CONTENTS
• Why Carry out a Gas Test

• What Defines A Safe Atmosphere

• Properties of Flammable, Explosive and Toxic Gases and

Vapours

• Properties, Effects and Symptoms of Hydrogen Sulphide

• Control of Substance Hazardous to Health

• Density of Gases and Vapours

• Characteristics of Gas

• Application and types of Portable Gas Detectors and Operation

INTRODUCTION

Many fatalities have occurred because gas

testing had not been conducted or the tests
have been inadequate.

Gas testing must be completed by trained

competent personnel. However, it is important
that everyone understands the basic
requirements.
In the oil/gas and petrochemical industries, gas
hazards are of particular importance. These
hazards can be split into 3 main categories

The first are oxygen hazards, in the air we breathe

if there’s too much or not enough oxygen you or
your work mates may die.

Secondly explosive gases and flammable vapours,

which, when mixed with air in certain proportions
can lead to fires or explosions.
And finally harmful or toxic gas hazards; these
cover everything from inert gases like nitrogen,
used in purging operations, which, simply displace
the oxygen out of the air we are breathing, right
through to the nerve gases like Hydrogen Sulphide,
which chemically interfere with the cells in our
body.

Each one of these hazards are serious and life

threatening.
Type of Gas Detector
The following abbreviations are used:

AGT - Authorized Gas Tester.

CH4 - Methane (a flammable hydrocarbon gas).

H2S - Hydrogen Sulphide (a toxic gas).

LEL - Lower Explosive Limit.

UEL - Upper Explosive Limit.

ppm - Parts Per Million.

 The Combustion Triangle

Fuel (Process)

Ignition Source
(Electrical &
Oxygen
Thermal Energy)
(In the air)
To prevent an incident 3 main types
of gas testing are undertaken:

1. Before entering a confined space or

vessel

2. Before undertaking any type of hot-

work

3. During inerting
The following definitions are used in this presentation:

1. Gas - any substance of very low density and

viscosity. ( No shape, fills the free space of container)

2. Vapour - mist or fumes suspended in air.

3. Liquid - any flowing substance with little tendency

to disperse. ( No shape, takes shape of container)
Gas testing is involved with the following
activities:
1. Hot work of any type where heat is used or
generated, e.g.. by welding, flame cutting
and grinding, etc.
2. Work which may generate sparks or other
sources of ignition.
3. Work which may cause an uncontrolled
release of hydrocarbons, other flammable
or toxic materials.
4. Electrical instrumentation work which may
cause sparks.
5. Entry into confined spaces and Gas
alarm investigation.
 WHY CARRY OUT A GAS CHECK?

Confined Space and Vessel Entry Gas Testing

• OXYGEN DEFICIENCY … SUFFOCATION / DEATH

• OXYGEN ENRICHMENT … FIRE / EXPLOSION HAZARD

• GAS OR FLAMMABLE VAPOUR …FIRE OR EXPLOSIVE HAZARD

• TOXIC GAS … POISONING HAZARD

To certify that the atmosphere within a
confined space is free from Flammable,
Explosive or Toxic substances and that
the Oxygen content is 20.9%

IN OTHER WORDS, TO CERTIFY THAT

THE ATMOSPHERE IS SAFE TO WORK IN!
 WHY CARRY OUT A GAS CHECK?

Hot Work Gas Testing

To certify that there are no leaks or accumulations of
Flammable Vapours or Explosive gases at the worksite
when Hot work is being under taken
 WHAT DEFINES A SAFE ATMOSPHERE?

Looking at all the essential needs of our body,

sufficient oxygen is the most urgent, immediate
and basic need we have. Without sufficient
oxygen we will lose consciousness quickly and
die in a few Minutes.

THE CORRECT FIGURES FOR OXYGEN IS

20.9%, BELOW OR ABOVE THIS FIGURE IS
POTENTIALLY HAZARDOUS.
LOW OXYGEN EFFECT AND SYMPTOMS

15 to 19% Strenuous work is difficult

12 to 14% Respiration and pulse increases,
co-ordination and judgment impaired
9 to 11% Nausea, fainting, blue lips,
unconsciousness
6 to 8% Death within 8 minutes, recovery if
resuscitated within 4 minutes

Remember! that rusting of steelwork and some

chemicals in confined spaces can reduce the oxygen in
the atmosphere to dangerous levels very quickly.
 HIGH OXYGEN EFFECTS AND SYMPTOMS

Above 23% oxygen serious fire risk causing some

materials to spontaneously combust, for example oily cloth
and steel wool >(30%)

Prolonged exposure causes damage to breathing processes

and an intoxication which seriously disturbs judgement
with (industrial 02 gas)

Most gas detection apparatus is uncertified if the oxygen

content is increased above atmosphere levels

Note:
The minimum content of Oxygen required for a Catalytic
Gas detector reading LEL, is 13% or more to read
accurately.
 PROPERTIES OF EXPLOSIVE GASES AND
FLAMMABLE VAPOURS

All combustible gases and vapours are

characterized 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 the Explosive or
Flammable limits
The Lower Explosive Limit (LEL) of methane is 5% by volume i.e.
5 volumes of methane mixed with 95 volumes of air.

This is the minimum quantity of Methane in a methane/air

mixture that will ignite to produce a self propagating flame if
exposed to a hot source or a spark from electrical or mechanical
equipment. if there is less thanLEL
SUBSTANCE 5% of
(Vol%) UELMethane
(Vol%) in the air by
volume the mixture is too lean to
ACETONE
ACETYLENE 2.4 support
2.15 13
88 combustion.
BUTANE 1.5 8.5
ETHANE 3 15.5
Explosive ranges of other gases
ETHYLENE
HEXANE
2.7
1.2
34
7.4
HYDROGEN 4 75.6
METHANE 5 15
PROPANE 2 9.5
 The Upper Explosive Limit ( UEL ) refers to the
highest concentration of a gas in the atmosphere which
results in a combustible mixture. For example, the UEL
of Methane in air is 15% by volume, which means that
if there is more than 15% of Methane in the air by
volume the mixture is too rich to support combustion.

Explosive ranges of other gases

SUBSTANCE LEL (Vol%) UEL (Vol%)
ACETONE 2.15 13
ACETYLENE 2.4 88
BUTANE 1.5 8.5
ETHANE 3 15.5
ETHYLENE 2.7 34
HEXANE 1.2 7.4
HYDROGEN 4 75.6
METHANE 5 15
PROPANE 2 9.5
For example, our list of L.E.L.s shows that Methane
has an L.E.L. of 5.0%. This means that a mixture
of 5.0% Methane and 95.0% air, equals 100%, the
L.E.L. for Methane
The most important point to remember is that any
indication between 5 – 10% LEL on the detector
means caution and possible danger
Properties of Harmful & Toxic Gases
Within the oil and gas industry a wide range of
harmful and toxic gases can be encountered
generally they can be sub-divided into Asphyxiant
and Toxic Gases.

ASPHYXIANT GASES:

Simple displacement of oxygen from the air we

breathe by any one of these gases can lead to
suffocation, remember nitrogen is widely used in
purging applications.
This heightens the importance of the oxygen gas
test at the entrance to any confined space,
remember 20.9% oxygen is the correct figure.
TOXIC GASES

Toxic gases chemically interfere with the vital

processes taking place within our bodies, only minute
amounts of these gases need to be present in our
breathing air to cause catastrophic effects..

As the amount needed to poison us, is well below 1%

in quantity, the expression ‘parts per million’ is used
to measure these very small quantities of gas.
examples: 10 ppm is the same as 0.001%
100 ppm is the same as 0.01%
1000 ppm is the same as 0.1%
10,000 ppm is the same as 1%
 PROPERTIES OF HARMFUL AND TOXIC GASES YOU MAY COME
ACROSS

GAS APPLICATION AND WHERE FOUND.

Condensate or heavy Crude oil residues, oil condensate

Hydrocarbon vapours and Sludges

Hydrogen Sulphide Reservoir gas, crude oil vapour

and stagnant water.

Carbon Monoxide Associated with combustion

process.

Carbon Dioxide Fire extinguishers and Deluge

systems.
 PROPERTIES OF HARMFUL AND TOXIC GASES YOU MAY
COME ACROSS

GAS APPLICATION AND WHERE FOUND.

Sulphur Dioxide Sulphur recovery plants and Flare

stacks.

Chlorine Water treatment.

Benzene Sometimes found in crude oil and

vapours.

Trichloroethane Solvent sometimes used in de-greasing

fluids and dye- penetrants.
 PROPERTIES OF HYDROGEN SULPHIDE

Hydrogen Sulphide is found widely in the oil

industry, it is found in crude oil, it is found in
some natural gases and it can even be found in
stagnant water, particularly sea water.

Hydrogen Sulphide is a ‘nerve gas ; its almost

as toxic as cyanide and whilst at very low
concentrations it is not considered to be
harmful to us, at high concentrations it
is lethal.
HYDROGEN SULPHIDE gas is referred
to by a variety of names:

• Sour gas
• Rotten egg gas
• Sulphurated Hydrogen
• H2S
 MAIN CHARACTERISTICS OF H2S:

• Potentially lethal.

• Colourless.

• Heavier than air.

• Readily dispersed by wind or air currents.

• Flammable - burns with a blue flame.

• Odour of rotten eggs (below concentration of 100

ppm).

• Highly corrosive to certain materials (eg. steel).

 EFFECT OF H2S ON PERSONNEL

The way in which H2S affects you depends on the following:

• Duration: the length of time the individual is

exposed.

Frequency: how often the individual has been

exposed.

Intensity: the concentration of exposure.

Susceptibility: the individual’s physiological make up.

 EFFECTS AND SYMPTEMS OF H2S

0.0025 ppm Minimum concentration which produces

odour

10 - 20 ppm Eye and respiratory tract irritation,

especially in vulnerable workers.

20 - 100 ppm Inflammation, blistering and opacity of the

eye, loss of the sense of smell, headache,
cough and nausea.

100 - 300 ppm Respiratory difficulty, respiratory depression

and irritation (exposures of 30 minutes to 8
hours).
 EFFECTS AND SYMPTEMS OF H2S

300 - 700 ppm Central nervous system effects , eg

tremors, weakness, numbness of
extremities, unconsciousness and
convulsions.

700 - 1000 ppm Rapid (one to several breaths will result

in unconsciousness)

Above 1000 ppm Cessation of breathing (instantaneous)

followed by death.
 Effect of H2S on personnel

If a person inhales H2S, it passes directly through the

lungs in to the bloodstream. To protect itself, the body
’oxidises’ (breaks down) the gas as rapidly as possible
into a harmless compound.

If the person breathes in too much H2S, the body cannot

oxsidise all of it, it builds up in the blood and the person
becomes poisoned. The areas of the brain which control
breathing become paralysed, the lungs stop working and
the person is asphyxiated.
 REMEMBER!
700ppm sounds a lot, but
it is only 0.07% vol.,
There may well be
99.93% vol. of fresh air
as the remainder.
EXPOSURE LIMITS AND THE COSHH REGULATIONS

The maximum amount of any toxic gas

that you’re allowed to be exposed to in
the workplace is controlled by law.

The Control Of Substances Hazardous to

Health in the UK or COSHH which states
how much of a particular toxic material
you are allowed to be exposed too and
for how long.
 DENSITY OF GASES AND VAPOURS

1.Relative Density of Pure Gas

Gases when pure and concentrated are

either lighter than air, neutral in density
or heavier than air. To simplify an
understanding of the density of gases,fresh
air is given a density which = 1.
DENSITY OF GASES AND VAPOURS

So gases, can then be compared with

air to see if they are lighter ( less dense )
or heavier ( more dense ).

Methane, the main component of natural

gas is lighter than air about half the
weight of air.
DENSITY OF GASES AND VAPOURS

Ethane 1.05
Propane 1.55
Butane 2.00
Pentane 2.50
H2S 1.18
Carbon Monoxide 0.97
Methane 0.55
 DENSITY OF GASES AND VAPOURS

Densities of Gas Clouds

The density of a flammable or toxic

gas cloud formed during a gas leakage
incident will depend not only on the
type of gas but more importantly on
its concentration within the gas cloud.
 DENSITY OF GASES AND VAPOURS
Popular Myth Toxic H2S gas clouds are heavier
than air, usually not true!

(a) 1000 ppm H2S in pure natural gas is

lighter than air.

(b) 1000 ppm H2S in a gas cloud formed

from a high pressure release is neutral.

(c) 1000 ppm H2S entrapped in a condensate

vapour cloud is heavier than air.
ATMOSPHERIC COMPOSITION

CARBON MONOXIDE
Same molecular weight as air
( same density as air)

HYDROGEN SULPHIDE
Heavier than air
(more dense)

METHANE
Lighter than air
(less dense)
 CHARACTERISTICS OF GASES

·Remember the flammable and toxic limit

values for gases such as hydrogen sulphide
require relatively large mounts to produce a
flammable mixture where as the quantity
necessary to produce a toxic gas mixture is
extremely small.
 APPLICATIONS AND TYPES OF PORTABLE GAS DETECTOR

Gas Test Detector Principle Measurement

Oxygen Electrochemical Cell % Volume

Methane or other Catalytic or Infra-red % L.E.L.

Flammable gases Infra-red or Tank scope % Volume

Electrochemical Cell
Toxic gases or Vapours or ppm
Chemical stain tube
 ELECTROCHEMICAL SENSOR
Used in portable and fixed gas detectors to
detect and measure % oxygen and other toxic
gas concentrations of Hydrogen Sulphide
(H2S), Sulphur Dioxide, Carbon Monoxide,
Chlorine etc,
 Catalytic Sensor
Platinum
Wire
The catalytic
sensors operate
on the combustion
principle, they
must be used in
environments
containing oxygen
Catalytically-Treated
Metal oxide material
THE CATALYTIC GAS SENSOR
 THE CATALYTIC GAS SENSOR
A methane calibrated gas detector will detect many other flammable
gases and vapours, but may seriously under-read the concentration
present.

For example, on a methane calibrated catalytic gas detector:-

100% LEL propane or butane will only indicate about

50-60% LEL on the display

100% LEL pentane or hexane will only indicate about

35-45% LEL on the display
SUBSTANCE LEL (Vol%) UEL (Vol%)
ACETONE 2.15 13
ACETYLENE 2.4 88
BUTANE 1.5 8.5
ETHANE 3 15.5
ETHYLENE 2.7 34
HEXANE 1.2 7.4
HYDROGEN 4 75.6
METHANE 5 15
PROPANE 2 9.5
 THE CATALYTIC GAS SENSOR

Limitations:
1. Cannot be used in an inert gas atmospheres – needs 13% or
more Oxygen.
2. Fails to danger due to Poisons and Blockage of flame
arrester
Silicones Water
De-greasing fluids Drilling fluids
Hot lube oils Oil
WD40
3. Methane calibrated detectors under-read concentrations of
higher hydrocarbon gases & vapours e.g. condensate vapours.
4. Older detectors can give ambiguous readings at high gas
concentrations
THE CATALYTIC GAS SENSOR

Catalytic sensors are

most commonly
calibrated to methane
for 0-100% LEL full
scale range

Why?
 THE CATALYTIC GAS SENSOR

Methane gas is a very common gas

and is often encountered in many
applications
 HOW FREQUENT SHOULD YOU CALIBRATE YOUR
GAS DETECTOR?

The only way to know that the readings are

accurate is to expose the instrument to known
concentration test gas;
To check the accuracy of the instrument on a
regular basis
 HOW FREQUENT SHOULD YOU CALIBRATE
YOUR GAS DETECTOR?

Any instrument which may be used in a

potentially hazardous location should be
checked with a known concentration test gas
before any daily period of use.

Normally 2.5% Methane in Air

PREMIXED CALIBRATION GAS
WHAT ARE THE BENEFITS FOR CALIBRATION?

Gas detectors are designed to help keep

your safe in potentially life threatening
environments.
If you test your instrument on a daily
basis you know that your readings are
accurate.
Confined spaces and other areas where
the air is potentially dangerous are
environments where you want to be sure
Don’t take a chance
with your life.

Verify accuracy
daily!
Summary
 EXPLOSIVE RANGE

100%
in volume

NO COMBUSTION (lack of oxygen)

UEL Upper Explosion Limit

HAZARDOUS AREA

LEL Lower Explosion Limit

Flammable gas
Sensor range No combustion (lack of gas

0%
in volume
 PERMIT TO WORK

Prior to Hot-Work in zones 1 or 2 or a Enclosed

Space, the areas must be checked to make sure that
it is safe for work to be carried out.

This work is carried under the Permit to Work system,

part of this includes the signing by a competent person
that the atmosphere is safe to work in.

A. Hot Work in Zone 1 and 2 and near an enclosed

space

B. Enclosed Space Entry

C. Inerting Operations
 GAS TEST DETAILS OF METER
1. Meter Serial numbers
2. Last Calibration date: (within one month of
today’s date.
3. Battery Check ( Condition)
4. Zero Check in fresh air
5. Check of hand or electrical operated pump
operation

Test for:
Oxygen, Flammable / Explosive and Toxic
vapours and gases
Operating The Various Combustible Gas Detectors.

Some basic rules for operating gas detectors:

• Ensure you select a gas detector you know how to

operate.
• Check that it has been calibrated within the last
month.
• Look for any signs of damage or misuse.
• Turn it on and confirm the battery and battery
voltage are acceptable.
• Operate it in a safe and atmosphere area to ensure
it "zeros“ properly.
Operating The Various Combustible Gas Detectors.

Refer to and perform the checks listed on the

instrument checklist.
• Know the limitations of each instrument
• Perform the procedures and retests, required by the
work permit or work plan.
• Go over the safety procedures and cover any special
safety "know how" with the men doing the work.
• Always allow at least 3 seconds for every metre of
hose for the sample to reach the sensor.
• Always approach and begin testing from upwind and in
the open fresh air.
 Sampling Considerations:

• Oxygen level
• Type of combustibles
• Vapor density
• Temperature
• Wind and air movements
• Possible leak points and size
• Possible traps
REMEMBER .. Gas accumulations may be found
anywhere!
Possible leakage points:

• FLANGES

• VALVE PACKING

• INSTUMENTS

• PUMP & COMPRESSOR SEALS

• TANK & MAHHOLES

• DECK DRAINS
 Gas testing only to be
carried out by Authorised
Gas Tester
Sign Apparatus Out/ In in
LOG

Report Any Defects

Report Any Anomalies
Know Your Permit!
POTENTIAL HAZARDS
 FIRE
The combination of fuel, air and
heat results in fire.

You may not SEE FLASH FIRE

You may not SMELL The combination of an
You may not TASTE accumulation of vapor with air
and heat in an open area will
But COMBUSTIBLES result in a flash fire.
can cause an unexpected
EXPLOSION
The combination of an
accumulation of vapor air and
heat in the right proportion in a
confined space results in
explosion.
 THANK YOU FOR
YOUR ATTENTION