Gas Tester Training Module

GAS TESTER TRAINING MODULE
Introduction – Atmospheric Testing

 The atmosphere of a permit space which may contain a
hazardous atmosphere should be tested for residues of all
contaminants identified by testing using Requisite
Instrument/equipment to determine that residual
concentrations at the time of testing and entry are within the
range of acceptable entry conditions,
 Air is a mixture of gases; any deviation from the normal
poses a serious threat in the working environment
 Gas detection minimizes the chances of serious injury or
death in the workplace, by proactive corrective actions.
2 Rev 01 07.05.09
We will Discuss
 Definitions
 Hazardous Atmospheres
 Confined Spaces
 Oil & Gas Hazardous Area.
 Physical & Chemical Properties of Gases
• Oxygen-hazard
• Combustible Atmospheres
• Toxic Gases- hazards
 Hazardous area mechanical & electrical equipment protection
methods
 Gas detectors & method of alert communication
 Atmospheric Testing
3 Rev 01 07.05.09
JARGON
 LEL: Lower Explosive Limit - % LEL
 PPM: Parts Per Million - toxic gas measurement
 PEL: Permissible Exposure Limit -
8 hr/day - 40 hrs/wk - (OSHA)
 TWA: Time Weighted Average - 8hr/day- (ACGIH)
 STEL: Short Term Exposure Limit -
15 mins/4x shift - (w/ 1 hr break - ACGIH)
 IDLH: Immediately Dangerous to Life and Health
30 mins - (NIOSH)
4 Rev 01 07.05.09
contd.
 Flamable Gas:
 Toxic Gas:-Toxic gas, vapours, or materials are those which have a
DAMAGING EFFECT on Health. In sufficient quantities they
can KILL or, cause considerable damage to the body.
 Gas Detectors: There are many types available which measure the
actual concentration of flammable / Explosive / Toxic gases in the
air,
 Auto Ignition Temperature: Is the temperature at which the
vapour will ignite WITHOUT A FLAME OR SPARK being applied.
5 Rev 01 07.05.09
.
CLASSIFICATION OF
HAZARDOUS AREA
6 Date:5.12.08
Hazardous Atmospheres
Def: Atmosphere that may expose employees to the risk
of death, incapacitation, impairment of self rescue, injury,
or acute illness
 An Atmosphere containing any flammable gas in a

concentration capable of ignition.
 Confined Spaces, and open locations can both contain
Hazardous Atmospheres
 Examples of these hazards atmospheres enriched with or
deficient in oxygen, are Combustibles, or Toxic Gases
7 Rev 01 07.05.09
CONFINED SPACES
8 Rev 01 07.05.09
Confined Spaces
An area that is large enough and so configured that an
employee can bodily enter and perform work; and has limited
or restricted means for entry or exit; and is not designed for
continuous employee occupancy
 Hazards  Fatality Factors
 Atmospheric  failure to recognize hazards
 O2 deficiency  incorrect emergency response
 O2 enrichment
 Prevention
 combustibles
 detection
 toxics
 monitoring
 Physical engulfment
9 Rev 01 07.05.09
Confined Space Examples
 Storage Tanks  Pipelines

 Sewers  Trenches
 Boilers  Pits
 Manholes  Silos
 Ship Voids  Vats
 Tunnels  Wells
10 Rev 01 07.05.09
Confined Space Entry
Deaths by Atmospheric. Hazard Types 2005
24%
7%
139 Incidents reported
28% all Involving Deaths,
41%
No Detection or
ventilation was used
Oxygen Deficiency
Combustible Gases 24 % of spaces were
Toxic Gases
Other
Toxic before entry.
11 Rev 01 07.05.09
Confined Spaces
Deaths by specific personnel 2005
139 Incidents Reported

139 Deaths
33% Supervisors
60% Rescuers
Tanks, vats/pits, digesters, and sewer manholes are the most

frequently encountered confined spaces
12 Rev 01 07.05.09
Permit Required Confined Spaces
Def: a confined space that has one or more of the following

characteristics:
 Contains or has the potential to contain a hazardous atmosphere

 Contains a material that has the potential for engulfing an entrant
 Has an internal configuration such that an entrant could be trapped or asphyxiated
 Contains any other recognized serious safety or health hazard
13 Rev 01 07.05.09
Classification of Hazardous Area
in Oil Mines
14 Date:5.12.08
What is Hazardous Area in Oil & Gas field?
An area where Hazardous atmosphere exists or is likely to have
occurrence of combustible & or Toxic gases
Classification:-
 Zone 0: This is an area in which hazardous atmosphere
is continuously present.
 Zone I: Any area in which hazardous atmosphere is
likely to occur under normal operating conditions
 Zone II: An area in which hazardous atmosphere is
likely to be present under abnormal operating
conditions
15 Date:5.12.08
A. Drilling & Work over Operation
1 Well Head Area
 When the derrick is not enclosed and substructure is

open to ventilation, the area in all directions from the
base of rotary table extending up to 3.0 m shall be
Zone 2 hazardous area. Any cellars, trenches & pits
below the ground level shall be Zone 1 hazardous area;
the area lying up to 3.0m in horizontal direction from
the edge of any cellars, trenches or pit & 0.5m
vertically above the cellars. Trenches or pit shall be
zone 2 hazardous area
16 Date:5.12.08
17 Date:5.12.08
Well Head Area
Contd
.
 When the derrick floor & Substructure are enclosed , the

enclosed substructure below the derrick floor, including
cellars, pits or sumps below the ground level, shall be Zone
1 hazardous area; the enclosed area above the derrick floor
shall be Zone 2 hazardous area
18 Date:5.12.08
. 2 Mud Tank & Channel
The free space above the level of Mud in tank and

channel shall be zone 1 hazardous area; the area in a
radius of 3.0m in all directions from the edge of Mud
tank and channel shall be zone 2 hazardous area
19 Date:5.12.08
3 Shale Shaker
 The area with in a radius of 1.5m in all directions from
the Shale Shaker in open air shall be Zone 1 hazardous
area. The area beyond 1.5m and up to 3m in all
directions from the shall shaker shall be zone 2
hazardous area
 When the shale shaker is located in enclosure, the
enclosed area shall be zone 1 hazardous area to the
extent of the enclosure. the are outside the shale shaker
& up to 1.5m in all directions from the shale shaker
shall be zone 2 hazardous area
20 Date:5.12.08
4 Degasser
The area within a radius of 1.5m from the

open end of the vent extending in all
directions shall be zone 1 ; the area beyond
1.5m and up to 3m in all directions from
the open end of the vent shall be zone 2
hazardous area
21 Date:5.12.08
5 Desander & Desilter
.
The area within a radius of 1.5m in all

directions from the desander and desilter
located in open air shall be zone 2
hazardous area
22 Date:5.12.08
6 Effluent Pit & Open Sump
 The free space above the level of flammable liquid within

the effluent pit or sump shall be zone 1 hazardous area; the
free space lying up to 3.0 in horizontal direction from the
edge of any effluent pit or sump & 0.5 m vertically above the
effluent pit or open sump shall be zone 2 hazardous area
23 Date:5.12.08
B. Oil Wells
A Flowing Well
An area below the ground level shall be zone 1 hazardous area;
the area lying up to 3.0m in horizontal direction from the
edge of any cellars, trenches or pit and 0.5. vertically above the
cellars, trenches or sump shall be Zone 2 hazardous area
24 Date:5.12.08
Flowing Well Layout
25 Date:5.12.08
B Artificial Lifted Wells
 the area in Wells equipped with sucker-rod pump to 3m above

the ground level and up to 3m horizontally in all directions
from the well head shall be zone-2 hazardous area. In case of
cellar, an area below the ground level shall be zone 1 hazardous
area the area lying up to 3.0m in horizontal direction from the
edge of any cellars and 0.5m vertically above the cellars shall be
zone 2 hazardous area.
 The area in wells equipped with submersible electric motor
driven pump or hydraulic sub-surface pump or gas lift well shall
be same as specified in clause B (1) when the Well is provided
with cellar or sump
26 Date:5.12.08
C
Well under production Test
 The area within a radius of 8m from an open

discharge of petroleum bearing fluid from a well
under production test shall be zone 1 hazardous area.
The area beyond zone 1 hazardous area for a further
distance of 8m in all directions shall be zone 2
hazardous area
27 Date:5.12.08
D Well Servicing Operation
 The area within a radius of 10 m in all direction from a

well-pulling and other such well servicing shall be zone 2
hazardous area.
Provided that where cellar or sump is present; the area
within the cellar or sump shall be zone 1 hazardous area
and the area up to 3.0m in horizontal direction from the
edge of any cellars or sump and 0.5m vertically above the
cellars or sump shall be zone 2 hazardous area
28 Date:5.12.08
Layout-Oil Servicing Operation
29 Date:5.12.08
E Gas vent
 The area within a radius of 1.5m from open end of the

vent extending in all directions shall be zone 1
hazardous area & area lying within a radius beyond
zone 1 hazardous area up to 3.0m of the vent shall be
30 Date:5.12.08
Oil & Gas processing and
storage Equipment
31 Date:5.12.08
1 Oil- gas separation vessels, fired vessels,
dehydrator , stabilizer, hydrocarbon recovery unit:-
 The area within a radius of 3.0m from any oil-gas
separation vessel, fired vessel, dehydrator , stabilizer
and hydrocarbon recovery unit shall be zone 2
hazardous area
 Any trench or pit below the ground level shall be
zone 1 hazardous area and the area lying up to 3.0, in
horizontal direction from the edge of any trench or
pit and 0.5m vertically above the trench or pit shall
be zone 2 hazardous area
32 Date:5.12.08
2 Gas vent
 The area within a radius of 1.5m from open end of the

vent extending in all directions shall be zone 1
hazardous area & area lying within a radius beyond
zone 1 hazardous area up to 3.0m of the vent shall be
33 Date:5.12.08
3 Relief valve
The area within a radius is not less than 3.0m from

discharge of a relief valve, extending in all directions
shall be zone 2 hazardous area subject to the conditions
that there shall be no electrical equipment in direct
path of discharge from relief valve
34 Date:5.12.08
Relief Valve
35 Date:5.12.08
4 Pig Trap
 The area within a radius of 1.5m of pig launching

/receiving trap extending in all directions shall be zone
1 hazardous area. The area lying beyond zone 1
hazardous area & up to a radius of 3m in all directions
from pig launching/receiving trap shall be zone 2
hazardous area
36 Date:5.12.08
Pig Trap
37 Date:5.12.08
5 Pump or Gas Compressor
 where a pump handling flammable liquid or a gas compressor

is located in open air or under well ventilated shed without
walls, the area lying up to 3.0m in all directions from the pump
or compressor shall be zone 2 hazardous area
 Where a pump or a compressor is located in an adequately
ventilated building, the entire interior of such building
including an area within 1.5m of th event shall be zone 2
hazardous area
 Pits, sumps, trenches below the ground level shall be zone 1
hazardous area and the area lying up to 3.0m in horizontal
direction from the edge of any trench or pit and 0.5m vertically
above the pits, sumps or trenches shall be zone 2 hazardous area
38 Date:5.12.08
Pump or Gas Compressor Layout
39 Date:5.12.08
6 Storage Tanks
 In case of floating roof tank, the space above the floating

roof & inside the enclosures up to top level of the
enclosure wall shall be zone 1 hazardous area. The area
beyond zone 1 hazardous area and up to a radius of 4.5m in
all directions from tank shell & shell top shall be zone 2
hazardous area. In case of a dyke , zone 2 hazardous area
shall extend vertically up to the height of the dyke &
horizontally up to the physical boundary of the dyke
40 Date:5.12.08
6 Storage Tanks
Contd.
 In case of fixed roof tank, the area inside the tank
and within a radius of 1.5m from all opening
including breather valve, dip hatch, thief hatch and
safety valve shall be zone 1 hazardous area. The area
beyond zone 1 hazardous area and up to a radius of
3.0m in all directions from shell & roof of the tank
shall be zone 2 hazardous area. In case of a dyke,
the sump in the dyke shall be zone 1 hazardous area
and an area extending vertically up to a height of
the dyke & horizontally up to the physical
boundary of the dyke shall be zone 2 hazardous area
41 Date:5.12.08
D. General
 Where ever sampling cock or bleed off valve is fitted, the

area up to 1.5m in all directions from the release point shall
be zone 2 hazardous area
42 Date:5.12.08
PHYSICAL & CHEMICAL PROPERTIES OF
GASES & EXPOSURE LIMITS
43 Rev 01 07.05.09
OXYGEN
44 Rev 01 07.05.09
Oxygen Deficiency
 Risk of asphyxiation
 Caused by
19.5% Oxygen
 Consumption
 people
 oxidation
 Displacement
 combustion
 decomposition
 Inertion
45 Rev 01 07.05.09
Oxygen Enrichment
 Serious fire hazard

 Materials burn much more rapidly
 Caused by
 leaking valves Oxygen
 leaking cylinders
23%
46 Rev 01 07.05.09
Effects of Oxygen
 23.5% Maximum safe level (OSHA)
 23.0% Oxygen enriched - fire hazard
 21.0% Oxygen content in “Air” (20.954%)
 19.5% Minimum safe level (OSHA)
 17.0% Impairment of judgement begins
 16.0% First signs of Anoxia
 16-12% Breathing and pulse rate increase,

coordination is impaired
47 Rev 01 07.05.09
Effects of Oxygen
 14-10% Fatigue, disturbed respiration
 10-6% Nausea and vomiting, inability to move

freely and loss of consciousness
 <6% Convulsive movements and gasping

respiration occurs; respiration
tops/minutes later heart action ceases
 3-5% Life expectancy; 3 - 5 minutes
48 Rev 01 07.05.09
COMBUSTIBLE ATMOSPHERE
49 Rev 01 07.05.09
Fire Triangle
Portable instruments:
Detect the combustible gas (fuel)
Detect oxygen level (air)
Must be intrinsically safe
(not source of ignition)
fuel air
source of ignition
50 Rev 01 07.05.09
LEL AND UEL FOR COMMON COMBUSTIBLES
NAME LEL UEL
Methane 5.3 13.9

Ethane 3.0 12.5
Propane 2.4 9.5
Butane (N) 1.9 8.5
Butane (ISO) 1.8 8.4
Hydrogen Sulphide 4.3 45.5
Gasoline 1.3 7.6
51 Rev 01 07.05.09
Example of Combustion
CUMBUSTIBLE AND EXPLOSIVE ATMOSPHERE
100% LEL UEL
(Natural Gas)
Methane
(CH4)
0 5.0 15 100% Vol
Too Lean Explosive Too Rich

to Burn Mixture to Burn
52 Rev 01 07.05.09
Example of Combustion
CUMBUSTIBLE AND EXPLOSIVE ATMOSPHERE
LEL UEL
(Gasoline)
PENTANE
(C5H12)
0 1.4 7.8 100% Vol
Too Lean Explosive Too Rich

to Burn Mixture to Burn
53 Rev 01 07.05.09
TOXIC GASES
54 Rev 01 07.05.09
Toxic Gases
 Toxic gases are compounds of elements that pose a
threat to human life - react in the body in a
poisonous fashion
 Toxic gases can enter the body through various ways,
they can be ingested, injected, or absorbed through
the skin
 Toxic gases are often colorless and odorless making
them a serious threat in the working environment
 The two most common are CO & H2S
55 IMS/Rev 02 27.08.18
Toxic Gases
 Chronically Toxic  Acutely Toxic
 prolonged exposure  inhibit cell respiration
 effect on hemoglobin  effect on enzymes
 flu-like symptoms  shut down lungs and other
(headache, dizziness,) organs
 medical effect may not be  can cause death
felt for many years  Hydrogen Sulfide (H2S)
 Carbon Monoxide (CO) most common
most common
56 Rev 01 07.05.09
Carbon Monoxide Data
 CO: Colorless, Odorless, byproduct of incomplete combustion

 Hazard: Flammable, LEL 12.5%
 Health: Very Toxic (can be absorbed 200-300 time faster than
oxygen by the hemoglobin)
Exposures: PEL/TWA 25ppm
C 200ppm
IDLH 1200ppm
 Industries : Steel mills, garages, general industries
57 Rev 01 07.05.09
Effects of CO
 25ppm Permissible exposure limit, 8 hr
 400ppm Frontal headache in 2-3 hrs
 1600ppm Headache and nausea 20 mins

Collapse and death in 1-2 hrs
 6400ppm Headache, dizziness in 1-2

mins, unconsciousness and
death in 10-15 mins
58 Rev 01 07.05.09
Hydrogen Sulfide Data
 H2S: Colorless, Rotten egg smell

 Hazard: Flammable, LEL 4.0%
 Health: Extremely Toxic, appears
naturally from decomposition, reacts
with the enzymes in the blood - inhibits
cell respiration
 Exposure: PEL/TWA 10ppm
STEL 15ppm
IDLH 100ppm
 Industries : Oil and Gas, pulp and
paper, waste water treatment
59 Rev 01 07.05.09
Effects of H2S
 .13ppm - Minimal perceptible odor
 10ppm - Beginning of eye irritation,

permissible exposure limit
 100ppm - Coughing, eye irritation,

loss of sense of smell after
2-5 minutes
 500ppm - Loss of consciousness and

possible death 30 mins - 1 hr
60 Rev 01 07.05.09
Chlorine Gas Data
 CL2: Greenish-yellow gas with a pungent odor

 Hazard: Will not explode, will react explosively to
ammonia, turpentine & fuel oil
 Health: Extremely toxic
 Exposures: PEL/TWA 0.5ppm
STEL 1ppm
IDLH 10ppm
 Industries: Municipal pools, pulp and paper,
water treatment plants, Hazmat
61 Rev 01 07.05.09
Effects of CL2
 0.5ppm-Permissible
exposure Level
 3ppm - Irritation of the
mucus membranes, eyes and
respiratory track
 15ppm - Causes immediate
irritation of the throat
 30ppm - Maximum
exposure for a 30 minute
period
62 Rev 01 07.05.09
Nitrogen Dioxide Data
 NO2: Yellowish-brown gas with a pungent, acid odor
 Hazard: will not explode
 Health: Extremely toxic

 Exposures: PEL/TWA 1ppm
STEL 5ppm
IDLH 20pppm
 Industries: Mining and all machinery using diesel

engine, chemical plants
63 Rev 01 07.05.09
Effects of NO2
 1ppm - Permissible exposure limit (PEL)

 20ppm - Irritation of eyes, nose and throat
 50+ppm Chest Pain, Pulmonary Edema
64 Rev 01 07.05.09
Sulfur Dioxide Data
 SO2: Colorless gas, irritating pungent odor

 Hazards: will not explode, can combine with water to
form sulfuric acid (H2SO4) - “ACID RAIN”
 Health: extremely toxic
STEL 5ppm
IDLH 100ppm
 Industries: Pulp and paper, coal fired power
plants, fossil fuels
65 Rev 01 07.05.09
Effects of SO2
 0.3-1ppm - Initially detected by taste

 2ppm - Permissible exposure limit
 20ppm - Irritation of nose, throat and eyes **
 100ppm - Choking, Bronchial Restriction
** Sulfuric Acid (H2SO4) = SO2 + H2O
66 Rev 01 07.05.09
Ammonia Data
 NH3: colorless gas with a suffocating odor

 Hazards: Difficult to burn, LEL 15%
STEL 35ppm
IDLH 300ppm
•Industries: Fertilizer plants, poultry

farms, Refrigeration industries
67 Rev 01 07.05.09
Effects of NH3
 0-25ppm - Minor irritation of the eyes and respiratory tract
 25ppm - Permissible Exposure Limit

 50-100ppm - Swelling of the eyelids, conjunctivitis, vomiting,
irritation of the throat
•100-500ppm -Very dangerous concentrations,

death from prolonged exposure
68 Rev 01 07.05.09
Hydrogen Cyanide Data
 Hazard : Colorless to a pale blue gas, will explode,

LEL 5.6%
 Health : extremely toxic, has a distinct taste
resembling bitter almonds
STEL N/A
IDLH 50ppm
 Industries: Leaching of precious metals, mining, chemical
plants
69 Rev 01 07.05.09
Effects of HCN
 10ppm : Permissible Exposure

Limit
 5-10ppm: Headache, dizziness,
unsteadiness
 50-100ppm: Feeling of suffocation,
nausea
 100-200ppm: Death from
exposure in 30 to 60 minutes
70 Rev 01 07.05.09
Nitric Oxide Data
 NO: Colorless gas, typically formed when air is super
heated and nitric compound like dynamite explode
 Hazards: will not burn, will accelerate burning
 Exposure limit: PEL/TWA 25ppm
STEL N/A
IDLH 100ppm
 Industries: blasting, welding, and
diesel combustion
71 Rev 01 07.05.09
Effects of Various NO Levels
 0-50ppm - Slight irritation of mucous membranes.

 60-150ppm -Irritation is more intense, coughing and
burning of the throat is evident, symptoms will clear if
victim is removed quickly to clean air.
 200ppm+ Don’t go there!
72 Rev 01 07.05.09
HAZARDOUS AREA MECHANICAL
& ELECTRICAL EQUIPMENT
PROTECTION METHODS
73 Rev 01 07.05.09
.
74 Date:5.12.08
Regulation 67 “ Safe Distances”
Within 30 meters of any Wells, Separator, petroleum
storage tank or source of flammable gases-
Smoking
Naked light
Open flame
Spark
Flame type Equipment
75 Date:5.12.08
Regulation ”68 & 77’’
 Where an Internal combustion Engine is located with

in 30 meters of any Well
o Engine Exhaust shall be insulated and directed away
from Well
o Exhaust shielded to prevent its contact with liquids or
Gases which might otherwise fall on it.
o Diesel Engine equipped with air intake shut-off valve
(Kill-valve) and
o Spark Arrest on Exhaust
76 Date:5.12.08
Explosion proof Enclosure
 Explosion proof enclosure – By definition means it must prevent
the ignition of explosive gases or vapors that may surround it. In
hazardous areas class I, Div 1 and 2 arching devices such as
switches, contactors and motor starters must be enclosed in an
explosion proof enclosure specifically rated for that area.
 An explosion inside an enclosures must be prevented from starting
a larger explosion outside the enclosure.
 "Apparatus enclosed in a case that is capable of withstanding an
explosion of a specific gas or vapor that may occur within it and of
preventing the ignition of a specified gas or vapor surrounding the
enclosure by sparks, flashes, or explosion of the gas or vapor
within, and that operates at such an external temperature that a
surrounding flammable atmosphere will not be ignited thereby."
77 Date:5.12.08
Use of Electrical Equipment in hazardous area
 Zone 0: No electrical equipment should be allowed in this area
when this is not practicable intrinsically safe electrical equipment
categories Ia & Ib & associated circuits should be employed. Type
of protection ‘I’
 Zone I:
o Type of protection applicable for Zone ‘0’
o Flame proof equipment type of protection ‘d’
o Pressurized enclosures type of protection ‘P’
o Sand filled type of protection ‘q’
o Oil immersed apparatus type of protection ‘0’
o Such other apparatus as may be specially certified or assured for
78
use in zone ‘I’ area Date:5.12.08
Use of Electrical Equipment in hazardous area Contd.
 Zone II:
o Type of protection applicable for Zone ‘0’ & Zone ‘I’
o Increased safety type of protection ‘e’
o Non sparking apparatus type of protection ‘n’
Normally we use flame proof equipment (Ex-d) in Zone ‘I’ &

Zone ‘II’ because they are robust, permit the maintenance of
internal equipment & available in all ranges.
79 Date:5.12.08
EQUIPMENT CLASSIFICATION
European - IEC - Area USA - Area of use
Area of use of use Designation
. Designation Designation Standard
Standard Standard
Flameproof Enclosure – An Zones 1 & 2 Zones 1 & 2 Class 1 Divisions 1
enclosure used to house EExd Exd &2
electrical equipment, which EN50018 IEC60079-1 UL1203
when subjected to an internal
explosion will not ignite a
surrounding explosive
atmosphere.
Intrinsic Safety – A Zones 0, 1 & 2 Zones 1 & 2 Class 1
technique whereby electrical EExi Exi Divisions 1 & 2
energy is limited such that any EN50020 IEC60079-11 UL913
sparks or heat generated by
electrical equipment is
sufficiently low as to not ignite
an explosive atmosphere.
80 Date:5.12.08
Zones 1 & 2 Zones 1 & 2

Increased Safety – This
EExe Exe
equipment is so designed as to
EN50019 IEC60079-7
eliminate sparks and hot
surfaces capable of igniting an
explosive atmosphere.
Zones 1 & 2 Zones 1 & 2 Class 1

Purged and Pressurised – EExp Exp Divisions 1 & 2
Electrical equipment is housed EN50016 IEC60079-2 NFPA496
in an enclosure which is
initially purged to remove any
explosive mixture, then
pressurised to prevent ingress
of the surrounding atmosphere
prior to energisation.
81 Date:5.12.08
Encapsulation – A method of Zones 1 & 2 Zones 1 & 2
exclusion of the explosive EExm Exm
atmosphere by fully EN50028 IEC60079-18
encapsulating the electrical
components in an approved
material.
Oil Immersion – The Zones 1 & 2 Zones 1 & 2 Class 1
electrical components are EExo Exo Division 2
immersed in oil, thus excluding EN50015 IEC60079-6 UL698
the explosive atmosphere from
any sparks or hot surfaces.
Powder Filling – Equipment is Zones 1 & 2 Zones 1 & 2
surrounded with a fine powder, EExq Exq
such as quartz, which does not EN50017 IEC60079-5
allow the surrounding
atmosphere to come into
contact with any sparks or hot
surfaces.
82 Date:5.12.08
Powder Filling – Zones 1 & 2 Zones 1 & 2

Equipment is surrounded EExq Exq
with a fine powder, such as EN50017 IEC60079-5
quartz, which does not
allow the surrounding
atmosphere to come into
contact with any sparks or
hot surfaces.
Zone 2 Zone 2
Non-sparking – Sparking .
EExn Exn
contacts are sealed against
EN50021 IEC60079-
ingress of the surrounding
15
atmosphere, hot surfaces
are eliminated.
83 Date:5.12.08
Equipment Marking
84 Date:5.12.08
Ingress Protection
2 digits are used to denote the level of ingress protection that a piece of apparatus enjoys :–
(The first digit denotes the level of protection against solid objects and the second against liquids)
Solids Liquids
. .
0
No protection. 0 No protection.
1
Protected against solid objects 1 Protected against vertically falling
up to 50mm, e.g. hands. drops of water.
2
Protected against solid objects 2 Protected against water spray up
up to 12mm, e.g. fingers. to 15 degrees from vertical.
3
Protected against solid objects 3 Protected against water spray up to
up to 2.5mm, e.g. tools. 60 degrees from vertical.
4
Protected against solid objects 4 Protected against water sprays from
over 1mm, e.g. wires. all directions.
5
Protected against dusts. 5 Protected against water jets from
(No harmful deposits). all directions.
6
6 Protected against strong water jets
Totally protected against dust.
from all directions, e.g. Offshore.
7 Protected against immersion between
. . 15cm and 1m in depth.
8 Protected against long immersion
85
under pressure. Date:5.12.08
Flame proof Enclosure
 An enclosure used to house electrical equipment,
which when subjected to an internal explosion will
not ignite a surrounding explosive atmosphere.
 Zones 1 & 2, EExd – European
 Zones 1 & 2 Exd – IEC
 Zones 1 & 2 Class I Div I, - USA,
86 Date:5.12.08
GAS DETECTORS & METHOD OF
ALERT COMMUNICATION
87 Rev 01 07.05.09
The Gas detector are classified with respect to its applications and
accessibility to prevent the prevent emergency situation due
failure of basic controls to create an emergency situation.
 Hydrocarbon or LEL Gas detector / Explosive meter
 Multiple Portable Gas detector
 Fixed Gas detection system
 Personal Gas detector

The Gas detectors are equipped with several types of Sensors &
the selection and use of the gas detector is dependent on type of
hazardous environment, temperature and humidity in the
prevailing atmosphere.
Doc No.- IMS/HSE/PP-01/ENI/ Rev. No:
88 01
Sensors used for Detection Instruments
Catalytic sensor, - the operation of this type of sensor depends upon the
oxidation of gases on an electrically heated catalytic element
Electrochemical sensor (Electrochemical sensor), - The operations of

this sensor depends upon changes of the electrical parameters of electrodes
placed in an electrolyte due to redox reactions of the gas on the surface of
the electrodes.
Flame ionisation detector (FID sensor), - the operation of this type of

sensor depends upon the ionization of the gas being detected in a hydrogen
flame.
Flame temperature analyser (FTA sensor), - the operation of this type

of sensor depends upon the change of temperature of a flame by the gas
being detected.
Infrared absorption sensor, - the operation of this type of sensor
depends upon the absorption of infrared radiation by the gas being
detected.
Photo ionisation detector (PID sensor), - the operation of this type of

sensor is based on the ionisation of gaseous compounds by ultraviolet (UV)
radiation
89
Doc No.- IMS/HSE/PP-01/ENI/ Rev. No: 01
Generally used sensors
Catalytic Sensor-Flammable gas contacting the catalytic surface of the
detecting element is oxidised, causing a rise in temperature of the bead. This rising
temperature increases the resistance of the platinum coil. There is no such change
in the compensating element. The output signal of the detector is based on the
imbalance between the two resistances.
However catalytic sensors are poisoned or inhibited by silicones, sulphides, chlorine,
lead and halogenated hydrocarbons. The detectors therefore require regular
cleaning and calibration, increasing the costs of maintenance. Pellistor sensors also
require the presence of oxygen in order to operate.
Infrared Sensor -Gases that contain more than one type of atom absorb
infrared radiation. Hydrocarbon gases such as methane, propane and butane are
gases of this type. An infrared gas detector consists of an infrared source and an
infrared detector. When flammable gas passes between the source and detector, the
gas absorbs infrared radiation and a lower intensity is registered at the detector.
Specific gases are detected by measuring the amount of absorbed infrared radiation
at specific wavelengths, the difference being related to the concentration of gas
present.
Infrared detectors are immune to poisoning effects and operate in inert
atmospheres. They are therefore suitable for use in confined spaces where oxygen
depletion might limit the effectiveness of catalytic sensors.
90
Oxygen Detectors
Oxygen detectors used in industrial safety applications
typically utilise an electrochemical sensor, which contains a lead
wool material in contact with electrodes and electrolyte. When
oxygen is allowed to diffuse into this material the
electrochemical reaction causes a current to flow. Such sensors
are very reliable, but once all of the lead has been consumed
the sensor needs to be replaced.
The Alert alarm are set at 19.5 % by volume.
91
Multi Gas Detector
The portable multigas detector, which is
exceptionally easy to use and service, protects
against the four most prevalent gas hazards: carbon
monoxide (CO), hydrogen sulphide (H2S),
flammable gases and oxygen (O2) depletion or
enrichment.
A simple sequence of inspections may include the following:
1. checking the battery voltage and/or battery condition;

2. allowing adequate warm-up time;
3. checking for sample-line leaks and proper flow in aspirated apparatus;
4. checking that a zero reading is displayed when operated in clean air (see note below);
5. performing a response check.
92
Operational Checks of Portable Gas Detectors
a) Visual inspection
• Check the apparatus for abnormal conditions such as malfunctions, alarms, non-
zero readings, etc.
• Ensure that the detector head assembly is free of obstructions or coatings which
could interfere with the gas or vapour reaching the sensing element. Ensure that
the sample drawn is correct for sample-draw systems.
• For sample-draw systems, inspect flow lines and fittings. Cracked, pitted, bent or
otherwise damaged or deteriorated flow lines or fittings should be replaced with
those recommended by the manufacturer.
b) Response (sensitivity) checking
This should be, at least, the field check (response check) or the re-calibration in
either of these consists of:
• Ensuring that the apparatus indicates zero when zero gas is present;
temporarily isolating the sensing element if necessary.
• Applying a known calibration gas to the detector head, following the
manufacturer's instructions.
93
LEL GAS MONITOR
LEL Gas Monitor. An LEL Monitor is an instrument used to detect
hazardous levels of a combustible gas or solvent vapor in air, expressed in
% LEL, or Lower Explosive Limit. An LEL Monitor is also referred to as
an LEL Gas Detection System, can be an Explosimeter or Hydrocarbon
monitoring fixed gas detection system.
When a percentage of the lower explosive limit
(LEL) of an atmosphere is exceeded, an alarm
signal on the instrument is activated. "
94 Doc No.- IMS/HSE/PP-01/ENI/ Rev. No: 01

Fixed Gas detection System
Fixed monitors are
generally put in places
primarily to protect the
facility, to detect
catastrophic leaks or
to be an early warning
of gases leaking from
a system.
Fixed gas detection systems are often required to protect facilities by the
insurance companies who are underwriting them and even by some standard
electric codes. By protecting the facility, they are also protecting the lives of the
people working in the facility.
95
Fixed Gas Detection system
a) Apparatus having the sensor and control unit situated within
the hazardous area. In this situation the sensor and control unit
may be combined or supplied as separate items.
b) Apparatus having one or more sensors separate from the

control equipment. This type of apparatus usually consists of
individual sensors in the hazardous area, connected to the
associated control equipment in a safe area.
c) apparatus usually consists of one or more sampling points in

the hazardous area, connected to a sensor by means of aspirated
sample lines made of suitable materials which are compatible with
the sample. It may be more suitable than types a) or b) where
comparatively static process conditions apply and where
conditions (environmental or accessibility) at the same point are
unfavourable to the sensor, These devices may increase the
response time, may be affected by corrosion, and may be prone to
blockage by dust or condensation.

Operational checks of Fixed Gas Detection systems
1. Regular visual inspection - Regular inspection of the control panel
should be made (for example one per shift). Records made of each
check, including any problems, should be signed, dated and filed.
Problems found should be corrected promptly.
2. Regular functional verification - Regularly, verification of the control
and alarm panel should be made using test switches to ensure that
lights, alarms and electronics are operating normally. This functional
check will vary depending on the unit used. Problems found should be
corrected promptly.
3. Regular calibration and system operation test - This is essential for
the ongoing reliability of the system. In the case of sensor-based
systems it includes subjecting each head to the calibration gas, thus
allowing a complete loop check of the electronics and the sensor by
maintaining accurate records of information about system patterns,
particularities, component life, etc. By doing so, potential problems can
be averted before they develop.
97
Personal Detectors
Single-Gas, Gas Monitors. Improve
worker safety with wearable and hand-
held personal gas monitors. ...
The monitors can detect and monitor a
wide range of gases including Carbon
Monoxide (CO), Hydrogen Cyanide
(HCN) and Hydrogen Sulfide (H2S).
Toxic gas diffuses through a permeable membrane, as the volume of gas

increases in the air, an oxidation or reduction reaction occurs at one of the
electrodes, and as a result, a linear current change occurs, giving an alarm as it
goes beyond the PEL.
Personal monitors are designed to protect personnel who may be working in a
given area by alerting the person by audio visual alarm.

Routine checks and recalibration
Portable Gas detetctor apparatus should be regularly recalibrated in a suitable
workshop by a competent person. Any apparatus that is used infrequently should,
nevertheless, be regularly inspected, and calibrated, so that it may be available for
immediate use when required. This should be done in accordance with the
manufacturer's instructions and typically may include:
1. Resetting of the mechanical zero of analogue meters;

2. Checking the tightness of all electrical connections (remote detector head,
power supply etc.);
3. Allowing adequate warm-up time;
4. Checking for sample-line leaks and proper flow;
5. Checking for clogged or dirty flame-arresting systems;
6. Checking the battery voltage and/or battery condition and making any
required adjustments or battery replacements.
7. Performing a test of the failure (malfunction) circuit(s);

99 01
100
ATMOSPHERIC TESTING
101 Rev 01 07.05.09

Atmospheric Testing
Ref: CFR 1910.146 (C) subsection (C): before an employee
enters the confined space, the internal atmosphere shall be
tested for the following conditions in the order given:
 O2 – To check the oxygen level for deficiency or enrichment.
 Oxygen >19.5%vol
 Combustible gas – To test for levels of flammable or explosive gases.
 Combustible Gases <10% LEL / CH4
 Toxic gas levels –
 Toxic Gases depends on gas type
102 Rev 01 07.05.09

Evaluation testing
 Evaluation testing is done to:
 When about to work in a hazardous area it is necessary to
specifically check on the potential.
 Determine what chemical hazards are or may become
present in the space’s atmosphere, and toxicity of the
atmosphere and the likely origin of any oxygen deficiency
with the plant Safety Officer, or equivalent, particularly if
confined spaces are involved.
 Identify what steps must be followed and what conditions
must be met to ensure that atmospheric conditions are
safe for a worker to enter the space.
103
Safety Precautions by Tester
 Oxygen deficiency may be due to the presence of toxic amounts of some other
substance.
 Some flammable gases (for example ammonia, hydrogen sulphide) and almost all
vapours are also toxic and even lethal at very low percentages of LFL.
 If the combustible gas apparatus is also equipped with high sensitivity sensors for
specific toxic gases, it should be realized that they will usually not detect other
toxic materials.
 Gas detecting apparatus on its own may not be sufficient protection if toxic
substances are likely to be present. In some instances an appropriate respirator
and /or other devices may be needed as well.
 Switch on the apparatus, allow it to warm up as necessary, and perform any fresh
air checks in a safe area but as close as practicable to the ambient conditions in
the area to be monitored.
 When entering the potentially hazardous area the user should frequently observe
the readings on the apparatus. The user could be entering an already dangerous
situation and may need all the warning they can get.
104
Verification Testing
 Before a permit is issued space that may have a hazardous
atmosphere can be entered, the atmosphere must be tested using
the steps identified on the permit.
 Verification testing is done to make sure that the chemical hazards
that may be present are below the levels necessary for safe entry,
and that they meet the conditions identified on the permit.
 Test the atmosphere in the following order:
(1) for oxygen,
(2) for combustible gases, and then
(3) for toxic gases and vapors. The testing results -- the actual
test concentrations -- must be recorded on the permit
105 01
Duration of Testing
 One must allow enough time for the air from the space to be
drawn into the equipment and for the sensor (or other
detection device) to react to the chemical if it is present.
Known as “minimum response time”
 if you have attached hosing or a probe extension to the inlet.
The additional time is needed to allow the air from the
different depths of the space to be pulled into the equipment
inlet.

106 01
Atmospheric Testing
Sample When / Where?
prior to entry top, middle TOP
bottom continuously
During entry**
prior to re-entry MIDDLE
Sample Why?
stratification / weights
BOTTOM
** ref: CFR 1910.146 (c) subsection (D): there may be no
hazardous atmosphere within the space whenever any employee is
inside the space
107 Rev 01 07.05.09

Atmospheric Testing
METHANE (lighter than air)
108 Rev 01 07.05.09

Atmospheric Testing

CARBON MONOXIDE (A Bit lighter than air)
109 Rev 01 07.05.09
Atmospheric Testing

CARBON MONOXIDE (A Bit lighter than Air)
HYDROGEN SULFIDE (heavier than air)
110 Rev 01 07.05.09
 Alarm set point - Alarm setpoint fixed or adjustable
setting of the apparatus that is intended to pre-set the level of
concentration at which the apparatus will automatically
initiate an indication, alarm or other output function.
 As per the Flammability, Toxicity & Oxygen deficiency level,
against a specific type of Gas the alarm is set by Manufacturer
against the PEL, STEL, & TWA.

Exposure Alarm for STEL
 The STEL alarm is calculated over a 15-minute exposure. Calculation examples are as
follows: for H2S
 Assume the Detector has been running for at least 15 minutes:
 15-minute exposure of 35 PPM:
(15 minutes x 35 PPM) = 35 PPM
15 minutes
 10-minute exposure of 35 PPM
 5-minute exposure of 15 PPM:
(10 minutes x 35 PPM) + (5 minutes x 5 PPM) = 25 PPM
15 minutes
Alarm will sound at STEL above 15PPM.
112 Rev 01 07.05.09

Exposure Alarm for TWA
 The TWA alarm is calculated over an eight-hour exposure. Calculation
 examples are as follows:
 1-hour exposure of 50 PPM:
(1 hour x 50 PPM) + (7 hours x 0 PPM) = 6.25 PPM
8 hours
 4-hour exposure of 50 PPM
(4 hours x 50 PPM) + (4 hours x100 PPM) = 75 PPM
8 hours
(12 hours x 100 PPM) = 150 PPM
8 hours
113 Rev 01 07.05.09

Safety Precautions During Gas Testing
 Do not try to check the confined space
before gas testing.
 Do not get down to confined space to
test gas
 Testing Must be done by a Qualified
person using a Properly Calibrated
Direct Reading Instrument.
 Gas tester, should know how to use the
equipment.
 Lower the Gas detection instrument
probe
 The testing should be done at all
depths/levels to ascertain any type of
hazard.
114 Rev 01 07.05.09
 Check calibration before each day's use and adjust
if necessary.
 Check calibration more frequently if exposed to
silicone, silicates, lead-containing compounds,
hydrogen sulfide over 200 ppm or exposures
 over 50 ppm for one minute, or high contaminant levels.
 Recheck calibration if unit is subjected to physical
Shock.
 Use only to detect gases/vapors for which a sensor
is installed.
115 Rev 01 07.05.09

 Do not use gas detector to detect combustible dusts or
mists.
 Make sure adequate oxygen is present.
 Do not block sensors.
 Do not recharge Li ION battery in a combustible
atmosphere.
 Do not replace alkaline batteries in a combustible
atmosphere.
 Do not alter or modify instrument.
116 Rev 01 07.05.09

Summary
 Hazardous conditions can exist

ANYWHERE and at ANYTIME
 Never trust your senses, always use a
calibrated gas detection instrument
Because
 It may very well Save your Life
117 Rev 01 07.05.09

THANKS

118 01

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Introduction – Atmospheric Testing

 An Atmosphere containing any flammable gas in a

 Storage Tanks  Pipelines

139 Incidents Reported

Tanks, vats/pits, digesters, and sewer manholes are the most

Def: a confined space that has one or more of the following

 Contains or has the potential to contain a hazardous atmosphere

1 Well Head Area

 When the derrick is not enclosed and substructure is

 When the derrick floor & Substructure are enclosed , the

The free space above the level of Mud in tank and

The area within a radius of 1.5m from the

The area within a radius of 1.5m in all

 The free space above the level of flammable liquid within

 the area in Wells equipped with sucker-rod pump to 3m above

 The area within a radius of 8m from an open

 The area within a radius of 10 m in all direction from a

 The area within a radius of 1.5m from open end of the

 The area within a radius of 1.5m from open end of the

The area within a radius is not less than 3.0m from

 The area within a radius of 1.5m of pig launching

 where a pump handling flammable liquid or a gas compressor

 In case of floating roof tank, the space above the floating

 Where ever sampling cock or bleed off valve is fitted, the

 Serious fire hazard

 23.0% Oxygen enriched - fire hazard

 21.0% Oxygen content in “Air” (20.954%)

 19.5% Minimum safe level (OSHA)

 17.0% Impairment of judgement begins

 16.0% First signs of Anoxia

 16-12% Breathing and pulse rate increase,

 14-10% Fatigue, disturbed respiration

 10-6% Nausea and vomiting, inability to move

 <6% Convulsive movements and gasping

 3-5% Life expectancy; 3 - 5 minutes

NAME LEL UEL

Methane 5.3 13.9

100% LEL UEL

0 5.0 15 100% Vol

Too Lean Explosive Too Rich

Too Lean Explosive Too Rich

 CO: Colorless, Odorless, byproduct of incomplete combustion

 25ppm Permissible exposure limit, 8 hr

 400ppm Frontal headache in 2-3 hrs

 1600ppm Headache and nausea 20 mins

 6400ppm Headache, dizziness in 1-2

 H2S: Colorless, Rotten egg smell

 .13ppm - Minimal perceptible odor

 10ppm - Beginning of eye irritation,

 100ppm - Coughing, eye irritation,

 500ppm - Loss of consciousness and

 CL2: Greenish-yellow gas with a pungent odor

 Hazard: will not explode

 Health: Extremely toxic

 Industries: Mining and all machinery using diesel

 1ppm - Permissible exposure limit (PEL)

 SO2: Colorless gas, irritating pungent odor

 0.3-1ppm - Initially detected by taste

** Sulfuric Acid (H2SO4) = SO2 + H2O

 NH3: colorless gas with a suffocating odor

•Industries: Fertilizer plants, poultry

 0-25ppm - Minor irritation of the eyes and respiratory tract