AzSPU SSOW Procedure For Op and Maintenance of Gas Detection Equipment (Fixed & Portable)
AzSPU SSOW Procedure For Op and Maintenance of Gas Detection Equipment (Fixed & Portable)
AzSPU SSOW Procedure For Op and Maintenance of Gas Detection Equipment (Fixed & Portable)
AZSPU-HSSE-DOC-00052-2
Authority: AzSPU Safety & Compliance Custodian: Safety Systems/CoW Lead/Elman Shikhkerimov
Systems Manager/Yuliy
Zaytsev
Scope: AzSPU Document
Administrator: MS Document Coordinator
Issue Date: 05 October 2004 Issuing Dept: Safety & Compliance Systems
Revision Date: 25 January 2011 Control Tier: 2
Next Review 16 March 2011
Date:
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TABLE OF CONTENTS
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1. PURPOSE / SCOPE
This Safe System of Work provides the guidelines and procedures necessary to ensure a
safe working environment through the:
1.2 SCOPE
The contents of this procedure are applicable to all BP owned and managed sites /
installations in Azerbaijan and Georgia. Contractors working on BP owned or managed
sites / installations are also responsible for alignment with this procedure.
This document does not replace the procedures prepared and adopted by specialist
contractors. Neither does it supersede any national and local regulatory requirements.
This procedure contributes to compliance with Group Control of Work (CoW) standard that
the Hazards associated with BP activities are identified and that the risks are assessed and
managed.
All guidelines contained shall be regarded as the minimum requirements for BP owned or
managed sites / installations in Azerbaijan and Georgia.
The scope covers defined activities of BP and Contractors at all BP AzSPU sites and
installations.
2 DEFINITIONS
Refer to document AzSPU-HSSE-DOC-00021-2 HSE Definitions for definitions common to
this Procedure. Definitions specific to the Procedure are included below.
SM Site Manager
SC Site Controller
OIM Offshore Installation Manager
AA Area Authority
SSOW Safe System of Work
AGT Authorised Gas Tester
COW Control of Work
CSE Confined Space Entry
ICC Isolation Control Certificate
L2RA Level 2 Risk Assessment
PTW Permit to Work
RTC Risk It, Talk It, Check It Pre-Task Risk Assessment
TRA Task Risk Assessment
TA Technical Authority
Control Tier: <<2>> Revision Date: <<25 January 2011>>
Document Number: << AZSPU-HSSE-DOC-00052-2>> Print Date: 2/1/2011
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3 GENERAL REQUIREMENTS
In the absence of national legislation, or where national legislation is inconsistent with the
requirements of project specific agreements, BP Group Standards or applicable
requirements from UK or US legislation will be complied with.
Where requirements conflict, legal advice has been obtained and a defendable compliance
position adopted.
The standards and practices contained in this procedure are consistent with those
internationally recognized within the petroleum industry.
3.4 DEVIATIONS
This procedure is written in sufficient detail that it should be able to be applied consistently
at all sites / installations. There may still be the requirement for some local rules covering
site / installation specific logistical/administrative arrangements and local variations in
responsibilities to reflect differences in organisational arrangements. These local rules
should not deviate from the core processes within this document. Any form of deviation
from this procedure, including but not limited to local rules, shall be requested and
authorised in accordance with SSOW, Procedure for Deviations (Doc. No: AZSPU-HSSE-
DOC-00011-2).
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4 KEY RESPONSIBILITIES
The Site Manager / Site Controller / Offshore Installation Manager shall be responsible and
accountable for the application of this procedure in his area of responsibility, He shall
ensure:
That adequate numbers of Competent responsible persons are appointed to manage
and maintain the requirements of this procedure
Formally appointing suitably qualified and experienced persons to carry out:
o gas testing
o gas testing instrument calibration and testing
Ensuring that fixed gas detection systems on the site / installation are maintained in
an operational state
Ensuring that procedures are in place, to ensure gas testing is carried out wherever
necessary.
Area Authorities are responsible for ensuring that gas tests are carried out within their area
of responsibility wherever there is any possibility that combustible gas might be present.
Authorised Gas Testers are responsible for carrying out gas tests to the level to which they
are authorised.
5 GAS DETECTORS
Fixed gas detectors are detectors that are permanently placed at strategic locations, and
where deemed appropriate by local management, to monitor conditions on a continuous
basis. In particular they are placed wherever it is thought that combustible gas could collect
following an uncontrolled and unplanned release.
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Note: Fixed gas detection systems may initiate specific safety actions automatically.
Portable gas detectors are often used during activities that take place where
flammable/toxic gas could exist, for example, in confined spaces. In most cases, the use of
portable gas detection equipment will be called for by the work procedure / instruction.
It is recommended to use Multi-Gas detectors such as Triple Plus + IR (Intrinsically Safe
Portable Monitors), or Tetra (Intrinsically Safe Personal Multi-Gas Monitor).
Note: When the facility operates on purchased electrical power, shutdown features
must incorporate adjustable time delays to prevent plant shutdown from short
duration power outages. Automatic restart systems shall be overridden by the
shutdown system.
Partially attended sites / facilities (those which are not manned 24 hours a day) must
have suitable provisions incorporated so that affected plant / equipment can be
automatically shutdown for 24 hours without causing damage to the facility.
In partially attended facilities, any malfunction, abnormal condition, or failure of the fixed
gas detection system that actuates a plant or machinery shutdown must also actuate a
visual enunciator. A remote signalling device must be actuated during unattended periods.
In fully attended facilities, each any malfunction, abnormal condition, or failure of the
fixed gas detection system that actuates a plant or machinery shutdown must actuate a
visual and audible alarm prior to the shutdown. These alarms must actuate sufficiently
ahead of each shutdown point to give time for corrective measures to prevent a shutdown.
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Concentrations of combustible gases that will trigger alarms and shutdowns shall be as
follows. These are maximum set values. Set points may be lower.
Preferred solution
Voted gas detection system (eg 2003)
One detector achieve 20% Lower Explosive Limit – Low alarm, actuate
alarms/enunciator
Two detectors achieve 20% Lower Explosive Limit – High alarm, actuate trip
signal.
Non-preferred solution-required TA approval for new systems
Non-voted gas detection system (eg 1001)
The detector achives 20% Lower Explosive Limit – Low alarm, actuate
alarms/enunciator
Two detectors achieve 60% Lower Explosive Limit – High alarm, actuate trip signal.
Concentrations of toxic gases that will trigger alarms and shutdowns shall be as follows.
COSHH (UK)
Toxic Gas STEL (ppm) TWA (ppm)
CO 200 30
CO2 15 000 5000
H2S 10 5
HF 3 N/A(1.8)
5.2.4 Calibration
5.2.4.1 Frequency
Combustible gas detection systems shall be calibrated in accordance with the
manufacturer’s recommended procedures or at least every 6 months functional test/PM
shall be performed by authorized instrument or F&G technician which passed CAMS for
PMs.
Gas detectors are usually tested by using filter or gas from a test gas tank (2.5 %, 3.5%
and 4% methane in a nitrogen balance).
If failure functional test the detector will be replaced and returned to manufacture for
calibration/investigation.
Test Gas Tanks
Gas detectors are usually calibrated using gas from a calibration gas tank. It is a good
safety practice to install a tube from floor level to detectors placed at high levels and
ceilings. This permits introduction of the calibration gas through the tubes at ground level.
The contents of the test gas tank are under pressure. Therefore the following precautions
should be observed at all times:
Do not allow oil, grease or flammable solvents to contact the flow control of the
calibration gas tank.
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Do not store calibration gas tanks near heat or fire, or in room used for habitation.
When the tank is exhausted, discard in a safe place such as burial in the earth or in
sanitary landfill.
Do not throw in fire or incinerate.
Keep out of the reach of children.
It is not permitted and it is hazardous to refill these gas tanks.
Do not attach the test gas tank to any other apparatus other than described above.
5.2.4.2 Functional test/PM Records
Records must be maintained on the functional test/PM of these instruments at the site /
installation. Records should include the:
Detector location
Detector make/mode
Detector type
Date of functional test/PM
Functional test/PM results
Name of the person who completed the calibration
Note: On BP sites and installations in Azerbaijan and Georgia this means that
portable gas detectors may only be used by Authorised Gas Testers.
5.3.1.2 Use
Portable gas detectors, or explosimeters, use a set of batteries to measure the oxidation
rate of the combustible gas. This measurement is then read from a meter showing the gas
combustibility.
Portable combustible gas detectors shall be used when:
Introducing flame into an area which may contain a flammable atmosphere.
Lighting fired heater vessels.
Issuing hot work permits.
Doing all confined space entry work
Control Tier: <<2>> Revision Date: <<25 January 2011>>
Document Number: << AZSPU-HSSE-DOC-00052-2>> Print Date: 2/1/2011
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Leak seeking
Verifying gas-free conditions
Authorised Gas Testers are approved persons who have been trained and certified in gas
testing, they are authorised to test for the presence of flammable vapours, toxic gas and
oxygen as required in support of the Permit or Entry Certificate as requested by the AA.
Personnel required to operate portable gas detectors shall have completed the training
programme for Authorised Gas Tester Level 1, Level 2 or Level 3 and shall be formally
appointed by the Site Manager, Site Controller or Offshore Installation Manager for carrying
out gas test (see Safe System of Work AZSPU-HSSE-DOC-00012-2 Authorisation).
All training will be conducted by qualified personnel only and will be documented and kept
on file.
5.3.2.1 Gas Tester Level 1
Level 1 AGT’s are competent to carry out gas testing on all activities including Confined
Space Entry (CSE) activities. For confined space work the Level 1 AGT must retest the
atmosphere at the start of each shift, or when the work has been suspended for an
extended period within the shift.
5.3.2.2 Gas Tester Level 2
Level 2 AGT’s are qualified to carry out gas tests in support of all activities excluding
Confined Space Entry & carry out continuous monitoring during ongoing work.
5.3.2.3 Gas Tester Level 3
Level 3 AGT’s are individuals, usually the Performing Authority, who is approved by the
Site Manager / Site Controller / Offshore Installation Manager as having undergone
practical instruction on the use and interpretation of the results from both portable and
personal gas monitors. The AGT 3 has no authority to record gas test results the PTW:
their responsibility is only for continuous monitoring.
5.3.3 Operation
5.3.3.1 Personal Protective Equipment
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picture of the entire contents of the space. If the presence of a vapour is indicated,
the space or area must be re-evaluated to determine why, and corrective measures
must be taken before work proceeds.
Field calibration records must be documented by the tester. This documentation
should include the serial number of the unit, the date and results of the calibration
and the name of the person performing the calibration/gas testing.
5.3.3.3 Test Location
Location is important because the hazard may be restricted to a small portion of the entire
volume. Therefore, it is important to test the whole volume. If the vapour or gas has a
specific gravity which is different from that of air, there may be lighter gases collecting at
the top of the space while the heavier ones will hug the floor and collect in pits and sumps.
Note: Most flammable gases are heavier than air and will settle in low-lying areas.
5.3.3.4 Reading Interpretation
The operator must always watch the meter while testing. The needle can quickly rise and
fall in a high concentration and come to rest on that part of the scale that would indicate a
safe reading, yet in actual fact, an extremely dangerous concentration could exist. This is
particularly evident when strong concentrations of explosive vapour are in an oxygen
deficient atmosphere.
Some instruments cannot be used in oxygen deficient atmospheres. In these cases
detector tubes will be used to give accurate readings, or alternatively, purpose made gas
detector for oxygen deficiency atmosphere can be used, e.g. Triple Plus + IR. Utilizing
infrared sensing technology Triple Plus + IR is suitable for both high gas concentrations
and for use on inert (oxygen free) backgrounds.
5.3.3.5 Handling Portable Gas Detectors
Sampling Hoses:
Select the correct sampling hose for the specific application and always use the shortest
length of sampling hose (this will minimize the possibility of vapours condensing in the
hose), with exception of vessel sampling, i.e. testing from door way.
Before Use:
Before use, check the:
Calibration of the instrument to be sure it is reading accurately.
Battery charge and/or zero adjustment periodically.
Instruments for tightness
Purging:
Whenever a reading is obtained, purge the instrument in fresh air, and take a second test
to be certain of an accurate reading.
Purge the indicator by drawing in fresh air, even if another sample is not to be taken right
away, as this removes any possibility of contamination by corrosive gases in the
combustion chamber.
Restrictions in Use:
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Warning: Do not remove the flashback arrestors from the instrument. They
prevent the explosion that occurs in the combustion chamber from
passing back to the mixture being sampled.
Do not sample high temperatures with a cold instrument. Condensation may occur
and give a false reading. Whenever possible, the instrument must be at the same
temperature as the vapour being sampled.
Do not use the indicator for sampling gasoline vapours containing TEL (tetrathylead,
liquefied lead additive) unless the indicator has been approved for this specific
application.
Do not let the sampling hose or probe reach into a liquid.
Do not adjust the voltage when a sample is in combustion chamber.
5.3.4 Calibration
5.3.4.1 Calibration
Generally the portable gas detectors will be calibrated every 6 month in accordance
with the manufacturers’ instruction. Usually this is performed by sending detector to
a 3d party/manufacture or calibrated by certified personnel at site. An additional
calibration may be required when one of the following has happened:
Has been dropped
Used in a highly contaminated environment
Has been subjected to fluid entry
Has been subjected to extreme temperature change
5.3.4.2 Before Use
Portable combustible, toxic, oxygen gas detectors shall be inspected and zero checked, in
accordance with the manufacturer’s instruction, prior to use.
Check detector has a valid calibration
Where built-in test facilities are provided, function of the detector shall be confirmed prior to
use (self-test).
All such tests will be done upwind, in a clean fresh air environment, away from the area to
be tested. The reasons for testing in this area are to ensure:
The instrument is not contaminated and therefore may give false readings.
That personnel are in a safe working environment
Note: Function tests do not replace calibration. Function tests are only used to
confirm operation of the sensor and alarms.
Warning: Using a butane lighter to activate the alarm during function testing is
dangerous
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5.3.4.3 Records
Portable gas detectors will have calibrated sticker attached to them showing due date of
next calibration; carried out by properly trained and certified personnel amongst a staff.
Calibration and maintenance records must be documented by operating personnel and
maintained on file at the local field office.
Records must be maintained on the calibration of these instruments at the installation /
local field office. Records should include the:
Detector make/mode
Detector type
Date of calibration
Calibration results
Name of the person who completed the calibration.
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Revision/Review Log
30 September 2008 Central H&S Manager Central Safety TL General: The titled of the Procedure is
Alan McNulty Abbas Islamov changed to „Procedure for Operation and
Maintenance of Gas Detection Equipment
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05 December 2008 Yuliy Zaytsev Adalat Mamedov Authority position/name and custodian
Safety & Compliance Central Safety TL name have changed to reflect org changes
Systems Manager in HSE&TD.
16 September 2009 Yuliy Zaytsev Niyaz Mamedov, The numbering of the whole procedure is
Safety & Compliance HSE Systems / CoW changed in accordance with requirements
Systems Manager Adviser of Standardized Document Control
Procedure Template (AzSPU-HSSE-DOC-
00026-2).
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