JMS Consultants

Authorised Gas Tester

Assessed Competency
Course

Presented by:
John M Sonley, C.Sci C.Eng
MIGEM MEI C.Chem FRSC

Gas Molecules

Properties of Flammable Gases

FLAMMABILITY AND IGNITION
Most natural gases are mainly methane - typically 70 - 90 % methane
mixed with smaller amounts of the other hydrocarbon gases
Flammability Limits for Methane in Air

% Vol. Methane % LEL Methane

UEL 17%

LEL 4.4%

80% LEL

= 3.52% methane in air

60% LEL

= 2.64% methane in air

40% LEL

= 1.76% methane in air

20% LEL

= 0.88% methane in air

0% Methane
( Clean Air)

BUMP Test
2.2% methane in air

Ignition of methane
= 50% LEL
Flammable mixtures of methane and air may ignite if heated above
the auto-ignition temperature , which for methane is 538oC
- without any other source of ignition being present
Flammability of Other Gases BS EN 61779-1:2000

Gas
Ethane
Propane Butane
Pentane Hydrogen -

LEL
2.5 %vol.
1.7 %vol.
1.4 %vol.
1.4 %vol.
4.0 %vol.

Response Factors
of the catalytic flammable gas sensor
to a range of hydrocarbons

Gas at its LEL Concentration

Meter Reading % LEL

Methane

100

Ethane

68

Propane

55

n-Butane

59

n-Pentane

46

Hexane

37

Heptane/Octane

38

Nonane

31

Hydrogen

77

Containment of:
Gases/Vapour/Liquids

Containment of hazard
.

use sampling system

Condensate
or Solvent

Other heavy gases:

Carbon dioxide: R.D. =
1.5
Chlorine: R.D. = 2.5

Vapour Cloud

Units of Measurement
Oxygen

10
10% vol

Flammables

Toxics

10

10

10% LEL
0.44% vol

10 ppm
0.001% vol

Clean Air

Oxygen = 20.95% vol.

Nitrogen = 78.08% vol.

Properties of Harmful
and Toxic Gases
ASPHYXIANT GASES
Large amounts of natural gas and some
other gases displace oxygen from the air
we breathe and cause suffocation

GAS

APPLICATION / WHERE FOUND

Nitrogen Pipeline and vessel purging

operations
Pipe freezing operations
Argon

Argon arc welding

Hazards of Oxygen

<19% Oxygen
Deficiency

>23% Oxygen
Enrichment

Properties of Harmful and Toxic Gases

TOXIC GASES
Small amounts of some gases and vapours found in the oil
industry poison our bodies- we measure these amounts in
parts per million - ppm.
For example :

10 ppm = 0.001%
1000 ppm = 0.1 %

GAS

APPLICATION / WHERE FOUND

Condensate / heavy
hydrocarbon vapours

Crude oil residues, oil condensate residues

and sludges

Hydrogen sulphide

Found widely in reservoir gas, crude oil

vapours and around stagnant water

Carbon monoxide

Associated with combustion processes

Carbon dioxide

Fire extinguishers and deluge systems

Sulphur dioxide

Sulphur recovery plants, flare stacks formed when hydrogen sulphide is burned

Chlorine

Water purification processes

Benzene

Occasionally found in crude oil gases and

vapours

Hydrazine

Used in water treatment processes

For Toxic Gases

C.O.S.H.H.
Control of Substances Hazardous to Health

Workplace Exposure Limit

WEL

8 HOUR LIMIT

15 MINUTE LIMIT

WELs published in HSE document

EH40 each year

Control of Substances Hazardous to Health - COSHH

Workplace Exposure Limits for Toxic Gases
WEL

8 Hour Limit

15 Minute Limit

GAS
Carbon
Monoxide
Hydrogen Sulphide
Light Petroleum
Hydrocarbons
( Condensates )
Medium Petroleum
Hydrocarbons
( Sludges)
Carbon Dioxide
Sulphur Dioxide

30 ppm

200 ppm

5 ppm

10 ppm

500 ppm

250 ppm

5000 ppm

15000 ppm

No longer listed

No longer listed

Chlorine

0.5 ppm

1 ppm

Benzene

3 ppm
(1 ppm 2003)

Hydrazine

0.02 ppm

0.1 ppm

A number of the listed Workplace Exposure Limits are cancer

causing, carcinogenic. As a principle, no exposure to concentrations
greater than the WEL shall be permitted, and for carcinogenic
compounds, adequate control should be to as low a level as is
reasonably practicable.

Properties of Hydrogen Sulphide

Occurrence

Important Properties

Deadly toxic gas at high concentration

In crude oil - Sour crude
In reservoir gas - Sour gas Colourless
Smells of bad eggs at low
In stagnant water
concentrations
Paralyses sense of smell at high
concentrations

H2 S
Effects and Symptoms of H2S
0.15ppm -------------------------------- threshold of smell - 0.000015% vol.
5ppm ----------------------------------------------------- 8 hour exposure limit
10ppm ------------------------------------------------- 15 minute exposure limit
20ppm ---------------------------- strong bad - eggs smell, eye irritation
100ppm ------------------------------- loss of sense of smell in 3 - 15 mins
200 - 300ppm ----------------------- instantaneous loss of sense of smell
(thats why you cannot use your nose as a gas detector!)
700ppm or more -------breathing ceases, loss of consciousness and
death unless resuscitated

REMEMBER! - 700ppm sounds a lot but its only 0.07% vol.

- -there may well be 99.93% vol. fresh air as the remainder

Physical Properties of
Hydrogen Sulphide
1. Flammable gas:
LEL = 4.0% vol = 40,000 ppm!

2. Reacts with iron in an inert

atmosphere to create :
Pyrophoric Iron Sulphide a
fire and explosion hazard

3. Heavier than air:

Relative Density = 1.2
(Air = 1)

Industries with SRB

Problems

Hazards of
Carbon Monoxide - CO
1. Produced by incomplete
combustion
2. Haemoglobin in your blood prefers
CO to oxygen 240 times more!
to form carboxyhaemoglobin
3. Colourless gas of neutral density
4. Odourless gas it doesnt smell of
exhaust fumes!
5. Flammable gas: LEL = 10.9% vol.
in air
6. Smokers have 5 10% of their
blood permanently complexed as
carboxyhaemoglobin

The Catalytic Gas Sensor

USED IN PORTABLE AND FIXED GAS DETECTORS
TO DETECT AND M EASURE
METHANE AND OTHER FLAMMABLE GASES IN AIR
( Hot work and Confined Space Entry Gas Testing )
The Catalytic Gas Sensor ( Pellistor )
Catalyst

Platinum wire
coil

Approx.
550 oC

Approx. 1 mm
Pellistors measure combustible gases in air at concentrations of up
to the Lower Explosive Limit. Flammable gases are burnt on the hot
catalytic detector element and the resulting heat generated increases
the electrical resistance of the platinum wire coil. This change in
resistance produces a reading on the detector which is directly
proportional to the amount of flammable gas present in the atmosphere
Limitations - needs 13% or more oxygen
1. Cannot be used in inert gas atmospheres
2. Fails - to - danger due to
arrestor

Poisons

and

Silicones
De-greasing fluids
Hot lube oils / WD40

Blockage of the flame

Water
Drilling fluids
Oil

3. Methane calibrated detectors seriously under-read concentrations of the

higher hydrocarbon gases and vapours e.g. condensate vapours
4. Older gas detectors can give ambiguous readings at high gas
concentrations
Old Wives Tale Dont bump test the detector too often because it wears out the sensor untrue!

Catalytic Sensors
- EEV pellistors

A Simple
Explosimeter

Gas Detectors dont like

water !

Corrosion of catalytic
sensors

Catalytic fixed gas

sensor

The Thermal Conductivity Gas Sensor

USED IN PORTABLE GAS DETECTORS TO MEASURE THE PERCENTAGE
OF FLAMMABLE GAS MIXED WITH AN INERT GAS ( NITROGEN )
DURING PURGING OPERATIONS
Principle
Thermal conductivity sensors detect a gas by comparing the heat conducting properties
of that gas with the heat conducting properties of a reference gas, usually nitrogen
Typical Application - entry into a vessel that contains natural gas
Step 1.
Natural
gas

Step 2.
Purge vessel
with nitrogen

Step 3.

Less than
Purge vessel
7.5% methane
in nitrogen
with air

20.9%
oxygen

(a) Permit to Enter issued

(b) Entry made, work completed
20.9%
Oxygen

Purge vessel
with nitrogen

Step 4.

Less than
7.7%
oxygen

Purge vessel
with natural gas

Step 5.

Natural
gas
Step 6.

Limitations
1. For accurate results, the detector should be calibrated with the natural gas
in use and be zeroed with the inert (purge ) gas being used
2. The detector is sensitive to changes in sample gas flow rate
IMPORTANT
Thermal conductivity based gas detectors are calibrated % volume
and CANNOT be used for Hot Work and Confined Space Entry gas
testing - - - - - - they are too insensitive!

Principle of Infra-red
Gas Detection

Sieger Searchpoint
infra-red point detector

Sieger Searchline
Open-path detector for
flammable gases

PLMS Line of Sight

Infra-red Flammable Gas
Detector

Installation of
Open Path Gas
Detection

Draeger Multiwarn II
- infra-red flammable
gas sensor

The Infra Red Gas Sensor

USED IN PORTABLE AND FIXED GAS DETECTORS
TO DETECT AND MEASURE HYDROCARBONS AND CARBON
DIOXIDE

Broad-band infra red light from a source shines through a window and into a
cuvette where ambient air to be monitored diffuses or is pumped. The light is
reflected from a concave mirror, back through the window on to an angled
beam splitter. Part of the light penetrates the beam splitter, passes through a
narrow band interference filter tuned to the absorbtion wavelength of the gas
being detected and through to a detector. The remainder of the light is reflected
by the beam splitter through an equivalent filter tuned to a reference
wavelength, slightly away from the absorbtion wavelength of the gas being
detected and through to a reference detector.

Features
Can be configured to be Fail Safe, unlike catalytic detectors
Electrically more stable than catalytic detectors
Will operate in inert gases as well as air purging applications
Cannot be used to detect hydrogen
Interference filters available for several gases
Widely used in Line of Sight or Open Path gas detectors

The Electrochemical Cell

USED IN PORTABLE AND FIXED GAS DETECTORS
TO DETECT AND MEASURE :
% OXYGEN
AND TOXIC GAS CONCENTRATIONS (ppm) OF:
HYDROGEN SULPHIDE
SULPHUR DIOXIDE

CARBON MONOXIDE
CHLORINE
Electrochemical
Capillary Diffusion
Air
Oxygen Sensor
Barrier
Oxygen
electrochemical cells
are self powered, metal
- air batteries
+++++++++++
+ +CATHODE + +
consisting of an anode,
+++++++++++
a gel electrolyte and an
air permeable cathode.
Load
ELECTROLYTE
V
Oxygen within the air
Resistor
supply diffuses in a
controlled manner
____________
4e
_ _ _ ANODE _ _ _
through a barrier,
____________
chemically reacts
within and the reaction
produces a voltage
Limitations
proportional to the
Selective, but some cross-sensitivity
concentration of
oxygen
Gas batteries which become flat and need replacement
Temperatures greater than 400C cause rapid failure and leakage
Toxic gas sensors - radio transmitter interference
Oxygen sensors - air pressure pulses cause false alarms

H2S Paper Tape

Detector

Chemical Stain Tubes

Chemical Stain Tubes

Draeger Chemical Detector Tubes

USED MAINLY WHEN TESTING CONFINED SPACES AND VESSELS
FOR TOXIC AMOUNTS OF THE FOLLOWING SUBSTANCES :
(a) Vapours from crude oil residues, condensates and sludges
(b) Residual motor spirit vapours
(c) Paint and other solvent fumes and vapours
(d) Carbon monoxide and carbon dioxide
(e) Hydrogen sulphide and mercaptans
(f) Benzene and other aromatics

Limitations
1. Tubes are gas specific, choose the correct tube
2. Tubes are concentration specific, choose the correct tube
3. Instructions enclosed with each box of tubes
4. Tubes can only be used once
5. Accuracy only plus/minus 25%, dont use for oxygen tests
6. Single test only - not a continuous monitor
7. Shelf life - typically 2 years, see use-by date on box

Kitagawa
Chemical Stain Tube

Gastec Chemical
Stain Tube

Calibration Gases

2.2% methane in air stable gas mixture

Low ppm mixtures of many reactive toxic
gases in air NOT stable
Examples: H2S, SOx, NOx Cl2 these gas
mixtures require special cylinders,
regulators and tubing

Explosive Atmospheres Certification

1. The EEx label is on the outside of the certified

product some detectors need leather cases
2. Dont infringe the EEx certification by a cowboy
repair

GAS DETECTOR APPLICATIONS

AND
TYPES OF PORTABLE GAS DETECTOR
1. HOT WORK Gas Testing
Gas Test
Methane
( and other
flammable gases)

Flammable Gas
Detector Principle

Unit of
Measurement

Catalytic
or
Infra-red NOT
for Hydrogen!

% LEL

2. CONFINED SPACE OR VESSEL ENTRY Gas Testing

Unit of Measurement

Gas Test

Detector Principle

Oxygen

Electrochemical cell

% O2

Methane or
other
flammable
gases

Catalytic or
Infra-red

% LEL
(flammable
gas in air)

Toxic gases or
vapours

Electrochemical cell
Chemical stain tube

ppm toxic
gas

3. INERT GAS PURGE Gas Testing

Oxygen

Electrochemical cell

Methane

Thermal conductivity

% O2
% volume methane
in inert gas

Pre-issue Testing of Detector

Mechanical Checks
BEFORE USING A PORTABLE ELECTRICAL GAS DETECTOR
1. Check body of detector for physical damage and loose
components
2. Check gas inlet port for water / mud / oil contamination
3. Check that flammable atmospheres safety label
(BASEEFA or others) is attached and recalibn. date is OK
4. Connect and check aspirator bulb and tubing for wear,
blockage, leakage or water / oil contamination
5. Check any user accessible filters for dust, oil or water
contamination
BEFORE USING A DRAEGER CHEMICAL TUBE DETECTOR
1. Check that bellows spring(s) is not broken or dislodged
by squeezing bellows and observing
2. Check that you have chosen the correct tube for your
application - - correct gas, correct concentration and
correct use-by date
3. Check that the bellows do not leak by inserting unbroken
tube into the aspirator ( with or without the extension
tube )compress bellows and confirm that bellows do not
expand.
- - - and if your detector fails any one of these checks
return it to the issuing authority

Pre-issue Testing of Detector

Electrical / Gas Checks

VA 16

BEFORE USING A PORTABLE ELECTRICAL GAS DETECTOR

1. Switch on and study any diagnostic messages
2. Check condition of battery using built - in indicator
3. Check functioning of audible and visual alarms during
warm - up (when applicable) - cancel alarms
4. Note reading in clean air to be 20.9 or 21% for oxygen
and zero for flammable and all toxic gases
5. If detector has an electrical aspirating pump, seal gas
inlet with finger and check the operation of the flow
failure indicator or note change in sound of the pump
6. Check correct functioning of a catalytic sensor by
aspirating a standard test gas through the detector
and noting :
(a) activation of both audible and visual alarms at
the set alarm level, usually 20% LEL
(b) meter indicates plus/minus 5% LEL of the correct
reading :
with 2.2% methane in air reading is 45 - 55% LEL
with 1.1% methane in air reading is 15 - 25% LEL
7. Check correct functioning of a thermal conductivity
sensor by aspirating a 50% by volume methane in
nitrogen gas mixture through the detector and noting
a reading of 50 plus / minus 2 % vol.
- - - and return faulty detectors to the issuing authority

- - and finally !

Why are you carrying out a gas test?

Answer : To certify that the
atmosphere is safe to work in
TRUST THE INDICATION
ON YOUR GAS DETECTOR - - - - PERHAPS THAT LITTLE
READING
IS NOT

JUST ZERO DRIFT !