0310-10 Rev 2 CBTA Gas Tester TRAINING.pdf

THIS DOCUMENT INCLUDING, DRAWINGS, PROCEDURES, SPECIFICATIONS, AND ITS CONTENTS IS THE EXCLUSIVE PROPERTY OF MODEC AND IS FURNISHED ON A CONFIDENTIAL BASIS, AND WITH THE EXPRESS AGREEMENT THAT IT WILL NEITHER BE USED, SOLD, TRANSFERRED, COPIED, TRACED, PHOTOGRAPHED, NOR REPRODUCED IN ANY MANNER WHATSOEVER IN WHOLE OR IN PART, NOR ANY ITEM HEREIN BE SOLD, MANUFACTURED OR ASSEMBLED WITHOUT THE WRITTEN AGREEMENT OF MODEC THE RECIPIENT OF THIS DOCUMENT AGREES NOT TO DISCLOSE TO ANY OTHER PARTY INFORMATION CONTAINED HEREIN, OR NOT TO USE SUCH INFORMATION, EXCEPT FOR THE SPECIFIC PURPOSE INTENDED AT THE TIME OF RELEASE OF THIS DOCUMENT.

Dave Laws

Digitally signed by Dave Laws DN: cn=Dave Laws, o=Modec Ghana, ou=Training, email=dave.laws@m odec.com, c=GH Date: 2011.11.21 14:57:56 Z

2

ISSUED

21 NOV 2011

GOK/ MV21

DL

DL

1

IFU

08 NOV 2010

SB / MV21

DL

CD

Rev

Status

Date

Originator

Checker

Approver

Document Title:

CBTA GAS TESTER TRAINING MODEC Project No.

Client Document No.

Page

10-01-MOD-J87-0310-10 Document No.

WS245

0245-MI20-OPSM-0310-10

FPSO KWAME NKRUMAH MV21

1 of 16


CBTA Gas Tester TRAINING Document #: 0245-MI20-OPSM-0310-10 Rev 2

REVISION HISTORY REVISION NO.

DATE

REVISION INFORMATION

A

08 MAY 2010

Doc created. Issued for review

B

02 SEPT 2010

Issue for facility review

0

25 OCT 2010

Received from review. Issue for use

1

08 NOV 2010

Offshore review / detector name changes for new items

2

21 NOV 2011

Reviewed and re issued for use

Page 2 / 16 A PRINTED VERSION OF THIS DOCUMENT IS UNCONTROLLED



TABLE OF CONTENTS 1.0

INTRODUCTION ............................................................................................................... 4 1.1 PURPOSE ............................................................................................................. 4 1.2 SCOPE .................................................................................................................. 4 1.3 REFERENCES ...................................................................................................... 4 1.4 DEFINITIONS ........................................................................................................ 5 1.5 RESPONSIBILITIES ............................................................................................. 5

2.0

TRAINING PROCESS ...................................................................................................... 6 2.1 GENERAL PRINCIPLES ....................................................................................... 6 2.2 COMPETENCY STANDARD ................................................................................ 6 2.3 TRAINING STRATEGY ......................................................................................... 6 2.4 ASSESSMENT PROCESS ................................................................................... 6 2.5 RECOGNITION OF PRIOR LEARNING ............................................................... 6

3.0

PART 1 – ORAL / WRITTEN ASSESSMENT .................................................................. 7 3.1 GAS TESTING RESPONSIBILITIES .................................................................... 7 3.2 EXPLOSIVE ATMOSPHERES AND HAZARDOUS ZONES ................................ 7 3.3 CONTROL OF PORTABLE GAS DETECTORS ................................................... 8 3.4 SELECTION OF PORTABLE GAS DETECTORS ................................................ 8 3.5 GAS TESTING FOR CONFINED SPACE ENTRY................................................ 9 3.6 HYDROGEN SULPHIDE AWARENESS ............................................................. 13

4.0

PART 2 – PRACTICAL ASSESSMENT ......................................................................... 13 4.1 GAS DETECTOR PREPARATION AND USE .................................................... 13 4.2 CONFINED SPACE ENTRY EXERCISE ............................................................ 14

5.0

TRAINING REQUIREMENTS ......................................................................................... 15

6.0

COACHES AND TRAINING PROVIDERS ..................................................................... 15

7.0

TRAINING INFORMATION ............................................................................................ 15

8.0

RECOGNITION OF PRIOR LEARNING (RPL) .............................................................. 16



1.0

INTRODUCTION

1.1

PURPOSE


This document is the training and learning guide for the Gas Tester competency module within the Competency Based Training and Assessment program. This document provides the Competency Standard questions and lists the training material for each competency module onboard the Facility.

1.2

SCOPE This document applies to Gas Testing activities on the FPSO Kwame Nkrumah MV21.

1.3

REFERENCES

0245-MI20-OPSM-0310

Competency Assurance Manual

0245-MI20-OPSM-0403

Operations: PTW Volume 1 Main Procedure

0245-MI20-OPSM-0406

PTW Vol.3 - Risk Assessment and HSE Checklist

0245-MI20-OPSM-0420

PTW - Isolation Procedure

0245-MI20-OPSM-1103

H2S Policy

0245-MI20-OPP1-1417

Calibration and testing of Portable Gas detectors

0245-34-1570-C41-0006

Manufacturer’s Manual for Portable Gas detectors



1.4

DEFINITIONS AGT

Authorised Gas Tester

CBTA

Competency Based Training and Assessment

CCR

Central Control Room

E/I

Electrical/ Instrument (Technician)

EPI

Extended Period Isolation

ESD

Emergency Shutdown

FPSO

Floating Production Storage and Offloading vessel

GA

General Alarm

H2S

Hydrogen Sulphide

HMI

Human Machine Interface

HOD

Head of Department

IR

Infra-red

ISC

Isolation Certificate

LEL

Lower Explosive Limit

MSDS O2

Material Safety Data Sheet Oxygen

OIM

Offshore Installation Manager

ppm

parts per million

SCBA UEL

1.5


Self Contained Breathing Apparatus Upper Explosive Limit

RESPONSIBILITIES The OIM has the overall responsibility for Competency Based Training and Assessment on board the Facility. The Superintendents will administer and execute the program to ensure compliance.



2.0

TRAINING PROCESS

2.1

GENERAL PRINCIPLES


The production facilities on board the FPSO Kwame Nkrumah MV21 consist of a number of discrete systems which interact together to produce oil and gas to the required specifications. These systems are grouped into certain areas, and the efficient operation of the Facility is formed around the concept of these areas and systems. To ensure competency in the operation of the Facility a Competency Based Training and Assessment module has been compiled for each system within a certain area.

2.2

COMPETENCY STANDARD The Standards of Competency on the Facility are based on the Operating Manuals, procedures and drawings for each system and process and these are the source of all training information. Other in-house procedures will be developed to cover special operations and these will be referred to as required for each module.

2.3

TRAINING STRATEGY The required system competencies for each area are referenced in Section 1.3 of this document and all manuals and procedures referred to are available in the Health Safety and Environment management system. Each candidate is to complete the training and learning module for each system. The modules are self paced, self study based. Supervisors and other competent personnel will assist and support the learning process. Candidates are to prepare themselves to the competency standards laid out in this guide with all aspects of each system and its operation. They then must complete any written pre-work required and mark up the relevant drawings and diagrams before presenting themselves for assessment.

2.4

ASSESSMENT PROCESS Competency is measured at the end of each module by completing the Competency Assessment (CBTA) for that system. The candidate must correctly answer all questions in an oral, written, and practical assessment, to the criteria stated in this module, with recourse to relevant documentation where required. The Production Supervisor or other competent person on the Facility will conduct the Competency Assessment.

2.5

RECOGNITION OF PRIOR LEARNING 

Evidenced competencies from prior training courses or assessments.



System commissioning, factory testing, operating procedure development.



3.0

PART 1 – ORAL / WRITTEN ASSESSMENT

Oral & Written Assessment 3.1 1.

3.2 1.


Training Information

GAS TESTING RESPONSIBILITIES Who is authorised to carry out a gas test for a Confined Space Entry. Hot Work and Cold Work on the Facility?

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 OIM / Superintendant / Coach

EXPLOSIVE ATMOSPHERES AND HAZARDOUS ZONES What is an explosive gas atmosphere?

Calibration and testing of Portable Gas detectors 0245-MI20-OPP1-1417 OIM / Superintendant / Coach

2.

Define LEL.

Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

3.

Define UEL.


4.

Define a “Hazardous Zone” as applicable to Area Classification.


5.

Describe the different types of Hazardous Zones.


6.

7.

Where on the Facility would you find a drawing indicating the layout of the MV21 Hazardous Zones?

Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411

What type of hazardous zone is the process area of the Facility?


OIM / Superintendant / Coach

OIM / Superintendant / Coach




Oral & Written Assessment


8.


Why is a gas test required for Hot Work?

OIM / Superintendant / Coach 3.3 1.

CONTROL OF PORTABLE GAS DETECTORS Name the different types of Portable Gas Detectors on the Facility.


2.

Who may carry out maintenance on Portable Gas Detectors?


3.

How often are Portable Gas Detectors calibrated?


4.

Who is responsible for the issue of Portable Gas Detectors?


5.

Where are the Portable Gas Detectors kept when not in use?


6.

What is calibration gas?


8.

What is a gas detector challenge?


3.4 1.

SELECTION OF PORTABLE GAS DETECTORS Describe the operation and characteristics of the Portable Gas Detectors available on the MV21.

Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 MSA Multi Gas Detector Vendor Page 8 / 16

A PRINTED VERSION OF THIS DOCUMENT IS UNCONTROLLED




Training Information Operating Instructions MSA Personnel 02 Meter Vendor Operating Instructions OIM / Superintendant / Coach

2.

Which would be the most suitable gas detector for conducting an AGT survey prior to hot work?

Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 MSA Multi Gas Detector Vendor Operating Instructions MSA Personnel 02 Meter Vendor Operating Instructions OIM / Superintendant / Coach

3.

Which would be the most suitable gas detector for personal use during localised Hot Work?

Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 MSA Multi Gas Detector Vendor Operating Instructions MSA Personnel 02 Meter Vendor Operating Instructions OIM / Superintendant / Coach

4.

Which would be the most suitable gas detector for inerting and purging a cargo tank? Explain why your choice of Gas Detector is the most suitable for this task.


MSA Multi Gas Detector Vendor Operating Instructions MSA Personnel 02 Meter Vendor Operating Instructions OIM / Superintendant / Coach 3.5 1.

GAS TESTING FOR CONFINED SPACE ENTRY Define a confined space.

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 PTW - Isolation Procedure 0245-MI20OPSM-0420 Page 9 / 16





Training Information Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

2.

Provide examples of confined spaces on the MV21.

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

4.

Why is gas testing results required prior to a confined space entry?

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403

What are the acceptable readings?

PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411

5.

Describe the preferred method for the initial testing of a confined space.


6.

Where are the results of the initial gas tests recorded?


7.

What is the oxygen content of fresh air?

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 Page 10 / 16





Training Information PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

8.

At what level of oxygen is a deficiency said to exist?


9.

When may entry to an oxygen deficient space occur?

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411

10.

Explain the entry requirements if hydrocarbon gas is present in a confined space, for the different levels of hydrocarbon gas detected.


11.

What danger exists in process vessels that may have already been gas tested and show no sign of hydrocarbon gas?

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach Page 11 / 16






12.

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403

For what reason does the AGT sign the declaration on the Confined Space Entry Certificate?

PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

13.

Where would you find information related to the properties of chemical substances if they were present in or to be used in a confined space?


14.

Which is the most appropriate gas detector to be used by the AGT for sampling a confined space prior to entry? Why?


15.

How often should the AGT carry out a survey of the atmosphere inside the confined space during the course of a job?


16.

What is the most appropriate gas detector for personal use by a person working inside a confined space?

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 PTW - Isolation Procedure 0245-MI20OPSM-0420 Page 12 / 16





Training Information Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

3.6 1.

HYDROGEN SULPHIDE AWARENESS What is hydrogen sulphide (H2S), and where is it present on the Facility?

Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 H2S Policy 0245-MI20-OPSM-1103 OIM / Superintendant / Coach

2.

What is the exposure limit to H2S that requires the use of breathing apparatus?


3.

What does H2S smell like?


4.

Can smell always be used as an indication of H2S? Why?


4.0

PART 2 – PRACTICAL ASSESSMENT

Oral & Practical Assessment 4.1 1.


GAS DETECTOR PREPARATION AND USE Demonstrate the procedure for obtaining a Portable Gas Detector for the purpose of conducting a gas test for hot work.

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach Page 13 / 16




Oral & Practical Assessment


2.


Perform the necessary preparations and checks prior to using the following gas detectors: 

MSA Altair 5 multi gas detector



MSA Altair 4 personal multi gas detector.

MSA Multi Gas Detector Vendor Operating Instructions MSA Personal 02 Meter Vendor Operating Instructions OIM / Superintendant / Coach

4.

Demonstrate the procedure for obtaining a Portable Gas Detector for the purpose of conducting a gas test for hot work.

Operations: PTW Volume 1 Main Procedure 0245-MI20OPSM-0403 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

A permit has been raised for a welding job on the process skids.

4.2 1.



Demonstrate on site the method to conduct a gas test for hot work.



Demonstrate where the initial readings are logged on the Hot Work Permit.

OIM / Superintendent / Coach Authorised Gas Tester Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411

CONFINED SPACE ENTRY EXERCISE Given an example of a Confined Space Entry Certificate, demonstrate/ simulate the correct method of conducting a gas survey of a confined space as the Authorised Gas Tester.

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 PTW Vol.3 - Risk Assessment and HSE Checklist 0245-MI20-OPSM-0406 PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

2.

Complete the Entry Certification as a result of the survey.

Operations: PTW Volume 1 Main Procedure 0245-MI20-OPSM-0403 Page 14 / 16




Oral & Practical Assessment

Training Information PTW Vol.3 - Risk Assessment and HSE Checklist 0245-MI20-OPSM-0406 PTW - Isolation Procedure 0245-MI20OPSM-0420 Portable Gas Detectors – Selection and Use 0245-M120-OPSM-1411 OIM / Superintendant / Coach

5.0

TRAINING REQUIREMENTS Gas Tester training to address the required outcomes from this CBTA module will be achieved during structured information sessions, exercises and drills conducted on board the Facility.

6.0

COACHES AND TRAINING PROVIDERS The answers to the above topics can be found in the listed reference documents. However, assistance can be provided by: 

Offshore Installation Manager



Operations Superintendant



Candidate’s Supervisor

These persons can also assist with coaching and practical training.

7.0

TRAINING INFORMATION Training Information Topic

Electrical Isolation:

Coach or Training Provider

Location

HOD, OIM

Facility

Responsibilities Explosive atmospheres and hazardous zones Control of portable gas detectors Selection of portable gas detectors Gas testing for confined space entry Hydrogen sulphide awareness Page 15 / 16 A PRINTED VERSION OF THIS DOCUMENT IS UNCONTROLLED


8.0


RECOGNITION OF PRIOR LEARNING (RPL) No recognition of prior learning will satisfy the competency requirements of this module.


0310-10 Rev 2 CBTA Gas Tester TRAINING.pdf

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