1. Purpose
The purpose of this policy is to ensure all personal gas monitors used by the company provide accurate, reliable, and timely warnings of hazardous atmospheric conditions. This policy establishes standardized requirements for inspection, bump testing, calibration, documentation, and record retention. Proper calibration and maintenance reduce the risk of false readings that could result in serious injury, illness, or fatality.
2. Scope
– All personal (wearable) single-gas and multi-gas monitors
– Company-owned, leased, or rented devices
– All employees and contractors required to use gas monitors
– Work activities including confined space entry, trenching, excavation, and other hazardous environments
3. Regulatory and Reference Basis
– OSHA requirements for calibrated direct-reading instructions
– OSHA Safety and Health Information Bulletin (SHIB) guidance on calibrating and testing portable gas monitors
– Manufacturer instructions for each monitor model (mandatory)
– International Safety Equipment Association (ISEA) best-practice guidance
– OSHA General Duty Clause – Section 5(a)(1) of the OSH Act
4. Definitions
– Bump Test (Function Test): A qualitative test exposing a monitor to a known concentration of gas to confirm sensor response and alarm activation. A bump test does not verify accuracy.
– Calibration Check: A comparison of monitor readings against a known gas concentration to assess accuracy.
– Full Calibration: Adjustment of sensor output to match certified calibration gas concentration, correcting sensor drift.
5. Roles and Responsibilities
– Equipment Inventory / Calibration Manager- Maintains inventory of gas monitors, schedules and performs calibrations, maintains calibration and bump test records.
– Supervisors- Ensure monitors are within calibration and remove deficient units from service.
– Employees / Monitor Users- Perform daily bump tests, inspect monitors before use, and report failures, damage or alarms immediately.
6. Bump Testing Policy
– A bump test is required before each day of use or at the start of each shift.
– The test must confirm sensor response.
– Audible, visual, and vibratory alarms must activate.
– Any monitor that fails a bump test must be removed from service immediately.
– Failed units shall not be used until successfully calibrated and retested.
7. Calibration Policy
– Full calibration shall be performed at manufacturer-specified intervals.
– Full calibration shall be performed after a failed bump test.
– Full calibration shall be performed after sensor replacement or repair.
– Full calibration shall be performed after exposure to extreme environmental conditions.
– Calibrations must follow manufacturer-approved procedures only.
– Monitors must be labeled with calibration date and next due date.
8. Calibration Gas Management
– Only certified, traceable calibration gas shall be used.
– Calibration gas must be the correct gas type and concentration.
– Calibration has must be within expiration date.
– Cylinders must be clearly labeled and properly stored per manufacturer guidance.
9. Out-of-Service Criteria
– Calibration is expired.
– A bump test is failed.
– Any alarm does not activate.
– Sensor malfunction is detected.
– Physical damage is observed.
10. Documentation and Record Retention
All bump testing and calibration activities must be documented. Records shall include monitor ID or serial number, date of test or calibration, results including pass/fail and readings, and technician or tester name. Records must be retained for a minimum of three (3) years.
11. Training Requirements
– Employees assigned gas monitors must receive training prior to use.
– Training shall include proper operation and limitations of the monitor.
– Training shall include bump testing and calibration awareness.
– Training shall include alarm recognition and response actions.
– Refresher training is required as equipment or procedures change.
12. Compliance
– Failure to comply with this policy may result in removal from work activities.
– Failure to comply with this policy may result in disciplinary action.
– Failure to comply with this policy may result in work stoppage where atmospheric conditions cannot be safely monitored.