Compressed Gas Cylinders training presentation

Compress Gas Cylinders

1. ARCHIRODON GROUP NV Health & Safety Training

2. Introduction of Trainer Evacuation of the Training Room Welfare Facilities Mobile Phones No Smoking / Breaks

3. Compressed Gas Cylinders

4. Many industrial and laboratory operations require the use of compressed gases for a variety of different operations. Introduction

5. Compressed gases present a unique hazard. Depending on the particular gas, there is a potential for simultaneous exposure to both mechanical and chemical hazards . Gases may be: Flammable or combustible Explosive Corrosive Poisonous Inert or a combination of hazards Compressed Gas Hazards

6. If the gas is flammable, flash points lower than room temperature compounded by high rates of diffusion present a danger of fire or explosion . Additional hazards of reactivity and toxicity of the gas, as well as asphyxiation , can be caused by high concentrations of even "harmless" gases such as nitrogen. Since the gases are contained in heavy, highly pressurized metal containers, the large amount of potential energy resulting from compression of the gas makes the cylinder a potential rocket or fragmentation bomb. Compressed Gas Hazards

7. Careful procedures are necessary for: handling the various compressed gases , handling the cylinders containing the compressed gases, the regulators or valves used to control gas flow, the piping used Compressed Gas Hazards

8. The contents of any compressed gas cylinder must be clearly identified. Such identification should be stenciled or stamped on the cylinder or a label. Identification

9. No compressed gas cylinder should be accepted for use that does not legibly identify its contents by name. If you cannot identify its content, the cylinder should be marked " contents unknown " and returned directly to the manufacturer. Identification

10. Prior to the release of any gas cylinder from the store, the supervisor of the area where the gas will be used shall proceed to the HSE department and together with the HSE Manager will complete the COSHH Assessment form in order to: COSHH Assessment identify which hazardous substances are present consider the risks they present to people’s health where there are significant risks, determine how often the substance is used and how hazardous it is decide the action needed to prevent exposure or reduce it as far as it is reasonably practicable decide the precautions need to be taken to avoid exposure to the hazardous substances (i.e. PPE)

11. COSHH Assessment Only when the COSHH Assessment has been fully completed and approved by the HSE Department, then the Supervisor will be able to release the gas cylinder for use in the working area The COSHH Assessment Form must be kept in the area where the gas cylinder is used

12. Identification Never rely on the color of the cylinder for identification. Color coding is not reliable because cylinder colors may vary with the supplier. Additionally, labels on caps have little value because caps are interchangeable. Always read the label!

13. All gas lines leading from a compressed gas supply should be clearly labeled to identify the gas, the laboratory or area served, and the relevant emergency telephone numbers. Identification

14. Signs should be conspicuously posted in areas where flammable compressed gases are stored, identifying the substances and appropriate precautions ( e.g ., HYDROGEN - FLAMMABLE GAS - NO SMOKING – NO OPEN FLAMES ) Signage

15. Evidence of smoking next to acetylene cylinders

16. Gas cylinders must be secured at all times to prevent tipping. Handling, Storage & Use

17. Cylinders may: be attached to a bench top be individually attached to the wall be placed in a holding cage have a non-tip base attached Chains or sturdy straps may be used to secure them always in UPRIGHT position and never in HORIZONTAL . Handling, Storage & Use

18. Handling, Storage & Use

19. Cylinders containing flammable gases such as hydrogen or acetylene must not be stored: in close proximity to open flames, in areas where electrical sparks are generated , where other sources of ignition may be present. Handling, Storage & Use

20. Subject to damage from other activities in the vicinity Cylinder laying in a horizontal position . Electrical cord in contact with the cylinder

21. Electrical arc damage Gas Cylinder damaged from electrical arc of a nearby cable

22. A welder was modifying a temporary structural steel bridge using an Oxygen/Acetylene torch setup on a cart, a portable welder, and a grinder. Apparently the Acetylene hose developed a leak and ignited during the grinding operation Incident Handling, Storage & Use

23. …the cylinders that contain compressed gases are primarily shipping containers and should not be subjected to rough handling or abuse. Such misuse can seriously weaken the cylinder and render it unfit for further use or transform it into a rocket having sufficient thrust to drive it through walls . Don’t forget… Handling, Storage & Use Tips

24. Missile Effect of falling Cylinders

25. Oxygen cylinder was blown through block cavity wall.

26. All cylinders containing flammable gases should be stored in a well-ventilated area. Oxygen cylinders, full or empty, shall not be stored in the same vicinity as flammable gases. The proper storage for cylinders requires : minimum of 6 meters (20 feet) be maintained between flammable gas cylinders and oxygen cylinders, or be separated, at a minimum, by a fire wall 1.5 meters (5 feet) high with a fire rating of 0.5 hours Handling, Storage & Use

27. A non-combustible barrier at least 1.5m (5 feet) FUEL & OXYGEN CYLINDERS

28. Handling, Storage & Use Housekeeping is a very important element when storing the Gas Cylinders (empty or full) Always store the cylinders in the dedicated storage area Always put the cap on the cylinder when storing, even if the cylinder is empty Never store in that area other items (drums with chemicals, lubricants, etc.) Never store the cylinders among other flammable material

29. This cylinder should be taken to the designated storage area and the housekeeping should be improved. ×

30. Standard cylinder-valve outlet connections have been devised by the C ompressed G as A ssociation ( CGA ) to prevent mixing of incompatible gases. The outlet threads used vary in diameter some are internal, some are external some are right-handed (generally used for non-fuel gases) some are left-handed (generally used for fuel gases) the assembly of miscellaneous parts should be avoided Cylinder Valves & Regulators

31. …the threads on cylinder valves, regulators and other fittings should be examined to ensure they correspond and are not damaged . Be Careful… an open flame shall never be used to detect leaks of flammable gases one common practice to detect a leak is to use a natural bristle broom to "sweep" the gas flow and locate the leak point …never apply oil or grease on the fittings of the valves and the regulators Cylinder Valves & Regulators

32. …cylinders should be placed with the valve accessible at all times …regulators are gas specific and not necessarily interchangeable Cylinder Valves & Regulators

33. The main cylinder valve should be closed as soon as it is no longer necessary. It should never be left open when the equipment is unattended or not operating The gas lines should not be left pressurized. Both pressure gauges should indicate “ ” pressure and the lines bled Cylinder Valves & Regulators

34. Regulator left pressurized after use ×

35. Cylinders are equipped with either a hand wheel or stem valve . Only wrenches or tools provided by the cylinder supplier should be used to open or close a valve. At no time should pliers be used to open a cylinder valve. Some valves may require washers; this should be checked before the regulator is fitted. Cylinder Valves & Regulators

36. Open up the oxygen cylinder valve stem just a crack. Ensure there is no gas leak Oxygen cylinders must have the valve opened up all the way because of the high pressure in the cylinder. There is a back-seating valve on the oxygen cylinder. This prevents the high-pressure gas from leaking out through the threaded stem. Once the needle on the high pressure gauge has stopped, open up the valve all the way. This back-seats the valve. Cylinder Valves & Regulators

37. When opening the valve on a cylinder containing an irritating or toxic gas, the user should position the cylinder with the valve pointing away from them and warn those working nearby. …cylinder valves should be opened slowly Cylinder Valves & Regulators

38. The following rules should always be followed in regards to piping : Plastic piping shall not be used for any portion of a high pressure system. Do not use cast iron pipe for chlorine. Do not conceal distribution lines where a high concentration of a leaking hazardous gas can build up and cause an accident. Copper piping shall not be used for acetylene . Gas Piping

39. The Oxyacetylene hoses are usually color coded: Oxygen (USA) ( green ) Oxygen (UK) ( blue ) Acetylene ( red ) LPG ( orange ) The material, the inner section of the hose is made, is flame retardant but will burn The threaded connectors are different, to avoid accidental mis-connection Oxygen is right handed, as normal Fuel gases use a left handed thread Oxyacetylene Hoses

40. Oxyacetylene Hoses

41. When Oxyacetylene hoses are not used it is recommended to cover them for protection from direct sunlight Oxyacetylene Hoses

42. oxy-acetylene hoses connected to bottles without the torch be connected . Always ensure that the torch is connected to the hoses before you connect them to the cylinders and open the cylinder valves Oxyacetylene Hoses

43. Backfire occurs when the torch flame burns back into the torch tip and is extinguished with a loud pop. They occur either because the torch tip touched the work or because of insufficient gas pressure and they are generally harmless Flashback is more serious when the flame front does not extinguish , but burns back sometimes beyond the mixing chamber, through the hoses, and even into regulator and supply. This can lead to an explosion Backfire & Flashback Flashback arrestors must be installed in both ends of the hose (cylinder end torch end)

44. Flame path is extinguished by meshed material inside Flashback arrestors are designed to prevent a flashback from reaching upstream equipment and the gas cylinder. Torch handle Flashback Arrestors Flashback Gas Cylinder Flashback Arrestor They offer added safety and often include reverse flow check valves in a single unit

45. A cylinder should never be emptied to a pressure lower than 172 kPa (25 psi/in2 ). The residual contents may become contaminated if the valve is left open When the cylinder is empty and needs to be removed: all valves shall be closed, the system bled, the regulator shall be removed, the valve cap shall be placed on top the cylinder is clearly marked as “ empty ” is returned to a storage area for pickup by the supplier Empty Cylinders

46. All compressed gas cylinders, including lecture-size cylinders, must be returned to the supplier when empty or no longer in use. Empty and full cylinders should be stored in separate areas. Empty Cylinders

47. No cap installed Cylinder not in use. Should be stored properly in the designated store room

48. Cylinder not in use with regulators still on the cylinder Free standing cylinder

49. Where the possibility of flow reversal ( “sucking back” ) exists , the cylinder discharge lines should be equipped with approved check valves (non-return) to prevent inadvertent contamination of cylinders connected to a closed system. This phenomenon is present where liquefied gases are used (chlorine). A cylinder in such a system should be shut off and removed from the system when the pressure remaining in the cylinder is at least 172 kPa (25 psi/in2). If there is a possibility that the container has been contaminated, it should be so labeled and returned to the supplier. Gas Flow Reversal

50. Liquid bulk cylinders may be used in tasks (i.e. purging) and areas (i.e. laboratories) where a high volume of gas is needed. These cylinders usually have a number of valves on the top of the cylinder. All valves must be clearly marked as to their function. These cylinders will also vent their contents when a preset internal pressure is reached, therefore, they should be stored or placed in service where there is adequate ventilation. Liquid Bulk Cylinders

51. Always use safety glasses (preferably with a face shield) when handling and using compressed gases, especially when connecting and disconnecting compressed gas regulators and lines. PPE Requirements Additionally use all the appropriate PPE as described in the COSHH Assessment performed by the HSE Manager and the area Supervisor. That may require respiratory mask, gloves, etc.

52. Always transport cylinders with the valve caps in place & secured Transporting Cylinders Never transport the cylinders in horizontal position Always use proper means for transporting the cylinders (trolleys, cages, etc)

53. Transporting Cylinders × 

54. NEVER : Move cylinders , using a sling wrapped around the protective valve cap Roll or drag a cylinder Drop or allow cylinders to strike violently against each other or any other objects Mis-use a Compressed Gas Cylinder Transporting Cylinders

55. REMEMBER… We want YOU to return home SAFE !!!