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1 AUSTRALIA CANADA USA UNITED KINGDOM SINGAPORE MALAYSIA Safetycare Australia Pty. Ltd. Telephone (03) Safetycare Inc. Telephone (905) Safetycare Inc. Telephone (800) Safetycare (UK) Limited. Telephone (0208) SafetyMax Corp Pte. Ltd. Telephone SafetyMax Sdn Bhd Telephone (603) The information contained in this Facilitator s guide is distributed and sold as a guide and for informational purposes only. Safetycare makes no representation or warranty as to the compliance of this program with any and all applicable laws of the purchaser's jurisdiction. 2. Safetycare's liability for any damages to the purchaser or to any other party shall not exceed the amount paid by the purchaser for the guide. In no event shall Safetycare be responsible for any indirect or consequential damages or loss of profits, even if Safetycare has been advised of the possibility of such damage. Some provinces/states do not allow the limitations or exclusion of liability for incidental or consequential damages, so the above limitations or exclusions may not apply to the purchaser. 3. This Facilitator s Guide is supplied as part of a subscription service. This guide is only to be used during a valid subscription period. Where a subscription is not valid, this guide may not be used. Facilitator s Guide GAS AND CYLINDER SAFETY Copyright - All Rights Reserved

2 Gas and Cylinder Safety CONTENTS Introduction to the Facilitator s Guide 3 Introduction to the Video Program; Gas and Cylinder Safety 4 Transcript of Video Program 5 Part 1 - Types of Gases 11 Part 2 - Identifying Gases 12 Part 3 - Before Using a Gas Cylinder 13 Part 4 - Safe Use and Handling 14 Part 5 - Safe Storage 15 Part 6 - Leak Testing 16 Assessment 17 Answers 20 2

3 INTRODUCTION TO THE FACILITATOR S GUIDE Gas and Cylinder Safety The aim of this Facilitator s Guide, when used in conjunction with the Video program, is to provide the facilitator with discussion points important to the overall development of the program and to allow participants the opportunity of discussing the impact the program may have on current work practices and whether in fact changes may be required. The time allocated to the program will be determined by which areas are seen as important to each Organisation, the time taken to develop the points made in the program and whether other data specific to your own environment is included in addition to, or instead of, the program examples. EACH FACILITATOR SHOULD CAREFULLY READ THE GUIDE DISCUSSION NOTES SUGGESTED AND PREPARE THEIR OWN INPUT ACCORDINGLY. The program transcript is included to allow your Organisation to fully research the program content and develop specific examples critical to the performance of your own workforce. Where the Video program is made available to small or remote sections of your Organisation, some other examples or discussion points may be preferred to suit the needs of these people and if so, should be developed prior to distribution of the program. Maximum benefit will then be obtained by your people. All information included in the Facilitator s Guide may be copied and distributed with the exception of the transcript of the Video program. Any information which is copied or distributed must only be used internally by the Organisation that purchased the guide. SCREEN SHOT FROM THE VIDEO PROGRAM 3

4 INTRODUCTION TO THE VIDEO PROGRAM Duration: 15 minutes Gas cylinders supply a wide variety of gases for a multitude of different industrial, medical and domestic purposes. Most people instinctively appreciate that there are hazards associated with gas bottles and cylinders. Included in this program: Types of gases The hazards associated with gases Things to do before using a gas cylinder General do's and don'ts Safe storage Safe handling Leak testing Emergency procedures Material Safety Data Sheets, safe work procedures and advice from the manufacturer and your supervisor should ensure the safety of all concerned with compressed gas cylinders. 4

5 TRANSCRIPT OF THE VIDEO PROGRAM Gas and Cylinder Safety Copyright Safetycare. All rights reserved Many products are available which contain gases, and mixtures of gases stored under pressure in cylinders. Gases are supplied for a multitude of different industrial, medical and domestic purposes. TYPES OF GASES There are two major groups of gases that are supplied in gas cylinders, and they are: Permanent gases, and Liquefied gases Permanent gases, such as oxygen, nitrogen and helium, are gases that cannot be liquefied at room temperature regardless of how high the pressure. Some gases will liquefy at low temperatures and can be kept in this liquefied state under pressure... common examples include propane and butane. Liquefied gas cylinders are not filled to the top, a vapour space is left for expansion. Acetylene is the only common gas which is not supplied as a permanent or liquefied gas. Acetylene is stored under pressure as a dissolved gas. The reason for this is that acetylene will decompose and explode violently at relatively low pressures. Acetylene cylinders are therefore filled with calcium silicate which is then saturated with acetone. THE HAZARDS Gas cylinders may rupture if the pressure is too great. This can occur if the cylinder is accidentally over-filled, if the cylinder is damaged or is structurally unsound, or if a gas cylinder is subjected to extremes of heat. In the event of an explosion, pressure shock waves and flying objects can cause serious injury and damage in these situations. Gas can also leak from a cylinder, and the hazard resulting from this will depend on: The location of the incident, and The properties of the gas involved; that is the gas may be flammable, poisonous and so on. 5

6 Fires can occur when using flammable gases and care should be taken: To avoid sources of ignition To avoid mixtures of flammable gases with air and oxygen, and To separate flammable gas cylinders from oxidising agents and other combustible materials. With flammable gas, there is also the potential for an explosion. There is a range where gas will explode if ignited. This range can be defined being between the: Lower Explosive Limit, below which there is insufficient fuel for an explosion, and the Upper Explosive Limit, above which there is insufficient oxygen for an explosion. Poisonous gas can obviously have long and short term effects on people and the severity will depend upon the gas involved, the concentration and the method of entry of the substance into the body. Gases will either be inhaled through the lungs or absorbed through the skin. There are a number of well known measures of toxicity including: Threshold Limit Value (TLV), Short Term Exposure Limit (STEL) and IDLH, which stands for Immediate Danger to Life and Health. Anyone using poisonous gases should be fully aware of these terms and their implications. Systems using poisonous gas should be first leak checked with an inert gas to ensure no leaks exist. Good ventilation or mechanical extraction combined with the monitoring of contaminants in the air and established work and emergency procedures will eliminate many of the hazards associated with using poisonous gases. One of the most dangerous risks associated with gas use is asphyxiation caused by reduction of oxygen in the atmosphere due to gas leaking from cylinders. Many processes such as welding also consume oxygen from the air as well as create gaseous contaminants. All gases with the exception of oxygen can cause asphyxiation. The air we breathe contains 21% oxygen. If this level is reduced to below approximately 18% we will begin to suffocate. Death occurs in seconds with no oxygen, and in minutes depending on the extent of the oxygen deficiency. Gases that present no warning signals such as smell, can overcome a victim who is totally unaware of the danger. 6

7 Oxygen enrichment of the atmosphere, even by a few percent, considerably increases the intensity of fire. Sparks which would normally be regarded as harmless can cause fire, and materials which do not normally burn in air, including fireproofing materials, can burn vigorously in oxygen-enriched atmospheres. Because of the extremely low temperatures of liquefied gases and because any rapidly expanding gas will have an extremely low temperature, "Cold Burns" can occur to the skin and flesh. Gas leaks can also cause skin damage and injuries to other parts of the body which are unprotected - often to the face and eyes. Obviously, appropriate use of personal protective equipment at least acts as a last line of defence should an accident occur. There are of course many other hazards associated with the use of gases in the workplace. Details from (Material) Safety Data Sheets and safe work procedures should be followed when dealing with any gas and any problems or uncertainties should be discussed with the manufacturer or appropriately qualified person. IDENTIFYING GASES It is crucial that the gas in a cylinder is correctly identified prior to use. Sometimes cylinders themselves are coloured as a guide to their contents, but the label is always the primary means of identification of the contents of a cylinder. Always read the label. Do not assume a cylinder contains a particular gas without confirming the name on the cylinder. Gas cylinder labels may include: The name and contact details of the manufacturer The name and grade of the gas contained in the cylinder The UN number, which is sometimes called the SI number Other relevant numbers and codes of classification Detail indicating the size of the cylinder and fill pressure Some general information about the properties of the gas contained in the cylinder, and Emergency contact information If the label is illegible, damaged or missing, do not use the cylinder and have it returned to the supplier. Information on things such as: Storage Handling Transport Personal Protective Equipment requirements, and 7

8 Incident Response may not be on a cylinder and should be obtained from (Material) Safety Data Sheets. Finally, never repaint a cylinder, change its marking or alter its label in any way. BEFORE USING A GAS CYLINDER Always identify and confirm the gas to be used by reading the label. Inspect the cylinder to make sure there is no damage to it, and that it is structurally sound. Also make sure the cylinder is not giving off odours, hissing, or otherwise leaking. Check the equipment that is connected to the cylinder, including hoses, regulators, gauges and so on, to make sure they are: Appropriate for the gas being used, and Free from damage SAFE USE AND HANDLING Many accidents and injuries with gas cylinders occur when moving or handling the cylinders themselves. The so-called portable gas cylinder can weigh up to 100kg (or 220lbs). Remember to always employ correct manual handling techniques. Use a mechanical aid when moving heavy cylinders, even for short distances and make sure the cylinder is secured. Trapping fingers between cylinders is also a common problem when they are being moved. There are many other general do's and don'ts when handling and using gas cylinders including the following: The regulator should always be removed when moving a cylinder, even for short distances and the valve should never be used as a lifting point. Unless specifically designed to be used otherwise, always use cylinders in the upright position and secure them so they won't be knocked over accidentally. Ensure the cap is in place to protect the valves when the cylinder is not in use. Make sure threads on regulators, gauges and connections correspond to those on the cylinder valve outlet. Also only use regulators designed for the particular cylinder and type of gas. 8

9 Never use a wrench or hammer on a gas cylinder, if hand pressure is not sufficient to open the valve have the cylinder returned to the supplier. Never use a compressed gas cylinder without the appropriate pressure- reducing regulator attached to the cylinder valve. Always open valves slowly. Always close the supply cylinder valve when not in use. Never attempt to repair or alter cylinders, valves or attachments... all this work must be performed by the manufacturer. Never permit sparks, molten metal, electric current, excessive heat or flames to come into contact with a cylinder or its attachments. Never use oxygen as a substitute for air - and finally, Never bring a cylinder into a confined space. Safe Storage Cylinders should only be stored in designated storage areas designed specifically for gas cylinders. They should be well ventilated, dry and secure. Storage areas should be designed to separate incompatible gases, for instance oxygen cylinders should be stored well away from flammable gas cylinders. Cylinders should be stored upright and secured on a level fireproof floor. Cylinders stored in the open should be protected from the ground and extremes of weather to prevent rusting, and from continuous direct sunlight. Cylinders should never be stored near heat sources or near flammable substances. Storage should be arranged so that cylinders are used in the order they were delivered from the supplier. That is; first in, first out. Empty and full cylinders should be stored separately. Empty cylinders should be clearly marked and grouped together with cylinders that contained the same gas. Leak Testing If the equipment to which a gas cylinder is attached is fitted with a shut-off valve there is a simple method of testing for a leak: Attach the regulator, hose and equipment Shut off the control valve on the equipment Slowly open the cylinder valve, then screw in the regulator control knob to pressurise the system. Close the cylinder valve and watch the regulator pressure gauges. If the pressure is retained there is no leak in the system. 9

10 If the pressure drops, a leak is present and it should be located with leak detection solution and then depressurised and repaired. This test will identify all leaks between the cylinder valve and the shut-off valve on the equipment. In addition to this test, leak detection solution should be used on: The cylinder valve gland The cylinder safety device, and The cylinder neck thread Emergency Procedures Because there are a large variety of potentially hazardous situations involving gas cylinders, it is important that proper emergency procedures have been established and personnel have been properly trained. A variety of techniques can be employed depending on the problem and the gas involved. In general these would often include: Isolating the gas supply by turning off the gas cylinder valve, but only if it is safe to do so. Isolating or removing the cylinder and or evacuating the area Removing sources of ignition and not starting any motors when flammable gas is involved Ensuring maximum ventilation Notifying the Fire Brigade and the manufacturer. Gases are essential for many industrial purposes and like many other hazardous materials; they can be used safely with the correct handling procedures. Material Safety Data Sheets Safe Work Procedures, and Advice from the manufacturer and appropriately qualified person should ensure the safety of all concerned when working with compressed gas cylinders. 10

11 PART ONE TYPES OF GASES There are two major groups of gases that are supplied in gas cylinders, and they are: Permanent gases Liquefied gases Permanent gases, such as oxygen, nitrogen and helium, are gases that cannot be liquefied at room temperature regardless of how high the pressure. Some gases will liquefy at low temperatures and can be kept in this liquefied state under pressure. Common examples include propane and butane. Liquefied gas cylinders are not filled to the top. A vapour space is left for expansion. Acetylene is the only common gas which is not supplied as a permanent or liquefied gas. Acetylene is stored under pressure as a dissolved gas. The reason for this is that acetylene will decompose and explode violently at relatively low pressures. Acetylene cylinders are therefore filled with calcium silicate which is then saturated with acetone. DISCUSSION What types of gases are used in your workplace? 11

12 PART TWO IDENTIFYING GASES It is crucial that the gas in a cylinder is correctly identified prior to use. Sometimes cylinders themselves are coloured as a guide to their contents, but the label is always the primary means of identification of the contents of a cylinder. Always read the label. Do not assume a cylinder contains a particular gas without confirming the name on the cylinder. Gas cylinder labels may include: The name and contact details of the manufacturer The name and grade of the gas contained in the cylinder The UN number, which is sometimes called the SI number Other relevant numbers and codes of classification Detail indicating the size of the cylinder and fill pressure Some general information about the properties of the gas contained in the cylinder, and Emergency contact information Information on things such as: Storage Handling Transport Personal Protective Equipment requirements, and Incident Response may not be on a cylinder and should be obtained from (Material) Safety Data Sheets. Finally, never repaint a cylinder, change its marking or alter its label in any way. DISCUSSION Why is it so important to read the label of a cylinder before using it? 12

13 PART THREE BEFORE USING A GAS CYLINDER Always identify and confirm the gas to be used by reading the label. Inspect the cylinder to make sure there is no damage to it, and that it is structurally sound. Also make sure the cylinder is not giving off odours, hissing, or otherwise leaking. Check the equipment that is connected to the cylinder, including hoses, regulators, gauges and so on, to make sure they are: Appropriate for the gas being used, and Free from damage DISCUSSION What specific equipment is connected to the gas cylinders in your workplace? 13

14 PART FOUR SAFE USE AND HANDLING There are many other general do's and don'ts when handling and using gas cylinders including the following: The regulator should always be removed when moving a cylinder, even for short distances and the valve should never be used as a lifting point. Unless specifically designed to be used otherwise, always use cylinders in the upright position and secure them so they won't be knocked over accidentally. Ensure the cap is in place to protect the valves when the cylinder is not in use. Make sure threads on regulators, gauges and connections correspond to those on the cylinder valve outlet. Also only use regulators designed for the particular cylinder and type of gas. Never use a wrench or hammer on a gas cylinder, if hand pressure is not sufficient to open the valve have the cylinder returned to the supplier. Never use a compressed gas cylinder without the appropriate pressure-reducing regulator attached to the cylinder valve. Always open valves slowly. Always close the supply cylinder valve when not in use. Never attempt to repair or alter cylinders, valves or attachments... all this work must be performed by the manufacturer. Never permit sparks, molten metal, electric current, excessive heat or flames to come into contact with a cylinder or its attachments. Never use oxygen as a substitute for air - and finally, Never bring a cylinder into a confined space. DISCUSSION How are gas cylinders moved and transported around your workplace? 14

15 PART FIVE SAFE STORAGE Cylinders should only be stored in designated storage areas designed specifically for gas cylinders. They should be well ventilated, dry and secure. Storage areas should be designed to separate incompatible gases, for instance oxygen cylinders should be stored well away from flammable gas cylinders. Cylinders should be stored upright and secured on a level fireproof floor. Cylinders stored in the open should be protected from the ground and extremes of weather to prevent rusting, and from continuous direct sunlight. Cylinders should never be stored near heat sources or near flammable substances. Storage should be arranged so that cylinders are used in the order they were delivered from the supplier. That is first in, first out. Empty and full cylinders should be stored separately. Empty cylinders should be clearly marked and grouped together with cylinders that contained the same gas. DISCUSSION Where are full and empty cylinders stored in your workplace? 15

16 PART SIX LEAK TESTING If the equipment to which a gas cylinder is attached is fitted with a shut-off valve there is a simple method of testing for a leak: Attach the regulator, hose and equipment Shut off the control valve on the equipment Slowly open the cylinder valve, then screw in the regulator control knob to pressurise the system. Close the cylinder valve and watch the regulator pressure gauges. If the pressure is retained there is no leak in the system. If the pressure drops, a leak is present and it should be located with leak detection solution and then depressurised and repaired. This test will identify all leaks between the cylinder valve and the shut-off valve on the equipment. In addition to this test, leak detection solution should be used on: The cylinder valve gland The cylinder safety device, and The cylinder neck thread DISCUSSION What procedures are in place in your workplace regarding the leak testing of equipment? 16

17 ASSESSMENT GAS AND CYLINDER SAFETY Name: Date:. I.D. (if applicable): Score 1. The 2 major groups of gases that are supplied in cylinders are permanent and gases. a) Dry-Ice b) Non-Permanent c) Temporary d) Liquefied 2. What is the only common gas that is not supplied as a permanent or liquefied gas? a) Oxygen b) Acetylene c) Helium d) Nitrogen 3. The primary means of identification of any gas cylinder should be to always read the a) SDS b) Paper c) Lab report d) Label 17

18 4. Which of the following can be found on a gas cylinder label? a) The name and contact details of the manufacturer b) Emergency contact information c) The UN number d) All of the above 5. What is the name of the document that contains information about a particular gas that is not on a gas cylinder label? a) The UN Number b) Delivery Docket c) Safety Data Sheet d) None of the above 6. Is it acceptable to repaint a cylinder, change its marking or alter its label in any way? a) Yes b) No c) Yes, only if your changing from one gas to another d) Yes, only if the gas is not flammable 7. A One of the most dangerous risks associated with gas use is caused by reduction of oxygen. a) Asphyxiation b) Fires c) Manual handling injuries d) Broken bones. 8. Approximately how much oxygen is in the air we breathe? a) 99% b) 90% c) 21% d) 1% 18

19 9. Which of these checks should be performed on a gas cylinder prior to using it? a) Make sure there is no damage to it b) Make sure the cylinders is not releasing odours c) Make sure the cylinder is not hissing d) All of the above 10. When moving or transporting a gas cylinder, what should be done with the regulator? a) It should be tightened b) It should be loosened c) It should be removed d) Nothing 19

20 ANSWERS TO ASSESSMENT 1. D) Liquefied 2. B) Acetylene 3. D) Label 4. D) All of the above 5. C) Safety Data Sheet 6. B) No 7. A) Asphyxiation 8. C) 21% 9. D) All of the above 10. C) It should be removed 20