Code of Practice for the Manual Handling of Gas Cylinder and exchange of regulators

Transcription

1 Code of Practice for the Manual Handling of Gas Cylinder and exchange of regulators General information The Manual Handling Operations Regulations 1992 (updated 1998) came into force in January The purpose of the regulations is to reduce the risk of injury from manual handling operations. To comply with these regulations, the University of Exeter as an employer must identify all manual handling operations undertaken by its employees and appoint a competent person to assess the risks involved in the manual handling activities. It is imperative to carry out a risk assessment on manual handling of gas cylinders which is a high risk activity. Cylinders are extremely heavy due to the fact that they are made of metal and have to withstand high pressure. They are also unstable when unsupported because of their long, thin shape. A total of 233 incidents relating to the supply and use of flammable gases were reported in 2011/12 to the Health and Safety Executive under RIDDOR 1995 (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations). To reduce these risks to staff that operate mechanical aids such as cylinder trolleys, staff must be fully trained in their use and the use of correct body mechanics for pushing and pulling these aids. The University of Exeter safety office will be able to provide advice and general training on manual handling to staff. Staff suffering from manual handling injuries must report it to the college safety office using the accident form that is provided and can be obtained from the College website.

2 GAS CYLINDERS Risk Assessment 1. Identify hazards associated with manual handling of gas cylinders The impact from falling cylinders can cause explosion resulting in injuries from flying parts. Manual handling of cylinders involving wrong postures can caused severe health problems such as disc injuries, sprains and strains when muscles are stretched. Fractures can be caused by crushing body parts under the heavy load of the cylinder. 2. Identify people at risk The risk assessment must identity everyone who is at risk for the hazards involved in handling gas cylinders: People directly involved in performing the tasks (technicians, post graduates students etc), and people who might be in the vicinity when there is an accident such as contractors, cleaners, maintenance workers, students, and visitors. Persons at risk must be identified to devise adequate control measures which must give priority to protecting the whole workplace instead of concentrating on individual measures such as use of protective personal equipment. 3. Evaluation of existing control Adequate control measures involved carrying out a risk assessment under the Manual Handling Operation Regulation 1992 (amended 1998) and taking the following point into account: - Mass and dimension of the gas cylinders (safety data sheet from supplier). - Establish gripping points before doing the lift such as valve guard. - Use of suitable PPE: lab coat, gloves, safety spectacles/goggles, safety shoes. -Use of ergonomically designed mechanical aids e.g. cylinder trolley. - Perform the task by two staff.

3 4. Record the finding The finding of the risk assessment must be recorded and communicated to all staff involved in the manual handling of gas cylinders. The risk assessment must be reviewed when there is any change in the task (longer carrying distance) or personnel (untrained staff) involved. Techniques for Safe Manual Handling of Gas Cylinders Loading Gas Cylinder on trolley Wear steel toe capped shoes and industrial quality gloves Undo securing bars on trolley and slide it near the cylinder Unhook chain from rack and place palm of hand on top of cylinder neck, get a firm grip Tilt cylinder slightly forward so it rests on the rim of the base and use the other hand to rotate cylinder milk churning it from rack to trolley Pushing trolley and unloading gas cylinder Fasten securing bars/chains on the trolley Place one foot on the axle and tilt the trolley back so it balances comfortably on the wheels Keeping back straight, push trolley and set it down in front of the laboratory bench Remove cylinder from trolley, milk churning it into its new position and clamp it securely to the bench using chains, or straps. Moving cylinders in lifts A summary of what needs to be done if moving cylinders between floors using a lift.

4 Because of the danger of leakage in a confined space, people should not travel in lifts with gas cylinders. Instead, a similar procedure to that used when moving liquid nitrogen vessels should be adopted. Enlist the help of a colleague before moving the cylinder. Ask them to stand outside the lift doors on the floor you want the cylinder to go to. Move to the floor where the cylinder is located. Ensure a sign is placed around the cylinder warning other staff members not to enter the lift. Call the lift and on arrival place the cylinder inside. Contact your colleague and ask them to call the lift up to their floor. Training Training is an important way of achieving competence and contributes to the laboratory s health and safety culture at all levels. All employees must be given the following training: 1. General training on Manual Handling as part of their induction training which should outline all the relevant health and safety issues associated with manual handling operations. 2. Task specific training identified by suitable risk assessment of all manual handling tasks performed by staff. All employees involved with handling of gas cylinders must receive specific manual handling training, as well as refresher training, including some practical session in the course to demonstrate to staff how to perform the manual handling task e.g. proper manual handling technique to load and propel a cylinder trolley. The objectives of this manual handling guidance is to assist the staff involved with manual handling of gas cylinders to reduce the number of manual handling injuries by providing practical advice to reduce the risks associated with handling of cylinders. Safe manual handling techniques when put into practice will help reduce accidents, sickness and absenteeism, lower healthcare costs, insurance premiums and compensation claims and improve productivity of the technical staff of the University of Exeter.

5 The college, at regular intervals, will provide training by a recognised provider with respect to the safe use of gases. This training will include the changing of cylinder regulators and the like. This training is mandatory for all employees carrying out these tasks. An example of Risk Assessment carried out on the Manual Handling of Gas Cylinder Manual Handling of loads: Assessment checklist Section A Preliminary: *Delete as appropriate Task description: Manual handling of gas cylinder. Load weight: 60 Kg Carrying distance: Basement to 3 rd Floor via lift. Assessment discussed with employees/safety representatives: Yes/No* Is an assessment needed? (e.g. is there risk for injury?) Yes/No* If Yes continue. If No assessment need go no further. Has operative had appropriate manual handling training? Yes/No* Section B _ Risk Assessment: Operations covered by this assessment: Gas cylinder from ground floor manoeuvred and placed on trolley which is then wheeled into lift. The lift is then sent to the desired floor with a label attached saying to not travel in lift with gas cylinder. Cylinder trolley is then pushed into the lab, unloaded and strapped to the lab bench or placed in designated cylinder cupboard. Locations: External cylinder store to Laboratory on 3 rd floor. Personnel involved: Lab Technician/Postgraduate Student.* Name of personnel:... Other persons at risk:... Control measures:...

6 Date of assessment:... General information GAS CYLINDER REGULATORS Pressure regulators, fitted to the outlet of gas cylinder valves, should be used and maintained in accordance with relevant standards. The following is in line with guidance on this matter issued by the British Compressed Gases Association and BOC. Guidance on safe usage Pressure regulators should be treated as precision instruments. They should not be stressed by rapid opening of the cylinder valve. The correct regulator should be used at all times, check the markings on the regulator and cylinder to make sure they match (This check should include to pressure and type of gas). Regulators which have damaged pressure gauges, pressure indicators, inlet or outlet connections or threads, should not be used. The regulator pressure adjusting screw should be set to the zero pressure position when the regulator is not in use. (De-gas the regulator by shutting off the regulator valve and releasing the pressure via the outlet). Regulators and pipework changes should only be carried out by a trained individual. All regulators should comply with BS EN 585 or BS Guidance on maintenance

7 Each time the equipment is used the operator should as per the manufacturers instructions, include the following: Visual examination should be carried out to determine suitability for service (e.g. gas, pressure rating, and damage), condition of threads and sealing surfaces, oil or grease contamination. Leak test all joints at working pressure. Replacement/Refurbishment intervals for all regulators (subject to conditions of use) are every 5 years or manufacturer/supplier's recommendation. Techniques for Safe removal/connection of gas cylinder regulators 1) Always contact the trained individual to carry out this process. 2) Make sure old cylinder valve is turned off and the gas pressure has been released from the regulator. 3) Remove the regulator from the cylinder with the appropriate spanner. 4) Take care to not damage the regulator when you have removed it. (Place on a solid surface and, if supplied, replace the plastic cap over the threads). 5) Remove the old cylinder and replace with the new one in compliance with the previously explained good practice. 6) When the new cylinder is strapped back to the bench or cabinet remove the plastic protective cap and check the threads for any damage. (Never use a cylinder that has a broken/removed plastic protective cap). 7) DO NOT use grease or oil on the threads of the regulator or cylinder. 8) Remove the protective cap from the regulator and screw, finger tight, into the cylinder head. 9) Tighten the regulator by holding the cylinder with one hand and tighten with the provided spanner with the other hand. 10) Make sure the regulator is turned off; turn the cylinder on full and then half a turn back with the spanner. 11) Check the seal with an appropriate leak detection solution, if it bubbles immediately turn off the cylinder. 12) Start the process again from the top. Make sure everything is dry before re-attaching the regulator. It may be necessary to perform a blow off procedure to remove any small pieces of debris from the seating area of the cylinder as directed during training. 13) If it continues to leak please report the fault to stores/suppliers for a replacement. 14) When all is safe you may turn on the regulator to the desired pressure and use. ALWAYS turn off the cylinder and remove pressure from the regulator when not in use.