Transcript Compressed Gases Part 1

Compressed Gases
Part 1
CHARACTERISTICS OF
CYLINDERS
A. General features
B. Designations
MARKING REQUIREMENTS
ICC 3AA2015
A25798641 2
PST 3
6 56 4 + 5
5-61
6
+
+
1
CAP
MARKING
NECK
RING
5
5
7
5-66 6
NO STAMPINGS BELOW THIS LINE
ALL STAMPING AT LEAST 1/4 INCH
HIGH, SEE 49CFR 1788.37-21
1. DOT or ICC marking may appear-new
manufacture must read:
“DOT” 49CFR171.14
“3AA” indicates spec in 49CFR178.37.
“2015” is the marked service pressure.
2. Serial number- no duplicates
permitted with any particular symbolserial number combination
CYLINDER
4. “5 56” date of manufacturer.
Month and year.
“
“ disinterested inspector’s official
mark
5. Plus mark(+) indicates
cylinder may be 10% even
per 49CFR173.302 (C).
6. Retest dates
7. 5 pointed star indicates
3. Symbol, or manufacturer, user, or purchaser
ten year retest interval See
49CFR173.34 (e)(15).
CHARACTERISTICS OF
CYLINDERS
HAZARDOUS PROPERTIES:
A. PHYSICAL PRESSURE
B. ANESTHETIC
C. CORROSIVE
D. FLAMMABLE
E. REACTIVE
F. INERT
G. RADIOACTIVE
H. TOXIC
HANDLING CYLINDERS
A. Receiving
B. Storage
-cylinders used for many gases can last for decades
-cylinders need to be test periodically
-visual inspection of cylinders for damage is important
C. Use
-Leak testing
-Pressure in system
-Heat source
-Structural damage
-Toxic or other health hazard
EMERGENCY HANDLING
A. Leaking cylinder
B. Damaged cylinder
COMPRESSED GAS
CYLINDERS
1. Content Identification
• Labels – Primary
• Color - Secondary
2. Handled by Trained Personnel
•
Labeled- Name or hazard class
•
No Smoking
•
Secured
•
Valve Caps/Plugs
COMPRESSED GAS
CYLINDERS
3. Defective Cylinders Not Utilized
• Leaks
• Bulges
• Defective Valves
• Defective Safety Valves
• Physical Abuse
• Fire/Heat Damage
• Rusting or Corrosion
1910.101 Compressed gases (general
requirements).
• Inspection of compressed gas cylinders. Each
employer shall determine that compressed gas
cylinders under his control are in a safe condition to
the extent that this can be determined by visual
inspection.
• Visual and other inspections shall be conducted as
prescribed in the Hazardous Materials Regulations of
the Department of transportation (49 CFR parts 171179 and 14 CFR part 103).
• Where those regulations are not applicable, visual
and other inspections shall be conducted in
accordance with Compressed Gas Association
Pamphlets C-6-1968 and C-8-1962, which is
incorporated by reference as specified in 1910.6.
(b) Compressed gases.
The in-plant handling, storage,
and utilization of all compressed
gases in cylinders, portable
tanks, rail tankcars, or motor
vehicle cargo tanks shall be in
accordance with Compressed
Gas Association Pamphlet P-11965, which is incorporated by
reference as specified in
1910.6.
(c) Safety relief devices for
compressed gas containers.
Compressed gas cylinders, portable
tanks, and cargo tanks shall have
pressure relief devices installed and
maintained in accordance with
Compressed Gas Association
Pamphlet P-1-1963 and 1965
addenda and S-1.2-1963, which is
incorporated by reference as
specified in 1910.6.
SAFE HANDLING
OF COMPRESSED
GASES IN
CONTAINERS
COMPRESSED GAS
ASSOCIATION, INC.
1. INTRODUCTION
1.1 Scope. The following guidelines compiled
by the Compressed gas Association, Inc. are
primarily for the guidance of users of
compressed gasses in containers and are based
upon accident experience. Some precautions
are also applicable to gas manufacturers and
distributors. It should not be assumed that
every applicable safety precaution or regulation
is contained herein. The term “container” as
used in this pamphlet shall refer to portable
compressed gas cylinders and liquid containers
made in accordance with the U.S. Department
of transportation (DOT) and Transport Canada
(TC) specifications. [1]1 and [3]
1.2 GENERAL
Compressed gas containers
constructed, maintained, and used in
accordance with applicable regulations
(as referenced in section 2 of this
document) are safe for the purposes
for which they are intended. Accidents
occurring during the transportation,
handling, usage, and storage of these
containers can invariably be traced to
failure to follow the guidelines set
forth in this pamphlet.
1.3.12. CYLINDER
Generally a compressed gas container
having a maximum water capacity of
1000 lbs. (453.6 kg.). This is
approximately the equivalent of 120
gallons (454.2 L). Newer specifications
permit the use of larger size containers
having a water capacity of
approximately 5000 lbs. (2268.0 kg.).
1.3.5 COMPRESSED GAS
• Any gas or mixture of gases having, in a
container, a pressure exceeding 40° psia at
70 degrees Fahrenheit
• Any flammable liquid having an absolute
vapor pressure exceeding 40 psia at 100
Fahrenheit
1.3.6 CONTAINERS (Compressed
Gas)
Vessels of various shapes, sizes,
materials of construction (e.g.,
cylinders, portable banks, stationary
tanks), and design meeting
specifications of either the American
Society of Mechanical Engineers,
Transport Canada, or the United
States Department of
Transportation.
1.3.23 HIGHLY TOXIC GAS
A compressed gas that has a
median lethal concentration
(LC50) of 200 parts and less than
2,000 parts per million by volume
of gas or vapor when
administered by continuous
inhalation for an hour (or less if
death occurs within one hour) to
albino rats weighing between 200
and 300 grams each.
POSIN GAS
1.3.32 PRESSURE RELIEF DEVICE
A pressure and/or temperature activated
device used to prevent the pressure from
rising above a predetermined maximum, and
thereby prevent rupture of a normally
charged cylinder when subjected to a
standard fire test as required by 49 CFR
173.34 (d) or 73.34 (d) of the TC
Regulations. The term “pressure release
device” is synonymous with “safety relief
device,” as used by DOT, and TC regulations.
1.3.33 psig. Pounds per square inch
absolute. (See gas pressure)
1.3.37 TOXIC GAS
A compressed gas that has a
median lethal concentration
(LC50) in air of more than 200
and less than 2,000 parts per
million or less by volume of gas or
vapor when administered by
continuous inhalation for an hour
(or less if death occurs within one
hour) to albino rats weighing
between 200 and 300 grams
each.
1.3.29 NESTING
A method of securing flat bottom
cylinders upright in a tight mass
using a contiguous three (3) point
contact system whereby all
cylinders, within a group have a
minimum of three (3) points of
contact with other cylinders,
walls, or bracing. See Appendix
D.
PROPERLY NESTED
CYLINDERS
WALL SUPPORTED
THREE POINT CONTACT SYSTEM
ALL CYLINDERS ARE IN CONTACT ON
THREE POINTS- EITHER WITH OTHER
CYLINDERS OR WALL.
NESTED UNSUPPORTED
THREE POINT CONTACT SYSTEM
ALL CYLINDERS ARE IN CONTACT WITH
OTHER CYLINDERS ON THREE POINTS.
IMPROPERLY NESTED
CYLINDERS
IMPROPERLY NESTED CYLINDERS
END CYLINDERS IN CONTACT WITH
OTHER CYLINDERS ON ONLY TWO
POINTS.
NESTED UNSUPPORTED
END CYLINDERS NOT IN CONTACT WITH
OTHER CYLINDERS ON THREE POINTS.
Paragraph 3.7.4.1 states that, “All
compressed gas cylinders in service or
in storage at user locations shall be
secured to prevent falling. At gas
manufacture’s facilities and
distributor's warehouse, the nesting of
cylinders is considered an equivalent
safe manner of storage.”
1.3.32 PRESSURE RELIEF DEVICE
A pressure and/or temperature
activated device used to prevent the
pressure from rising above a
predetermined maximum, and thereby
prevent rupture of a normally charged
cylinder when subjected to a standard
fire test
2.4 EMPLOYEE SAFETY AND HEALTH
REGULATING AUTHORITIES
Compressed gas containers shall be
marked, labeled, stored, handled, and used
in accordance with applicable Occupational
Safety and Health Administration standards
as well as other Federal, State, and local
regulations.
3. GENERAL SAFE HANDLING RULES
FOR COMPRESSED GAS CONTAINERS
Compressed gasses shall be handled and
used only by properly trained persons.
3.2.2 PRESCRIBED MARKINGS
The prescribed stamped
markings on the container shall
be made and kept in a legible
condition. The user shall not
remove or alter any of these
markings.
3.2.6 IDENTIFICATION
Containers not bearing a legibly
written, stamped, or stenciled
identification of the contents
shall not be used, they shall be
segregated for return to the gas
manufacturer or distributor.
3.3 LABELS
The labels applied by the gas
manufacturer to identify the
container contents shall not be
defaced or removed by the
user.
3.3 GENERAL PRECAUTIONS
The following precautions shall apply to
distributors, users, and manufacturers
when using or handling compressed gas
cylinders:
3.3.1 Compressed gas cylinders
shall not be used as rollers,
supports, or for any purpose other
than to contain and use the
content as received.
3.3 GENERAL PRECAUTIONS (CONT.)
3.3.2 Containers SHALL NOT be
placed where they might become part
of an electrical circuit. When
compressed gas containers are used in
conjunction with electric welding, they
shall not be grounded or used for
grounding. These precautions will
prevent the container from being
damaged by the electric welding arc.
3.3 GENERAL PRECAUTIONS (CONT.)
3.3.3 Compressed gas containers SHALL
NOT be exposed to temperature
extremes. High temperatures may result
in excessive cylinder pressure. NEVER
apply a flame or heat directly to any part
of a compressed gas container or allow it
to come in contact with an electrically
energized system. If ice or snow
accumulate on a container, thaw at room
temperature, or with water at a
temperature not exceeding 125 F° (51.7
C°)
3.3.1 CYLINDER MODIFICATIONS.
The user shall not modify,
tamper with, obstruct, remove,
or repair any part of the cylinder,
including the pressure relief
device and the container valve or
the valve protection device.
3.3.10 NONREFILLABLE
CYLINDERS
Nonrefillable cylinders shall not
be refilled with any material
after use of the original
contents. After usage such
cylinders shall be disposed of in
accordance with the cylinder
manufacturer’s
recommendations.
3.4 VALVE PROTECTION CAPS AND
VALVE OUTLET CAPS AND PLUGS
3.4.1 VALVE PROTECTION CAP
Where provided by the gas
manufacturer, the user shall keep
such caps on containers at all
times except when containers are
secured and connected to
dispensing equipment.
3.5 SAFE HANDLING OF CONTAINERS
• Users of compressed gas containers
shall ensure that they are not rolled in
the horizontal position or dragged. A
suitable hand truck, forklift truck, or
similar material handling device should
be used with the container properly
secured to the device.
• Caution should be used when handling
containers to guard against dropping or
permitting containers to violently strike
against each other or other surfaces.
3.5.1 Personnel who handle
containers shall be trained and
instructed NEVER to lift
containers by using the
container cap or magnets.
3.6 TRANSFILLING
Compressed gases shall not be
transferred from one container to
another container except by the gas
manufacturer using qualified,
trained personnel with the
appropriate equipment and
operating procedures.
3.7 STORING CONTAINERS
3.7.1 POSTING
Container storage areas shall
be prominently posted with the
hazard class or the name of
the gases to be stored and
with “NO SMOKING” signs
where appropriate.
3.7.2 STORAGE AREAS
3.7.2.1
• Storage areas shall be designed to
accommodate the various gases required by the
user.
• Adequate spacing, or segregation by
partitioning in accordance with applicable codes,
shall be provided so that the containers can be
grouped together by the hazard class of the gas.
• Additional consideration should be given to
separate storage of full and empty containers.
Further design consideration shall include a dry,
well-ventilated area, preferably of fire-resistive
construction.
3.7.2 STORAGE AREAS (CONT.)
• Containers are not to be stored near readily
ignitable substances, such as gasoline.
• Furthermore, containers should not be exposed
to corrosive chemicals or fumes. Corrosion may
damage the containers and may cause the
container valve protection caps to stick
3.7.2.2
• Containers shall be protected from
any object that will produce a
harmful cut or other abrasion in the
surface of the metal.
• Containers shall not be stored near
elevators, walkways, unprotected
platform edges, or in locations where
heavy moving objects may strike or
fall on them.
3.7.3.2
• User shall ensure that containers
stored or used in public areas are
protected against tampering and
damage.
• Furthermore, containers when
stored (either inside or outside) shall
not obstruct exit routes or other
areas normally used or intended for
the safe exit of people.
3.7.3.2 REMOVING PRESSURE
REGULATOR
Before a regulator is removed
from a container, the container
valve shall be closed and the
regulator relieved of gas
pressure.
3.7.3 OUTDOOR STORAGE
3.7.3.1
Cylinders may be stored in the
open, but to prevent bottom
corrosion, prolonged exposure to a
damp environment should be
avoided.
•
• Cylinders should not be exposed to
salt, corrosive chemicals, or fumes.
3.7.3.1 (Cont.)
• It is preferable to store cylinders on
paved surfaces, such as asphalt or
concrete which has been graded to
prevent accumulation of water.
Cylinders may be stored in the sun
except in locations where extreme
temperatures prevail.
• If the gas manufacturer recommends
storage in the shade for a particular
gas, such recommendations shall be
observed.
3.7.4 CYLINDER POSITIONS IN
STORAGE
3.7.4.1
• All compressed gas cylinders in
service or in storage at user locations
shall be secured to prevent falling.
• Properly secured cylinders with a water
volume less than 305 cu. in(5.01) may be
stored in a horizontal position.
3.8.1 CONTAINER VALVE
• The container valve shall be kept
closed at all times (charged or
empty) except when the container is
in use.
• Valve outlets shall be pointed away
from all personnel when the valve is
being opened.
3.8.1.1 MANUALLY OPERATED VALVE
• The container valve shall be
opened slowly.
• On valves without hand wheels,
the wrenches provided by, or
recommended by, the gas
manufacturer shall be used.
• The wrench shall remain on the
valve while the container is in use.
3.8.4 GAS TIGHT CONNECTIONS
• Piping, regulators, and other
apparatus shall be kept gas tight to
prevent leakage.
• This can be confirmed by the use of
a compatible leak test solution, or an
appropriate leak-detection
instrument.
CAUTION: Do not tighten
connections or leaking fittings or
attempt other repairs while the
system is under pressure.
3.10 EMERGENCY RESPONSE
An emergency response plan
shall be implemented wherever
compressed gas containers and
products are used, handled, or
stored.
3.10.1 QUALIFIED PERSONNEL
Only qualified and knowledgeable
personnel shall respond to an
emergency situation involving a
compressed gas container or
product.
3.10.2 MAINTAIN SAFE
CLEARANCE
Personnel shall be promptly
evacuated from the immediate
area in danger and kept up wind at
sufficient distance to avoid any
inhalation or contact with
potentially hazardous products
until safe re-entry can be assured.
3.10.3 IDENTIFY HAZARDS
Placards, container labels, and
markings when observed at a
safe distance provide available
information in identifying the
products involved.
4.2.1.3
• Flammable gases shall not be
used near open flames, sources
of heat, adjacent to oxidizers
and non-explosion proof electric
systems, or near undergrounded
electrical equipment.
• Transportation and use should
be in well ventilated vehicles and
areas.
4.2.1.4
Acetylene containers should be
stored valve end up ( the
container axis may be inclined
as much as 45 degrees from
vertical) to minimize the
possibility of solvent being
discharged.
4.2.1.5
• Portable fire extinguishers (of
carbon dioxide or dry chemical
types) shall be available for fire
emergencies at storage installations.
• No Smoking signs shall be posted
around the storage area of buildings
or at entrance(s) to special storage
rooms.
4.2.1.5
A flame shall not be used for
detection of flammable gas
leaks. Either a flammable gas
leak detector or compatible leak
detection solution shall be used.
4.2.1.6
Electrical equipment must
comply with the applicable
electrical code.
4.2.1.7
Spark proof tools should
be used when working
with or on flammable
compressed gas
cylinders/systems.
4.2.2 STORAGE OUTDOORS OR IN
SEPARATE BUILDING WITHOUT
OTHER OCCUPANCY
4.2.2.1
Provisions should be made to protect
flammable gases from hazardous exposures
to and against hazardous exposure from
adjoining buildings, equipment, property,
and concentrations of people.
• The storage area shall be well ventilated.
• Heating shall be by steam, hot water, or
other indirect means.
• Direct heating by flames or fire shall be
PROHIBITED.
• The interior and the area surrounding the
exterior of a building so used should be kept
free of combustible materials.
•
4.2.4 STORAGE IN BUILDING
AND ROOMS WITH OTHER
OCCUPANCY
4.2.4.1 Flammable gas containers
stored inside of buildings with
other occupancies shall be kept at
least 20 feet (6.10m) from
flammable liquids, highly
combustible materials, and
oxidizers and not near arcing
electrical equipment, open flame,
or other sources of ignition.
4.2.6 FLAMMABLE GAS
SYSTEMS
4.2.6.1 Flammable compressed
gas systems (piping, tubing,
fittings, gaskets, and thread
sealants) should be suitable for
the applicable flammable
compressed gas service and for
the pressures and temperature
involved.
4.2.6 FLAMMABLE GAS
SYSTEMS
4.2.6.2 Material specifications
and thickness requirements for
piping and tubing shall conform to
the American National Standard
Code for Chemical Plant and
Petroleum Refining Piping,
ANSI/ASME B31.3.[16]
4.2.6 FLAMMABLE GAS
SYSTEMS
4.2.6.3 All lines and equipment
associated with the flammable
gas systems should be grounded
and bonded.
4.4.4
• Oxidizers shall be stored
separately from flammable gas
containers or combustible materials
(especially oil or grease).
• A minimum distance of 20 feet or
a non combustible barrier at least
five feet high having a fire
resistance rating of at least one-half
hour is considered a minimum
requirement.
4.5.2.1
Every effort shall be made to avoid
contacting the skin or eyes or
inhaling any of the corrosive or
toxic gases. Areas where corrosive
gases are filled or utilized shall be
equipped with emergency showers
and eyewash fountains. The
capability for prompt emergency
medical treatment, including first
aid, shall be provided.
4.5.2.2
• Only trained and qualified
personnel shall be allowed to fill ,
process or utilize corrosive and toxic
gases.
• Training shall include the associated
hazards of the materials, necessary
precautions, protective equipment,
and emergency response procedures.
4.5.2.4 VENTILATION, STORAGE,
AND SITE CRITERIA
4.5.2.4.1
• Storage of toxic and corrosive gases within
these categories shall be outdoors, or in a
separate noncombustible building without
other occupancy, or in a separate room
without other occupancy and of
noncombustible construction with a fireresistance rating of at least one hour.
• Storage areas shall be adequately
ventilated to prevent hazardous
concentrations.
• Storage locations shall be protected
against tampering and damage.
2.5.2.4.1 (Cont.)
• It is also recommended that for inside
storage areas toxic gas monitors be
installed.
• Total quantity of these gases on the
user’s site should be limited to the user’s
near term foreseeable requirements.
4.5.2.4 VENTILATION, STORAGE,
AND SITE CRITERIA
4.5.2.4.2
• These gases shall be filled and utilized
only in forced ventilation areas or preferably
outdoors or in exhausted enclosures.
• These gases when emitted from
equipment in high concentrations shall be
discharged into appropriate treatment
equipment which will remove or neutralize
such toxic gasses so that they are not
present in the effluent gas streams at
hazardous levels.
4.5.2.3.2
• Where self-contained breathing apparatus are
provided they shall be of a positive pressure
type, with a minimum of two (2) units, one as a
backup, made available.
• Such equipment shall be stored in a location
that is in close proximity to the area(s) where
corrosive, toxic, or highly toxic gases are being
utilized, but one not likely to be affected by the
release of hazardous material.
• Only trained and properly qualified personnel
shall be authorized to use such equipment and
only when backup personnel and equipment are
present.
1910.102 ACETYLENE
(a) Cylinders. The in-plant
transfer, handling, storage, and
utilization of acetylene in
cylinders shall be in accordance
with Compressed Gas
Association Pamphlet G-1-1966,
which is incorporated by
reference as specified in
1910.6.
1910.103 HYDROGEN
(a) General-(1) Definitions. As used in
this section (i) Gaseous hydrogen
system is one in which the hydrogen is
delivered, stored and discharged in the
gaseous form to consumer’s piping. The
system includes stationary or movable
containers, pressure regulators, safety
relief devices, manifolds,
interconnecting piping and controls. The
system terminates at the point where
hydrogen at service pressure first
enters the consumer’s distribution
piping.
1910.105 NITROUS OXIDE
The piped systems for the inplant transfer and distribution of
nitrous oxide shall be designed,
installed, maintained, and
operated in accordance with
Compressed Gas Association
Pamphlet G-8.1-1964, which is
incorporated by reference as
specified in 1910.6.
1910.104 OXYGEN
(a) Scope. This section applies to the
installation of bulk oxygen systems on
industrial and institutional consumer
premises. This section does not apply
to oxygen manufacturing plants or
other establishments operated by the
oxygen supplier or his agent for the
portable containers, trailers, mobile
supply trucks, or tank cars, nor to
systems having capacities less than
those stated in paragraph (b)(1) of
this section.