�SAFETY TRAINING – �COMPRESSED GASES

Stories of Compressed Gases

• Employee killed when cylinder turned into a rocket because its valve was knocked off
• Employee suffocated after entering a space filled with nitrogen
• Facility damaged when acetylene cylinder heated up and exploded
• Eyebrows singed when lighting a gas BBQ

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Training Goals

• Compressed Gases and Cylinders in General
• Specific Compressed Gases
• Quiz

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Basics of Compressed Gases

• Chemicals include oxygen, argon, nitrogen, helium, acetylene, hydrogen, nitrous oxide, carbon dioxide, ammonia, chlorine, etc.
• Compressed gases used in bulk systems or portable cylinders
• Industry uses include welding, cutting, operating tools, transferring liquids, blowing agents, laboratories, etc.

HAZARDS OF COMPRESSED GASES

• Explosion
• Flammability
• Corrosive
• Toxicity
• Reactivity
• Air displacing
• Check MSDS for specific hazards

Markings or Labels

• Name of the compressed gas
• Required on all compressed gases
• Hazards of the compressed gas
• Required on all compressed gases
• National Fire Protection Association�(NFPA) labels
• Required for bulk tanks but not cylinders
• Blue = Health Yellow = Reactive Red = Flammability
• Department of Transportation (DOT) labels
• Do not remove any labels

Receiving Cylinders

• Check cylinders as they are received
• Verify labels, tags and shipping papers
• If cylinder’s content is not identified by marking, return cylinder to the supplier without using
• Reject and return cylinders with obvious damage
• Determine required caps & plugs in place

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Bulk Systems

• Built and maintained by qualified personnel
• Filled by trained and qualified personnel
• Tank and piping properly labeled
• Tank system protected from damage

Cylinder Transportation

• Receiving/shipping cylinders requires �DOT Hazardous Materials training
• Use lift trucks or hoists only with proper lifting equipment
• Never use a sling or electromagnet to hoist �a cylinder
• Never lift a cylinder by the valve cap

MANUAL CYLINDER HANDLING

• Close the valve and put �on the cap
• Do not “walk” cylinder �by holding onto valve �stem or cap
• Never roll a cylinder �on its side
• Use a hand truck with a secure system such as a chain

Cylinder Storage Area

• Dry, well ventilated, protected from weather
• Away from combustibles, heat sources, electrical systems
• No sparks, smoking, open flames
• Oxygen separated from fuels
• 20 ft from sources or separated by 5 ft tall ½ hr fire wall

Cylinder Storage Area Cont.

• Upright, secured, valve cap on
• Not in elevators, staircases, hallways, or high traffic areas
• Increases risk of knocking over a cylinder
• Sign requirements
• Depends on the type of gas being stored
• Common signs: “No Smoking”, “Danger”, “Caution” or “Warning”

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Cylinder Use

• Inspect Cylinder prior to use
• Check for leaks using soapy water
• Never use a flame to check for leaks
• Upright and secure
• Away from flames, sparks, electricity
• Keep oil, grease, flammables off cylinders
• Open valve by hand, if tools required don’t use the cylinder
• Open valve slowly with hand to the side
• Don’t tamper with safety devices

Burn

Gouge with deposit of weld metal

Gouge

Cut

EXAMPLES OF DAMAGE

General corrosion with pitting - reducing cylinder strength

Regulators and Gauges

• Regulator and gauge rated for the pressure �in the gas system
• Regulator must be compatible with the gas
• Do not exchange gauge from one gas to another
• Thread sealant recommended by manufacturer for application
• Wear eye protection when operating regulator

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LEAKING CYLINDERS

• Never try to repair
• Tag it, move it �outdoors, and keep �it away from heat �or flame
• Call manufacturer �or dealer

General Cylinder Safety

• Only accept and use DOT approved cylinders
• Do not drop cylinders
• Protect cylinders from cuts and abrasions
• Don’t use cylinders for unintended function such as a roller or support
• Don’t tamper with safety valves
• Caps on whenever not in use

Training Goals

• Compressed Gases and Cylinders in General
• Specific Compressed Gases
• Quiz

LPG (Propane)

• Liquid petroleum gases (LPG) include propane, propylene, butane, butylene
• Liquid under pressure, released as a gas
• LPG containers must meet specific �design criteria
• Cylinders have pressure relief valves
• Regulated by local fire department

LPG Hazards

• Flammable and reactive
• Gases are colorless and odorless
• Heavier than air, may build up �and explode unexpectedly
• Adequate ventilation required

LPG Containers

• Marked as an approved container
• Capacity and design pressure
• Shut-off valve, pressure relief valve, �level gauge
• Never use container not approved for LPG, corroded or damaged, missing accessory

LPG HANDLING

• No smoking, use �spark-less tools
• Fill or dispense outside �or in well-ventilated �area—wear PPE such �as glove and goggles
• Secure to forklift or �other vehicle

LPG HANDLING CONT.

• Report damaged cylinders
• Corrosion
• Dents
• Bent Valves
• Leak detection
• Hissing sound
• Distinct odor
• Freezing near leak outlet

Compressed Air

• Flying fragments penetrate eyes or skin
• Compressed air can penetrate skin, damage eyes or ears
• Use lowest pressure for the job
• Wear eye and skin protection
• Store air hose properly and inspect regularly

OXYGEN

• Does not burn or �explode by itself
• Supports �combustion process
• Explosive with �acetylene, hydrogen
• Never handle with oily �hands or gloves

Acetylene

• Flammable
• Cylinder packed with porous material and solvent that holds the acetylene
• Once the valve is opened, the acetylene flows out in gaseous form
• Pressure relief valve using fusible metal that melts at about 212 °F

Acetylene Case Report

• “A fitter with a work van left an E size Oxygen and Acetylene cylinder on the back seat of a Toyota dual cab over the weekend. The Acetylene cylinder must not have fully closed and a small leak occurred. Over the weekend the Acetylene had accumulated in the van. ”

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Acetylene Case Report Cont.

• “On the Monday morning the fitter approached the van and opened the door, a large explosion took place. We believe the ignition could have been caused by either the internal light, the automatic door control or by a mobile phone which was on the front seat of the van.
• The fellow was also a smoker. He has damage to his ear drums and facial damage. As you can see by the attached photos he was very lucky.

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Acetylene

• Flammability limits:  �Lower: 2.5%  Upper: 100% – an extremely wide range!
• Use or store only in a well-ventilated area. (Inside of the truck is not well ventilated.)
• NFPA RATINGS: Health 1; Flammability 4; Reactivity 3

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Poisonous Gases

• Personnel handling and using poison gases should have available for immediate use gas masks or self-contained breathing apparatus approved by U.S. Bureau of Mines* for the particular service desired

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*NOTE: This approval for respirators has been up-dated to the requirements of NIOSH (CGA P-1 2000)

Miscellaneous Gases

• Gases such as argon and nitrogen are �used to displace air
• Helium could cause rapid suffocation
• Gases like ammonia and chlorine will �cause large evacuations even for small leaks

Summary

• Cylinders must always be stored and �secured properly
• Use caution when transporting cylinders
• Understand the hazards of a compressed �gas before using it
• Even compressed air can be dangerous

Training Goals

• Compressed Gases and Cylinders in General
• Specific Compressed Gases
• Quiz