Presentation on theme: "WELCOME OSHA 29 CFR 1910.101 COMPRESSED GAS SAFETY CORPORATE SAFETY TRAINING."— Presentation transcript:
WELCOME OSHA 29 CFR COMPRESSED GAS SAFETY CORPORATE SAFETY TRAINING
Discuss Compressed Gas Program Requirements. Discuss Safety Inspection Requirements. Discuss The Types of Compressed Gases. Discuss Properties of Compressed Gases. Discuss Basic Skills in Hazard Recognition & Control. Discuss OSHAs Requirements for Gas Safety. Discuss the Compressed Gas Associations involvement. Discuss Use, Storage and Maintenance Requirements. COURSE OBJECTIVES
BASIS FOR THIS COURSE Employers are Responsible for Compressed Gas Safety. Compressed Gases Contain a Variety of Hazards. Compressed Gases are Maintained Under High Pressure. Compressed Gases are Extremely Hazardous Training Greatly Lessens the Probability of Disaster. This Training Helps Improve: Safety Morale Productivity Employee well-being
Gas Users Safety Committees Purchasing Agents Department Managers First Line Supervisors Maintenance Managers Shipping and Receiving Employees Accident Investigation Team Members COURSE ATTENDEES
FORWARD REGARDING COMPRESSED GAS SAFETY - Know the gas you are using, or dont use it! Never let your name, and the word dead be used in the same sentence. Billy N. Ring, Fire Captain Dayton Regional HAZMAT Coordinator 27 Years Experience
29CFR - SAFETY AND HEALTH STANDARDS INDUSTRIAL SAFETY COMPRESSED GASES (GENERAL) APPLICABLE REGULATIONS
COMPRESSED GAS ASSOCIATION CGA P-1 - SAFE HANDLING OF COMPRESSED GASES - Over 100 Other CGA Safety Manuals CONSENSUS STANDARDS DANGER COMPRESSED GAS STORAGE AREA
GENERAL PROGRAM REQUIREMENTS Assign Responsibility Establish a Written Program Conduct Gas Safety Training Develop Safe-Use Procedures Conduct Work Area Inspections Maintain a Safe Work Environment Conduct Regular Program Evaluations Ensure Proper Storage and Maintenance ALL EMPLOYERS MUST:
TRAINING REQUIREMENTS Properties of the Gases Being Handled. Explain Why a Particular Gas is Required. Conduct Training Prior to Job Assignment. Precautions to be Taken in Using Cylinders. Precautions to be Taken in Storing Cylinders. Precautions to be Taken in Moving Cylinders. Explain Proper Maintenance and Storage of Gases. Explain the Potential Hazards Associated with Gases. Explain The Nature, Extent and Effects of Gas Hazards. THE EMPLOYER MUST PROVIDE TRAINING :
REQUIRED WHEN THERE IS A: New Hazard or Gas. Program Related Injury. Change in Job Assignment. New Hazard Control Methods. Failure in the Safety Procedures. Reason to Doubt Employee Proficiency. RETRAINING REQUIREMENTS
TRAINING IS IMPORTANT Reduce injury and illness rates. Acceptance of high-turnover jobs. Workers feel better about their work. Reduce workers compensation costs. Elevate OSHA compliance to a higher level. A GOOD PROGRAM WILL HELP:
PROGRAM IMPLEMENTATION DEDICATION PERSONAL INTEREST MANAGEMENT COMMITMENT IMPLEMENTATION OF A COMPRESSED GAS SAFETY PROGRAM REQUIRES: NOTE: UNDERSTANDING AND SUPPORT FROM THE WORK FORCE IS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!
PROGRAM IMPLEMENTATION Establish responsibility. Conduct employee training. Periodically review the program. Perform inspections and maintenance. Modify policies and rules as appropriate. Eliminate hazardous gases where possible. Establish a corporate policy and develop rules. Substitute nonhazardous gases where possible. Conduct a compressed gas safety survey of the facility. Provide protection where hazard elimination is not possible. DEVELOPMENT SEQUENCE: Continued DANGER COMPRESSED GAS STORAGE AREA
IMPLEMENTATION STRATEGY RECOGNITION CONTROL IMPLEMENTATION EVALUATION
IMPLEMENTATION STRATEGY ASSESSMENT OF GAS HAZARDS: Known jobs/areas having gas usage. Jobs/areas with new equipment or processes. New jobs having little or no statistical injury data. Jobs/areas having had recent operational changes. RECOGNITION Continued
RECOGNITION CONTROL IMPLEMENTATION EVALUATION IMPLEMENTATION STRATEGY Continued
IMPLEMENTATION STRATEGY EVALUATION Facility audit data. Employee surveys. Accident investigations. Logs of employee complaints. Statistical evidence of known/potential hazards. Injury and illness data of known/potential hazards. Continued
RECOGNITION CONTROL IMPLEMENTATION EVALUATION IMPLEMENTATION STRATEGY Continued
IMPLEMENTATION Written program. Training program. Employee involvement. Supervisor involvement. Corrective action program. Job hazard analysis program. Safety in purchasing (new gases, substitutes etc.) IMPLEMENTATION STRATEGY Continued
RECOGNITION CONTROL IMPLEMENTATION EVALUATION IMPLEMENTATION STRATEGY Continued
IMPLEMENTATION STRATEGY CONTROL Periodic facility audits. Written program reviews. Employee feedback surveys. Job hazard analysis reviews. Recurrent training programs. Supervisor feedback surveys. Periodic statistical evaluations. Corrective action follow-up measures. Continued
IMPLEMENTATION STRATEGY CONTROL MEASURES CONSIDERATIONS: Capital improvement plan to eliminated hazards. Costs involved in purchasing substitutes gases. Length of time necessary for implementation. Level of urgency in implementation. Compatibility with existing processes or controls. Anticipated problems with employee use. Continued
IMPLEMENTATION STRATEGY PRIORITIZATION CONSIDERATIONS: Severity of injuries as a result of hazards. Consequences of an injury at the worksite. Likelihood that the operation will have an injury. The length of exposure to the hazard. Long-term effects of hazardous gas use. Continued
THE SUPERVISORS ROLE CONSIDER THE FOLLOWING: 1. KNOW THE GASES YOU USE! 2. GET INVOLVED IN THE HAZARD ASSESSMENTS. 3. OBTAIN ASSISTANCE (IF NEEDED) FROM YOUR SUPPLIERS. 4. OBTAIN ASSISTANCE (IF NEEDED) FROM EXPERTS IN THE FIELD OF GAS SAFETY, CGA (703) COMPLETE THE PAPERWORK (WORK ORDERS, POLICY CHANGES, ETC.) TO MAKE CORRECTIVE ACTIONS. 6. ATTEND THE SAME TRAINING AS YOUR WORKERS. 7. FOLLOW-UP ON THE ACTIONS YOU TOOK.
COMPRESSED GAS HAZARDS Extremely High Pressure. Toxicity. Reactivity. Instability. Flammability. Extreme Low Temperature. Asphyxiation. Radioactivity. PRINCIPAL HAZARDS:
COMPRESSED GAS HAZARDS Have Flown Over a Half Mile. Penetrated Brick Walls. Can Displace Oxygen in Extremely Large Areas. Can Oxygen-Enrich Extremely Large Areas. Can Spin and Ricochet Completely Out of Control. Can Immediately Freeze Exposed Skin. Can Explode With Tremendous Force. Can be Virtually Unstoppable. WHEN THINGS GO WRONG: Continued
COMPRESSED GAS HAZARDS 175 Pounds. 2,000 to 2,640 psig (some to 6,000 psig). Wall Thickness of About 1/4 Inch. 57 Inches Tall. 9 Inches In Diameter. Easily Toppled. Easily Corroded. Devastatingly Hazardous. THE TYPICAL COMPRESSED GAS CYLINDER: Continued
BASIC SAFETY RULES ILL GET THE RUST OFF OF THIS THING ONE WAY OR ANOTHER! KIDS DONT TRY THIS AT HOME!
BASIC SAFETY RULES THE BIG THREE: Continued Oxidizers: Must not be used in contact with oils, greases or other hydrocarbons. Flammables: Must not be exposed to flames, sparks or arcs including static electricity, hot surfaces or oxidizers. NonFlammables: Must not be allowed to displace air in confined work spaces so that there is insufficient oxygen for breathing.
BASIC SAFETY RULES FILLING OF CYLINDERS: Continued Cylinders may not be filled except by the supplier of the cylinder or with the suppliers consent. Where filling is authorized it must be accomplished in strict accordance with DOT, OSHA and CGA regulations.
BASIC SAFETY RULES CONTENT IDENTIFICATION: Continued Never assume you know what it is! Assuming (with gases) gets you dead! Labels must be legible at all times. Labels may not be altered or removed. Labels may not be bypassed, ignored, or otherwise defeated. Labels must be understood by all. Nonlegible/missing labels must be reported.
BASIC SAFETY RULES CONTENT IDENTIFICATION: Continued Labels and their means of attachment must withstand their normal operating environment. Labels may evoke a false sense of security, and their meaning needs to be understood. Labels must be securely attached to cylinders so that they cannot be inadvertently or accidentally detached during use. Each container must bear the proper label for the gas contained. Continued
BASIC SAFETY RULES PAINTING CONTAINERS: Continued Containers may not be painted. Painting may cover cylinder defects. Containers showing signs of corrosion must be removed from service and returned to the supplier. Never rely solely on the cylinder color for identification.
BASIC SAFETY RULES LEAKING AND DEFECTIVE CYLINDERS: Continued Never underestimate the hazard! Notify co-workers of the hazard. Consider evacuation of the area. Evacuate to open air, up-wind or side-wind. Report the contents, location, situation. Begin role call to account for co-workers. Do not return to work until all-clear is given.
BASIC SAFETY RULES CYLINDER USAGE REQUIREMENTS: Continued Verify contents before transporting or using. Keep cylinder caps on until ready to connect. Keep valve caps on until ready to use. Never use as a door stop. Never underestimate the hazard.
BASIC SAFETY RULES MOVEMENT OF COMPRESSED GAS CYLINDERS: Continued Never handle roughly. Never use magnetic lifting devices. Never lift by valves or cylinder caps. Never roll, drag, or slide the cylinder. Always use a hand-truck, fork truck etc. Cradles, ropes, chains, or slings are prohibited from use unless lugs or lifting attachments are provided by the manufacturer.
BASIC SAFETY RULES STORAGE REQUIREMENTS (GENERAL): Continued No Smoking signs must be posted. The name of the gas must be posted. Specific hazards must be posted. Containers must be stored up right. Gases must be stored with like gases. Do not intermingle full and empty containers. The oldest material must be used first. Stored only on stable surfaces. Some gases must always be shaded from sun.
BASIC SAFETY RULES STORAGE ROOMS (GENERAL): Continued Must be dry. Must not exceed 125 F. Must be well ventilated. Should be protected from tampering. Local fire inspectors should evaluate. NFPA guidelines should be reviewed. Subsurface storage should be avoided. Should be of fire-resistive construction.
BASIC SAFETY RULES STORAGE ROOMS (GENERAL): Continued Cylinders - Must not impede emergency egress. - Cannot be located near exits. - Cannot be located near stairs. Must be secured to prevent toppling.
BASIC SAFETY RULES OUTDOOR STORAGE (GENERAL): Continued Bottoms must be protected from corrosion. Must be secured to prevent toppling. Must be shaded in extreme temperatures. Some gases must always be shaded from sun. Should be of fire-resistive construction. Should be protected from tampering. Local fire inspectors should evaluate. NFPA guidelines should be reviewed.
NAME PRECAUTIONS RESTRAINED ABOVE MIDPOINT EMERGENCY & USE PROCEDURES AWAY FROM COMBUSTIBLES BASIC SAFETY RULES Continued DANGER NO SMOKING NO FUMAR ACETYLENE GAS INSPECTION CHECKLIST
BASIC SAFETY RULES GENERAL INSPECTION CRITERIA: Continued INSPECT FOR:POSSIBLE RESULT: DentsWeakening of cylinder wall Crevice CorrosionWeakening of cylinder wall BulgesWeakening of cylinder wall ARC/ Torch BurnsWeakening of cylinder wall Cuts, Gouges or DigsDecrease in wall thickness CorrosionDecrease in wall thickness PittingDecrease in wall thickness Neck DefectsLeak or cylinder explosion Valve Ease-Of-MovementCorrosion leading to leak Valve Thread ServiceabilityLeak during operation
BASIC SAFETY RULES PRE-OPERATION SAFETY RULES: Continued If youre not trained dont touch it! Read the Material Safety Data Sheet before use. Ensure an In Use label is present. Ensure all labels/warnings are readable. Place upright on stable dry surface. Ensure cylinder is restrained above midpoint. Keep heat, flame, & electrical sources from gas. Use in accordance with established procedures.
BASIC SAFETY RULES POST-OPERATION SAFETY RULES: Continued If youre not trained dont touch it! Read the Material Safety Data Sheet. Ensure an Empty label is present. Close valve completely and cap cylinder. Remove from operation (established procedures). Transport cylinder using a handtruck. Place in Empty Container storage area. Ensure Empty label is readable.
STORAGE RULES STORAGE VARIES GREATLY, HERE ARE A FEW EXAMPLES OF COMMON STORAGE REQUIREMENTS. ASK YOUR LOCAL FIRE INSPECTOR TO HELP YOU WITH YOUR SPECIFIC TYPES OF GASES.
Continued USE OLDEST STOCK FIRST! ACETYLENE DANGER COMPRESSED GAS STORAGE AREA DANGER FULL CYLINDERS NO SMOKING! GAS STORAGE CHECKLIST STORAGE RULES
FULL CYLINDER STORAGE RULES: Continued If youre not trained dont touch it! Read the Material Safety Data Sheet. Do not smoke. Mark cylinder with date of storage. Rotate oldest product to front. Rotate oldest product to front and use first. Inspect cylinder for damage before storage. Store with like kind of gas.
FULL CYLINDER STORAGE RULES: Continued Ensure all labels are readable. Ensure valve assembly is tightly capped. Ensure cylinder is restrained above midpoint. Store upright on stable dry surface. Keep electrical devices away from gas. Keep combustible materials away from gas. Keep heat, flame and ignition sources from gas. Never underestimate the hazard. Continued STORAGE RULES
EMPTY CYLINDER STORAGE RULES: Continued If youre not trained dont touch it! Read the Material Safety Data Sheet. Do not smoke. Ensure the cylinder is empty. Ensure valve assembly is closed tightly. Ensure valve assembly is capped tightly. Inspect cylinder for damage before storage. Store with like kind of gas cylinders. STORAGE RULES
EMPTY CYLINDER STORAGE RULES: Continued Ensure all labels are readable. Ensure cylinder is restrained above midpoint. Store upright on a stable dry surface. Keep electrical devices away from gas. Keep combustible materials away from gas. Keep heat and flame away from gas. Never underestimate the hazard. Continued STORAGE RULES
THERE ARE HUNDREDS OF GASES USED IN INDUSTRY. HERE ARE A FEW EXAMPLES OF COMMONLY USED GASES. ASK YOUR SUPPLIER TO HELP YOU WITH YOUR SPECIFIC TYPES OF GASES. SPECIFIC TYPES OF GASES
OXYGEN (INCLUDING OXIDIZING GASES): Continued Oxygen and oxidizers can be deadly. Cleanliness is absolutely essential!!! Explosion results upon contact with hydrocarbons. Keep oil, grease, and other hydrocarbons away! Ensure process or system is compatible with oxygen. Assess compatibility of equipment and materials. Separate from combustible materials. Oxygen can fuel enrich permeable materials. Oxygen enriched materials burn tremendously. SPECIFIC TYPES OF GASES
Continued SPECIFIC TYPES OF GASES THE pH of ACIDS AND BASES pH IS THE NUMERICAL MEASURE OF ITS RELATIVE ACIDITY OR ALKALINITY. THE RANGE IS FROM WITH A NEUTRAL LEVEL EXPRESSED AS A pH OF 7.0. pH ABOVE 7.0- MORE ALKALINE OR BASIC. pH BELOW 7.0- MORE ACIDIC.
Continued SPECIFIC TYPES OF GASES CHECK FOR COMPATIBILITY! HIGH pH BASE ACID LOW pH
ACID & ALKALINE GASES: Continued Avoid contact with all bodily routes of entry. Wear goggles and suitable skin protection. Consider effects on the respiratory tract. Long sleeves and trousers are mandatory. Open toed shoes or sneakers are prohibited. Gas masks/SCBA must be immediately available. SCBA must be used when the concentration could exceed the rating of the gas mask canister or if the gas could displace oxygen to below 19 percent. SPECIFIC TYPES OF GASES
ACID & ALKALINE GASES: Continued Emergency showers/eyewashes must be available. Quantities on-site must be limited. Ventilation must be adequate in the work area. Common corrosive and toxic gases include: SPECIFIC TYPES OF GASES Continued - Boron Trichloride - Bromine Trifluoride - Chlorine Trifluoride - Hydrogen Fluoride - Iodine Pentafluoride - Silicon Tetrafluoride - Sulfur Tetrafluoride - Tungsten Hexafluoride
BHOPAL, INDIA: Continued Over 2000 people died. Methyl isocyanate released. Occurred in December SARA Title III initially proposed as a result. The Union Carbide Facility was not unique. The accident could have occurred anywhere. Most were inhabitants in the area of the plant. SPECIFIC TYPES OF GASES
HIGHLY TOXIC GASES: Continued Remember Bhopal India! Training is critical. The specific hazards must be understood. Threshold Limit Values must be determined. Storage is critical and must be assessed. Ventilation is critical and must be assessed. Gas discharges must be scrubbed. Discharges must be neutralized. On-site quantities must be limited. SPECIFIC TYPES OF GASES
HIGHLY TOXIC GASES: Continued SPECIFIC TYPES OF GASES Medical services should be pre-planned. Suppliers/manufacturers should be consulted. Emergency responders should consulted. Common highly toxic gases include: - Arsine - Boron Trichloride - Bromine Trifluoride - Bromine Pentafluoride - Chlorine - Fluorine - Germane - Hydrogen Cyanide - Hydrogen Selenide - Hydrogen Sulfide - Nitric Oxide - Phosgene Continued
CRYOGENIC LIQUEFIED GASES: Continued SPECIFIC TYPES OF GASES In liquid form at relatively low pressures. Extremely low temperatures. Usually below - 238F (- 150C). Handled in heavily insulated containers. Insulated containers minimize evaporation. Proper operation of venting systems is essential. High expansion rate on vaporization. Can cause extreme bodily damage on contact. Full body protection must be utilized.
CRYOGENIC LIQUEFIED GASES: Continued SPECIFIC TYPES OF GASES Continued Oxygen Rate of Expansion - 238F 875 ft 3 +65F 1ft 3
Continued SPECIFIC TYPES OF GASES Continued LOX Use only hardware designed for cryogenics. Pain is not immediate. Tissue solidifies over time. Blood circulation is arrested. Serious skin burns may result. Blood clots are highly probable. Skin highly vulnerable to infection. Flush with tepid water. CRYOGENIC LIQUEFIED GASES:
Continued SPECIFIC TYPES OF GASES Can displace oxygen leading to asphyxiation. SCBA or airline systems must be used. Oxygen content below 19 percent is dangerous. Common highly inert gases include: INERT GASES: - Argon - Carbon Dioxide - Helium - Neon - Nitrogen - Xenon
GENERAL SAFETY CONSIDERATIONS Continued SPECIFIC TYPES OF GASES Dont be afraid to ask people to wait! Limit conversation while using gases. Know that you could be seriously injured. Know that no one ever expected to get injured. Know that none of us is immune to injury. Know the safe procedures before starting work. Know the location of first aid kits. Avoid horseplay - dont tolerate it from others. Think about going home in the same shape. Know your gas!
Develop a detailed inspection policy. Document each inspection. Inspect all gases before issue or use. Tag as unusable, damaged cylinders. Inspect cylinders before each use (without exception). Separate damaged cylinders from serviceable cylinders. Consider the effects on gases stored for long periods. Remove damaged cylinders from service immediately. INSPECTION CONSIDERATIONS: INSPECTION AND CARE OF GASES