Presentation on theme: "HAZMAT CYLINDER HANDLER COURSE"— Presentation transcript:
1 HAZMAT CYLINDER HANDLER COURSE In-House Pressure Related HAZMAT Training Title 49CFRWritten by:William L. High & Edward A. KastenPowerPoint developed by Don Kinney
2 Code of Federal Regulations (CFR) Title 49-172.700 All Persons who handle, transport or are likely to be affected by the hazards of compressed gas cylinders and their contents shall receive appropriate safety training.Hazmat Training within the dive and fire protection industries should provide specific safety awareness for all applicable groups such as employees, service technicians, air fill station operators (FSO), Nitrox gas blenders as well as volunteer helpers, and even customers
3 Regulatory AgenciesDepartment of Transportation (DOT) regulates the transport and handling of high pressure cylindersOccupational Safety and Health Administration (OSHA)- regulates the safety of employees.These regulations only apply to employees. It would not apply to a sole proprietor with no employees.
4 Required Employee Knowledge Know how to safely handle and fill cylindersIdentify illegal or damaged cylindersUnderstand the hazards of high pressure air and, where Nitrox service is provided, mixing and gas transfer procedures.Training in Hazmat makes the workplace safer.
5 Training Requirements Documented training should be provided to all employees before they encounter the real and potential hazards of compressed gasWithin 90 days of hireRefresher training every 3 yearsBy a certified instructor.PSI trained in inspections.A SCUBA instructor would not qualify.
6 Training shall include: Hazmat training should be provided whenever an employee is assigned new duties.General awareness/familiarization trainingFunction-specific trainingSafety Training to include:Emergency ResponseEmployee ProtectionAccident AvoidmentSafe handling Procedures
7 Required Documentation A written record of the training for each Hazmat employee shall be maintained.A copy of the training material shall be maintainedDocumentation that the hazmat employee has been trained and tested.
8 Record KeepingRecords are essential evidence in any civil or criminal actionRetain training and inspection records for at least 5 yearsThe record should include:Participant signatureDate and location of trainingDescription of materialName and number of PSI instructor
9 Consequences of Improper handling, Filling and inspection Several SCUBA or storage cylinders explode each year causing death, injury and property damage.The Kinetic energy stored within a full 80 cubic foot cylinder exceeds one million foot pounds:Enough to disintegrate walls and destroy vehiclesAbout 90 percent of cylinder explosions occur during the filling process.
10 Handling DangersWhen you carry the cylinder by the valve - keep opening away from your hand.Air embolism may occur through the skin if Secure cylinders to prevent movementMaximum operating temperature 130 deg. FPersonal injury or cylinder damage may occur from dropped cylinder
11 Service PressureService pressure must be clearly displayed on all cylindersThe service pressure is established by a calibrated gauge at a constant 70 deg. FA fill station operator will have no defense against civil or criminal charges if the cylinder later fails explosively due to over -pressurization of the cylinder
12 Filling Policies Fill at 300 – 600 psig per minute to service pressure DO NOT over - pressurize cylindersProvide protection for FSO’sReject (set aside for professional inspection) un-galvanized, steel coated cylindersRequire all persons to remain away from fill station
13 Cursory Inspection What to look for: Inspect exterior for damage caused by corrosion or exposure to heatPerform hammer test on Steel Cylinders (listen for bell-like tone)Look for EOI Sticker and proper hydrostatic test dateVerify specification codes are properIn the U.S. only fill-ICC, DOT, CTC/DOT and TC/DOT CylindersCheck cylinder residual air for odorInspect cylinder having zero pressureBe Alert for improper valves I.e. metric in national gas straight threaded cylinder
14 Reject on Cursory Inspection Set aside for professional inspection the following cylinders:Bevel bottom aluminum cylinders (SP6576)Any aluminum cylinder marked with SP6688Any cylinder marked with SP890COMPOSITE SCBA older than 15 yearsHoop wrap SCBA E NOT retrofittedSP6498, E6498, SP7042 and E7042 NOT Over-stamped with 3ALAll round bottom aluminum cylindersValves w/o pressure relief devices or with fusible plugs or known or suspected double discsCylinders with known or suspected history of overfillingCylinders with dents, bulges, line corrosion or pitsUn-galvanized, vinyl-coated steel cylinders
15 Disguised Damage Boots often hide corrosion damage Stickers may be placed over damageAuto Repair putty used to cover defectsOwner attempt to apply interior coating of paint, zinc or epoxyPhysically altered cylinder – cut and threaded to transport contraband
16 Filling CylindersConduct a cursory inspection of all cylinders before filling.Most explosions could have been avoided by a simple cursory inspectionThe fill station operator may question the validity of the stickerIncomplete inspectionInvalid inspectionNo sticker at allDuring fill, be cautious of a cylinder falling
17 Condemned CylinderAny cylinder marked condemned or having obliterated codes may NEVER be returned to serviceDO NOT FILL IT!A trained PSI cylinder inspector may condemn a cylinder
18 Fire vs. CylindersThe Maximum sustained exposure temp. for 3AL cylinders is 265 degrees FBetween 265 and 350 degrees the cylinder must be hydro-ed before being placed in serviceReject the cylinder if exposed to over 350 deg. F and refer to a trained PSI inspectorIf any plastic has melted the cylinder has been exposed to temperatures in excess of 350 degrees. The tank must be condemned
19 Visual InspectionIf you have not been trained in Cylinders inspections – DO NOT DO IT!Title 20CFR (a) – 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 HAZMAT Regulations of DOT(49CFR, Parts and 14CFR part 103). Where those regulations are not applicable, visual and other inspections shall be conducted in accordance with CGA pamphlet C-6.
20 Visual Cursory Inspection Vs. Internal Inspection Anytime you fill/use a cylinder you should perform a cursory visual inspection.An internal inspection should be conducted at least annually by a trained PSI Inspector.If necessary - depending on circumstances – the cylinder may be inspected more often.
21 Transporting Cylinders Secure the cylinders verticallyIf they can not be transported vertically, secure them horizontally facing sidewaysValves placed forward or to the rear may shear in a crash causing catastrophic damage
22 Transporting Cylinders According to DOT:When transporting cylinders for commerce, it is necessary to place placards on all four corners of your vehicle when the load of cylinders meets or exceeds 1000 pounds.Approximately 29 cylinders (aluminum)The placard must state: NON-FLAMMABLE GAS - AIR
23 Cylinder Storage Store vertically, when possible, and secured tightly Store below 130 deg. F in a dry environmentProtect from casual passersbyO2 cylinders must be stored at least 20’ from flammable gas containers or combustible materials.
24 Cascade or Bank SystemDOT storage cylinders are large (9” diameter by 51” long)Store in cool dry areaValve caps should remain on inactive tanksSecure cylinders with chain to prevent fallingYou should not roll a cylinder to move it. Use a proper dolly or other device.10 year star service does not apply to cascade or banked cylinders when they are attached to a compressor.
25 ASME Cylinders American Society of Mechanical Engineers (ASME) These cylinders are intended for permanent installations and do not require hydro retest.ASME cylinders should still be visually inspected at least annuallyASME cylinders are usually plugged at each rounded endSidewall plug allows the cylinder to be mounted horizontally and frequently drained.
26 SCBA (Self-Contained Breathing Apparatus) OSHA 1910.134 Written standard operating proceduresUser must be instructed/trained in proper use of respiratorsRespirator must be cleaned and disinfected after each useRespirators for emergency use shall be thoroughly inspected at least once a month or after each use.
27 SCBAComposite SCBA’s are generally manufactured starting with a thin aluminum shell. The shell is then reinforced with fiberglass or a carbon material.Manufacturing the cylinder this way makes it lighter for the user, but does NOT make it less susceptible to damage.SCBAs are NOT designed for SCUBA useSCBA cylinder SP12479 has been tested for scuba use but there are concerns about its continued use in underwater environment
28 SCBA Information Cylinder Types (2000 psig-4500psig): SteelAluminumComposite – hoop or full wrapSteel and Aluminum solid wall have an unlimited service life5 year hydro retest intervalALL Composite cylinders are limited to a 15 year service lifeFiberglass and Kevlar - 3 year hydro retest intervalCarbon - 5 year hydro retest interval
29 SCBA Operating Procedures SCBA’s manufactured by MSA ( Mine Safety Appliance) and Interspiro have been designed for emergency fill rates as high as 6,000 PSIG/MIN
30 SCBA LimitationsAlthough protected to some degree by the protective overwrap, the SCBA aluminum liner should not reach a sustained temperature exceeding 250 deg. F.
31 SCBA UseWarn users against storage restraints that may cause cylinder abrasions.Composite cylinders are not designed for underwater use and should NOT be filled in a water bath.Examine exterior at least every 30 days.Look for: distortion, dents, cuts & abrasionsSCBA’s require visual inspectionsDamage limits for composites are listed in the CGA manual C-6.2.
32 SCBA Damage Levels Three Levels of Damage recognition Level 1 - AcceptableNormal wear and tear and Minor damageLevel 2 - Rejected or RepairedDepth of damage is greater than .005” but less than the value appearing in CGA C6.2Tank should be re-hydro tested after repairLevel 3 - CondemnDamage or abrasions greater than CGA C6.2 valueFrayed or delaminated fibers from the cylinder may be reason for condemning it. (Refer cylinder to trained PSI inspector for inspection)
33 Resource Materials Inspecting Cylinders –By William (Bill) High Guide to SCUBA Cylinder Inspections –By Luxferesd5 Cylinder ManufacturingLuxfer SCBA Guide