1. HAZMAT CYLINDER HANDLER COURSE
In-House Pressure Related HAZMAT Training Title 49CFR
Written by:
William L. High & Edward A. Kasten
PowerPoint 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 Agencies
Department of Transportation (DOT) regulates the transport and handling of high pressure cylinders
Occupational 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 cylinders
Identify illegal or damaged cylinders
Understand 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 gas
Within 90 days of hire
Refresher training every 3 years
By 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 training
Function-specific training
Safety Training to include:
Emergency Response
Employee Protection
Accident Avoidment
Safe 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 maintained
Documentation that the hazmat employee has been trained and tested.

8. Record Keeping
Records are essential evidence in any civil or criminal action
Retain training and inspection records for at least 5 years
The record should include:
Participant signature
Date and location of training
Description of material
Name 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 vehicles
About 90 percent of cylinder explosions occur during the filling process.

10. Handling Dangers
When 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 movement
Maximum operating temperature 130 deg. F
Personal injury or cylinder damage may occur from dropped cylinder

11. Service Pressure
Service pressure must be clearly displayed on all cylinders
The service pressure is established by a calibrated gauge at a constant 70 deg. F
A 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 cylinders
Provide protection for FSO’s
Reject (set aside for professional inspection) un-galvanized, steel coated cylinders
Require 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 heat
Perform hammer test on Steel Cylinders (listen for bell-like tone)
Look for EOI Sticker and proper hydrostatic test date
Verify specification codes are proper
In the U.S. only fill-ICC, DOT, CTC/DOT and TC/DOT Cylinders
Check cylinder residual air for odor
Inspect cylinder having zero pressure
Be 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 SP6688
Any cylinder marked with SP890
COMPOSITE SCBA older than 15 years
Hoop wrap SCBA E NOT retrofitted
SP6498, E6498, SP7042 and E7042 NOT Over-stamped with 3AL
All round bottom aluminum cylinders
Valves w/o pressure relief devices or with fusible plugs or known or suspected double discs
Cylinders with known or suspected history of overfilling
Cylinders with dents, bulges, line corrosion or pits
Un-galvanized, vinyl-coated steel cylinders

15. Disguised Damage Boots often hide corrosion damage
Stickers may be placed over damage
Auto Repair putty used to cover defects
Owner attempt to apply interior coating of paint, zinc or epoxy
Physically altered cylinder – cut and threaded to transport contraband

16. Filling Cylinders
Conduct a cursory inspection of all cylinders before filling.
Most explosions could have been avoided by a simple cursory inspection
The fill station operator may question the validity of the sticker
Incomplete inspection
Invalid inspection
No sticker at all
During fill, be cautious of a cylinder falling

17. Condemned Cylinder
Any cylinder marked condemned or having obliterated codes may NEVER be returned to service
DO NOT FILL IT!
A trained PSI cylinder inspector may condemn a cylinder

18. Fire vs. Cylinders
The Maximum sustained exposure temp. for 3AL cylinders is 265 degrees F
Between 265 and 350 degrees the cylinder must be hydro-ed before being placed in service
Reject the cylinder if exposed to over 350 deg. F and refer to a trained PSI inspector
If any plastic has melted the cylinder has been exposed to temperatures in excess of 350 degrees. The tank must be condemned

19. Visual Inspection
If 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 vertically
If they can not be transported vertically, secure them horizontally facing sideways
Valves 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 environment
Protect from casual passersby
O2 cylinders must be stored at least 20’ from flammable gas containers or combustible materials.

24. Cascade or Bank System
DOT storage cylinders are large (9” diameter by 51” long)
Store in cool dry area
Valve caps should remain on inactive tanks
Secure cylinders with chain to prevent falling
You 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 annually
ASME cylinders are usually plugged at each rounded end
Sidewall plug allows the cylinder to be mounted horizontally and frequently drained.

26. SCBA (Self-Contained Breathing Apparatus) OSHA 1910.134
Written standard operating procedures
User must be instructed/trained in proper use of respirators
Respirator must be cleaned and disinfected after each use
Respirators for emergency use shall be thoroughly inspected at least once a month or after each use.

27. SCBA
Composite 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 use
SCBA 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):
Steel
Aluminum
Composite – hoop or full wrap
Steel and Aluminum solid wall have an unlimited service life
5 year hydro retest interval
ALL Composite cylinders are limited to a 15 year service life
Fiberglass and Kevlar - 3 year hydro retest interval
Carbon - 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 Limitations
Although protected to some degree by the protective overwrap, the SCBA aluminum liner should not reach a sustained temperature exceeding 250 deg. F.

31. SCBA Use
Warn 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 & abrasions
SCBA’s require visual inspections
Damage limits for composites are listed in the CGA manual C-6.2.

32. SCBA Damage Levels Three Levels of Damage recognition
Level 1 - Acceptable
Normal wear and tear and Minor damage
Level 2 - Rejected or Repaired
Depth of damage is greater than .005” but less than the value appearing in CGA C6.2
Tank should be re-hydro tested after repair
Level 3 - Condemn
Damage or abrasions greater than CGA C6.2 value
Frayed 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 Manufacturing
Luxfer SCBA Guide