1. This work has been produced by DGL (Aust) Pty Ltd
Safety Systems of DGL
This work has been produced by DGL (Aust) Pty Ltd
This Learner’s Tool is about the skills and knowledge required to store and warehouse division 2 Gases at DGL (Aust) facilities. This includes operational requirements for the safe and efficient control of all functions and effective management of hazardous situations.

2. Before you get started
It is important that you complete all sections in this learning tool as it has been designed so that
You can abide by the procedures of our organization.
You can apply what you have learnt in this package in your day to day activities
This Learning Tool is designed to be relevant only to DGL (Aust) Pty Ltd employees and only applied whilst employed with DGL (Aust) Pty Ltd
You may have already acquired knowledge in the area identified in this package as you may have completed some specialized training. Or you may have been working within the industry for some time. Should you identify any improvement opportunities in the information contained in this package or have difficulties completing the package please contact
National Training and Compliance Manager
DGL (Aust) Pty Ltd
PO BOX 1594
EAGLE FARM QLD 4009 Ph
Fax

3. Aim of training
Increase employees’ awareness regarding workplace safety
Provide employees with tools to reduce risks of illness and injury in the workplace
Inform employees of their rights and responsibilities regarding workplace safety
Comply with regulatory mandates

4. Sections covered by training
Responsibilities
Tool Box Meetings
Safety Walks
Five minutes of safety
Internal Audit
Safety Audit
Injury and accident investigation
Improvement Opportunities
Monthly Store inspection
(warehousing business unit only)

5. QMS DGL is committed to provide as save
work place for all employees and
contractors
This is controlled by the Quality Management
System (known a QMS) of DGL
DGL holds ISO accreditation to standard
ISO 9001:2008

6. DGLs Goals Provide a safe and healthful workplace for employees
Reduce risk of disease, illness, injury and harmful exposures to the community
Reduce worker's compensation claims and costs
Improve employee morale and efficiency
Comply with regulatory mandates
Zero harm to employees

7. Safety System Elements
Assigns responsibilities for health and safety
Establishes mechanisms for hazard identification and hazard mitigation
Requires workplace inspections and accident investigation
Requires communication of health and safety information
Reaffirms training and documentation mandates

8. Rights – As an employee you have a right to:
A safe workplace free from recognized hazards
Receive training on hazards associated with your job
Know how to control hazards of your job
Report workplace hazards without fear of reprisal

9. Roles & Responsibilities – Managers and Supervisors
Managers and Supervisors are expected to provide Environmental Health and Safety leadership and guidance within their division

10. Managers and Supervisors will
Inform employees about specifics of the divison
Provide safety training consistent with employee job duties
Enforce safety rules and regulations within the department
Provide a means to identify workplace hazards
Maintain all Health and Safety documentation
Place safety above all other tasks completed

11. Roles & Responsibilities – All Employees
All employees have a responsibility to maintain a safe and healthful work environment

12. As an employee, you will Follow safe work practices
Know the potential health and safety hazards of your job and how to protect yourself
Know how to report unsafe conditions
Report any work-related injury or illness to your supervisor
Know what to do in an emergency

13. As an employee, you should:
Correct unsafe conditions within your authority
If you are unclear about your responsibilities ask your supervisor

14. Roles & Responsibilities – Health Environment Safety and Quality (HSEQ)
HSEQ has responsibility for monitoring compliance of the DGL’s QMS system to minimize or prevent occupational injuries and illnesses, and to protect the quality of the workplace and surrounding environment

15. HSEQ:
Advises the workforce of its responsibilities with respect to health and safety issues
Recommends appropriate corrective actions and programs
Implements new health and safety programs
Serves as the liaison between DGL and various external agencies and regulatory bodies

16. Classification of division 2
The transport condition of a gas is described according to its physical state as:
(a) Compressed gas —a gas which when packaged under pressure for transport is entirely gaseous at -50 °C; this category includes all gases with a critical temperature less than or equal to -50 °C; or
(b) Liquefied gas —a gas which when packaged under pressure for transport is partially liquid at temperatures above -50 °C. A distinction is made between:
High pressure liquefied gas —a gas with a critical temperature between 50°C and +65 °C, and
Low pressure liquefied gas —a gas with a critical temperature above +65 °C; or
(c) Refrigerated liquefied gas —a gas which when packaged for transport is made partially liquid because of its low temperature; or
(d) Dissolved gas —a gas which when packaged under pressure for transport is dissolved in a liquid phase solvent.
(Note 1)
Note (1) Source the Australian Dangerous Goods Code 7th Edition page 53

17. Storage
The following precautions shall be observed when storing and handling gases in cylinders:
(a) Areas in which cylinders are kept shall be—
(i) away from any artificial sources of heat, e.g. radiators, boilers or steam pipes, except when there has been prior consultation with the cylinder supplier on the particular circumstances; and
(ii) kept clear of combustible materials, vegetation and refuse for a distance of not less than 3 m from any cylinder.
(b) All cylinder stores shall be provided with adequate ventilation at all times.
NOTES:
1 Ventilation should be adequate to maintain exposure levels to any gases in the store below recommended workplace exposure standards and lower explosive limits, and to maintain safe oxygen levels.
2 Reference should be made to AS for requirements for mechanical ventilation of enclosures.
(c) divisions of gases shall be segregated within the store, but need not be separated.
(d) The floor should be flat, solid, and constructed from non-combustible materials. It should drain away from the cylinders. Concrete flooring is preferred.
Note (1) Source the Australian AS The storage and handling of Gases in cylinders Page 12 & 13

18. Management of Leaks General
The following general procedures apply to the management of leaks. They should only be attempted by trained personnel, when it is safe to do so, and when wearing suitable personal protective equipment, and where the characteristics of the gas involved are well understood. Additional special considerations are required in confined spaces or where ventilation is
poor.
LARGE LEAKS
If there is a large leak, the procedure set out below should be followed:
(a) Evacuate the area after providing maximum ventilation if it is possible and safe to do so. If a flammable gas is leaking, remove or isolate any ignition sources.
(b) Immediately contact the gas supplier for advice, giving location and a return contact. Where appropriate, contact the emergency services.
(c) Consult the MSDS for the hazards of the gas involved and activate the site emergency plan
(d) Do not approach the cylinder until trained personnel and expert advice are available, especially if the gas is flammable or toxic.
SMALL LEAKS
If there is a small leak, the procedure set out below should be followed:
(a) If it is safe and possible to do so, quickly close the cylinder valve. ‘Back off’ any regulator (i.e. reduce downstream pressure to zero) and shut off any downstream valves. If a flammable gas is involved, isolate any electrical equipment. Consider evacuating the area.
NOTE: Do not use excessive force to shut off a cylinder valve as this can damage the valve seat or break the spindle, making the leak worse.
(b) Ventilate the area as well as possible. Open windows and doors; and start up any existing fume extraction system.

19. Management of Leaks Continued
(c) Turn off any air conditioning system to prevent spreading the hazard.
(d) If appropriate, contact the gas supplier or emergency services for assistance.
(e) Consult Appendix A and the MSDS about the characteristics of the gas.
(f) Wearing appropriate PPE, approach the cylinder from an upwind area and attempt to locate the leak point. An appropriate leak detection method should be used.
NOTE: In many cases, soapy water or a proprietary leak detection solution may be used. However, some gases could react with water and make the leak worse.
(g) Attempt to minimize or stop the leak. The method chosen will depend on the location of the leak and type of gas, and the following should be taken into account:
(i) If the leak is on the cylinder Do not attempt to repair a leaking cylinder safety device, tighten a valve into a cylinder or tighten a leaking valve gland that is
under pressure.
(ii) If the leak is through the valve seat outlet Close the cylinder valve, but do not over-tighten. If a suitable regulator is available, ‘back it off’ fully and screw it onto the cylinder valve outlet. If the cylinder has been provided with a gas-tight outlet cap or plug, screw this onto the valve outlet and close it.
(iii) If the gas is flammable Remove all sources of ignition, sparking or static electricity from the area.
(iv) If the gas is toxic Ensure that the correct PPE is used, including self-contained breathing apparatus (SCBA) if necessary.
(v) If the gas is a liquefiable gas Attempt to position the cylinder so that the leak point is in the vapour space (i.e. highest point) to prevent a liquid leak.
(h) Once the leak is minimized or controlled, and it is safe to do so, relocate the cylinder to a safe, well ventilated area where any leaking gas can dissipate safely, e.g. outdoors, or in a fume cupboard with an extraction fan.
(i) Securely tag the cylinder as ‘faulty’, giving reason and leak location.
(j) Arrange for the supplier of the cylinder to collect and remove the cylinder
Note (1)
Note (1) Source the Australian AS The storage and handling of Gases in cyclinders Page 52 & 53

20. Personal Habits
Personal habits and hygiene practices have an important bearing on health and safety.
The following rules shall be followed by all persons whose work involves the handling of division 2:
(a) Do not introduce, keep, prepare or consume any food or drink, or use tobacco. In any place where dangerous goods are stored or handled.
(b) Always wash your hands before eating, drinking or smoking, and after work.

21. First Aid
The following first aid procedures shall be adopted for the treatment of accidents relating to the handling of division 2 - Gases:
First Aid Station
A first aid station shall be provided in a clean area. It shall comprise, as a minimum, an appropriate first aid kit and first aid instructions, e.g. MSDS for all gases being kept or handled on the premises.
Safety Shower and Eye Wash Facilities
Provision of a readily accessible safety shower (or ‘plunge bath’) and eye wash facilities, both complying with ANSI Z 358.1, should be considered, especially where corrosive or toxic gases or cryogenic or refrigerated fluids are handled.
First Aid Procedures
The first aid procedures set out in the relevant MSDS shall be adopted.
Note (1) Source the Australian AS The storage and handling of Gases in cylinders page 33

22. Test your knowledge
Through the following slides you will be asked an number of questions to show that you have understood the content of this learning tool
Please record your answer on a sheet of paper.
For example for Question 1 you have four possible answers, therefore record either a b c or d.
You will be required to submit the answers to all questions at the end of this leaning tool

23. Question 1
What is a Gas?
a) 50 °C has a vapour pressure greater than kPa
b) Is a liquid that is stored in cylinders
c) is completely gaseous at 20 °C at a standard pressure of kPa
d) Both A & C

24. Question 2 What are the three Divisions of division 2 and their names?
a) 2.1 Toxic Gases, 2.2 Flammable Gases, 2.3 Non-flammable, Non-toxic Gases
b) 2.1 Non-flammable, Non-toxic Gases, 2.2 Toxic Gases, 2.3 Flammable Gases
c) 2.1 Flammable Gases, 2.2 Toxic Gases, 2.3 Non-flammable, Non-toxic Gases
d) 2.1 Flammable Gases, 2.2 Non-flammable, Non-toxic Gases, 2.3 Toxic Gases

25. Question 3
It is ok to introduce, keep, prepare or consume any food or drink, or use tobacco. In any place where dangerous goods are stored or handled.?
a) True
b) False

26. Question 4
There are four classifications of Gases for Transport which one has the following definition : a gas which when packaged under pressure for transport is entirely gaseous at -50 °C; this category includes all gases with a critical temperature less than or equal to -50 °C?
a) Liquefied gas
b) Compressed gas
c) Dissolved gas
d) Refrigerated liquefied gas

27. Question 5
What is the Segregation distance between Combustible products and division 2 products when being stored in a warehouse?
a) 1m
b) 5m
c) 3m
d) None required

28. Question 6
In an event of a small Flammable Gas leak, you have isolated any electrical equipment what else should you consider doing?
a) Going back to work
b) Evacuating the Area
c) Closing the storage area
d) Going Home

29. Question 7
When a leak is minimized and under control and you can proceed safely and it has been relocated to a well ventilated area what is the next step in the chain?
a) Securely tag the cylinder as ‘faulty’, giving reason and leak location.
b) Arrange for the supplier of the cylinder to collect and remove the cylinder.
c) Seal up the gas leak and proceed to use the cylinder.
d) Dispose of the cylinder in the general waste bin when the leak has been found.

30. Question 8 What should you resort to in case of First Aid emergency?
a) The products label
b) The MSDS
c) Word of mouth
d) Your instinct

31. Complete the assessment
Your Details
Feedback on training program
Question 6 Answer Question 7 Answer Question 8 Answer
Enter your answers here
Question 1 Answer Question 2 Answer Question 3 Answer Question 4 Answer Question 5 Answer

32. Additional information
For more information on division 2 products the following sources may be of assistance
Australian Dangerous Goods Code 7th Edition
Available to all DGL employees via the company’s intranet
Australian The storage and handling of Gases in cylinders