Compressed Gas Safety (2)
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Transcript of Compressed Gas Safety (2)
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Topics
PPT-043-01 2
RegulationsUses
Properties and examples
Compressed gas
Liquefied gasCryogenics
Terms and behavior
Containers and markings
Pressure relief valvesViolent reactions
Handling and storage
Inspections
Emergency responseAssist standards
Bibliography
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Regulations
PPT-043-01 3
Regulations for use, storageand handling will be accordingto the authority havingjurisdiction, or AHJ
In the absence of codes, the
following may provideguidance:
Compressed Gas Association
National Fire ProtectionAssociation (NFPA)
Safety Data Sheet (formerlyMaterial Safety Data Sheet)
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Other Sources
PPT-043-01 4
For determining hazardsand for planning purposes:
NIOSH Pocket Guide to
Chemical Hazards
2012 Emergency
Response Guidebook
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Uses
PPT-043-01 5
Industrial uses include:processes, heating,forklifts; industrial gasesmay also have othergases added for processpurity
Medical gases are blendsof several gases
Vehicles converted fromgasoline or diesel
Citizen use for heating
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Gas Properties
PPT-043-01 6
Gases can be: Flammable
Non-flammable
Oxidizers
Corrosive
Asphyxiants
Poison
Inert Or a mixture
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Physical States
PPT-043-01 7
Gas In Cylinder Temperature
Compressed Gas +70 to +32 F in gaseous state
Liquefied Gas +32 to -130 F in liquefied
state
Cryogenic Liquid -130 to -432 F refrigeratedliquefied gas
Storage temperatures are gas-dependent
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Compressed Gas Examples
PPT-043-01 8
Vapor
Types Hazard Class Density LEL/UEL Flashpoint (F)
Methane 2.1 Fl 0.55 5-15% -306
Ethane 2.1 Fl 1.04 3-12.4% -211
Propane 2.1 Fl 1.52 2.2-9.5% -56
Butane 2.1 Fl 2.0 1.8-8.4% -101
Nitrogen 2.2 Non-Fl 0.96 Inert ------
Oxygen 5.1 Ox 1.1 NF/Oxidizer ------
Arsine 2.1 FL/2.3 poison gas 2.69 4.5-64% ------
Chlorine 2.2 NFl/2.3 poison gas 2.48 Oxidizer ------
Fl=Flammable
NFl=Non-Flammable
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Definitions
PPT-043-01 9
Gas: State of matter in which material has a very
low density and viscosity
Can expand and contract in response to
temperature and pressure changes Easily diffuses into other gases; distributes
itself inside a container
If the temperature is dropped and pressure
increased, the gas can be changed to a liquidor semi-solid state
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Compressed Gas
PPT-043-01 10
Material or mixture having in the container anabsolute pressure exceeding 40 psi at 70oF or,regardless of pressure at 70oF, having anabsolute pressure exceeding 104 psi at 130oFor any liquid material having a vapor pressureexceeding 40 psi absolute at 100oF asdetermined by ASTM Test D-323
page 597, CGA Handbook, 3rd Edition
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Liquefied Petroleum Gas
PPT-043-01 11
LP Gas or LPG
Any material with a vapor pressurenot exceeding that allowed forcommercial propane
Composed predominantly of thefollowing hydrocarbons, either bythemselves or as mixtures:propane, propylene, butane
(normal butane or isobutene) andbutylenes
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Liquefied Natural Gas
PPT-043-01 12
Also called LNG
A fluid in the cryogenicliquid state that iscomposed predominantlyof methane
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Cryogenic Liquid
PPT-043-01 13
Cryogenic liquid:Refrigerated liquefiedgas with normalboiling point below -
130oF Hazards include those
of the gas, frostbiteand asphyxiation if
breathable oxygen inair is displaced
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Terms
PPT-043-01 14
Boiling Point:Temperature when a gas converts from itsliquefied state to vaporous state
Critical Pressure:
Temperature above which a gas cannot beliquefied by pressure alone
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Triple Point
PPT-043-01 15
The only temperatureand pressure at whichthree phases (gas,
liquid and solid) in aone-componentsystem can exist inequilibrium
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Compressed Gas Terms
PPT-043-01 16
Vapor Density (Gas Specific Gravity):A comparison of the weight of the gas to air(1.0); heavier-than-air gases will have a vapordensity greater than 1.0; lighter gases will have
a vapor density less than 1.0
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TLV-TWA
PPT-043-01 17
TLV-TWA (threshold limit value - time weighted
average):
Given in ppm (parts per million); exposure amountwhich most people can work in for an eight hour daywithout suffering harmful effects
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IDLH
PPT-043-01 18
IDLH: Immediately Dangerous to Life and Health
Amounts to which persons should not be exposed
due to their harmful effects; sources fordetermining these limits will be found on the SDS,as well in various guides, i.e. NIOSH Pocket Guideto Chemical Hazards
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LEL
PPT-043-01 19
Lower Explosive Limits(LEL) also known as lowerflammable limits (LFL):least percentage of a gas,
mixed with the properproportions of air,whereby having thenecessary heat applied,combustion may result
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UEL
PPT-043-01 20
Upper Explosive Limits(UEL), also known asupper flammable limits(UFL): greatest
percentage of a gas,that when proportionedwith air, may permitsustained combustion
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Flammable Limits
PPT-043-01 21
Flammable Limits, alsoknown as the flammablerange: percentage of gaswithin the LEL and UELwhere combustion may
occur and be sustained
Shown: Hydrogenapproximated (4-75percent)
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Ignition Temperature
PPT-043-01 22
Ignition temperature: Unique to various solids,vapors and gases, the requisite heat from anopen flame source required to ignite materials
Autoignition temperature: The temperaturerequired to ignite materials absent an openflame source
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Expansion Rate (or ratio)
PPT-043-01 24
Conversion of cubic feet ofliquid to cubic feet of gas
Can result in achievingthe LEL or flammablelimits in an inside
environment
Can also result in thetoxic levels or IDLH for agas expressed as
percentage by volume orppm (parts per million)
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Expansion Rate
PPT-043-01 25
Gas Expansion Rate
Methane 625:1
Propane 270:1
Butane 284:1Nitrogen 696:1
Oxygen 860:1
Chlorine 444:1
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Gas Laws of Gas Behavior
PPT-043-01 26
Boyles Law:
Decrease a containersvolume by one half
Temperature andamount of gas remainconstant
Pressure will double
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Gas Laws
PPT-043-01 27
Charles Law:
When the temperatureincreases, the volume
increases
Perhaps the containerwill not be able tohandle the volume
increase
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PVT Relationship
PPT-043-01 28
If temperature of a gasincreases in cylinder,volume of cylinder cannot be increased
Pressure increases andmay activate relief valve
If pressures increase toorapidly, cylinder may
rupture
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Rule of Thumb
PPT-043-01 29
Increase gas temperature 500 degrees = double
pressure
Increase gas temperature 1,000 degrees = triplepressure
Increase gas temperature 1,500 degrees =
quadruple pressure
(Some gas cylinders do NOT have
a pressure relief valve, could
be catastrophic rupture!)
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Cryogenic
PPT-043-01 30
Heat expands a gas
If we pressurize a gas whilecooling it, we can turn a gasinto a liquefied gas
Further cooling and pressuremay convert it to a cryogenicgas
This increases the amount of
product that can be put in acylinder
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Gas Containers
PPT-043-01 31
Lecture Bottles
Cylinders
Tank Trucks
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Gas Containers
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Railroad Tank Cars
Portable Tanks
Fixed Storage
Pipelines
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Cylinders
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ConstructionMust be compatible
with the material
contained
Markings
Labeling required to
identify the gas in storage
and during shipment
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Markings
PPT-043-01 34
Nomenclature relatedto the cylinder and itscontents will assist inthe safety process
Low pressure: Below900 psi
High pressure: 900psi or greater
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Storage Pressure
PPT-043-01 35
Storage Ignition
Types Pressure (PSI) Temperature
Methane up to 6000psi 999 F
Ethane 544 959 F
Propane 109.7 871 F
Butane 31 761 F
Nitrogen 2,000/below 200 as cryogen Inert
Oxygen 2,000/below 200 as cryogen Inert
Arsine 219.7 (*see note)
*Note: Arsine has no given Ignition Temperature but decomposes into arsenic
and hydrogen between 446 F to 464 F
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Color Codes
PPT-043-01 36
Cylinder shells can also
be color coded to betteridentify the contentspermitted into thespecific type of cylinder
This eliminates cross-contamination byintroducing non-
compatible gases intonon-specificationcylinders
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Medical Gas Color Codes
PPT-043-01 37
Medical gases willoften be a blend of aparent gas withfractions of othergases introduced forpurity and stability
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Labels
PPT-043-01 38
FTSC CodeStandard numerical code
for a gas indicating:
Flammability Toxicity
State of the gas
Corrosiveness
CGA V-7 pamphlet provides more in-depth information
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Diaphragm Valve
PPT-043-01 39
Diaphragm valve betterretains the cylindercontents
Not as prone to leakage
as the packed valve Note the diaphragms
location
Note also the relief
valves location in theproduct line
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Packed Valve
PPT-043-01 40
The packed valve haspacking between theupper stem andbonnet
This type is knownfor leaking throughthe packing
Often the leak maybe secured by
tightening the bonnet
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Pressure Relief Valve (PRV)
PPT-043-01 41
May be activated bypressure, temperatureor spring to permitcontainer contents to
escape, therebyaverting a containerrupture
The PRV is in the
product line
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Fusible Plug/Combination
PPT-043-01 42
Fusible plug melts at adesignated temperatureand permits the productof a cylinder to be
released to avert acatastrophic rupture
Combination relief: Onewith a rupture disk andfusible plug
Both are non-resealing
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Rupture Disk
PPT-043-01 43
Rupture disk (frangible
disk) - Operating part ofa PRV: ruptures at apredetermined pressureallowing cylinder
contents to escape Non-resealing
Poison gas cylinders donot have a PRV
depending on theirclassification (PRVs areprohibited)
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Cylinder Hazards
PPT-043-01 44
Material Hazards
Flammability
Spontaneously
flammable (arsine, silane
and phosphine) Corrosivity
Reactivity
Poison
Carcinogenic
Container Behavior
Frostbite
Rupture
Rocketing
Boiling liquidexpanding vaporexplosion (BLEVE)
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BLEVE (Boiling Liquid Expanding Vapor Explosion)
PPT-043-01 45
A cylinder or tank is heated
Contents absorb heat and convert to pressurized vapor
Relief valve activates
Pressure increases beyond the PRV capacity
Container, thermally stressed, violently ruptures
If the gas is flammable, the fireball is
devastating
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BLEVE (Boiling Liquid Expanding Vapor Explosion)
PPT-043-01 46
BLEVEs can occur withliquefied nitrogen andhelium or refrigerantsand cryogens as well
as LP gas or LNG
The pressure, volume,temperature
relationship drives theBLEVE
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BLEVE
PPT-043-01 47
Cylinder exploded inside a
building
Cylinder exploded outside
May occur with liquefied
petroleum gas (LPG)propane and butanebeing main componentsor
With liquefied natural gas(LNG) of which methaneis the largest component
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Railroad Tank Car BLEVE
PPT-043-01 48
Crescent City, Illinois;June 21, 1970,
7:30 am
Train No. 20 derailed
involving three tankcars
BLEVE was 34,000gallons of Propane
Emergency planningpaid off
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Fixed Location BLEVE
PPT-043-01 49
65,000 gallons ofpropane at bulkstorage location inCanada, 2008
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Hydrocarbon Gases
PPT-043-01 50
Contain flammablehydrogen andcombustible carbon intheir make-up
Flammable
Non-corrosive
Non-toxic
Colorless
Examples include:
Propane and
Butane
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Hydrocarbon Gases
PPT-043-01 51
Ignition
Gas Formula Temperature (F)
Methane CH4
999
Ethane C2H6 959
Propane C3H8 871
Butane C4H10 761
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Oxygen
PPT-043-01 52
Not flammable
Sensitizes flammable andcombustible materialsrequiring less input heatfor ignition
In some cases, materialsimpregnated with oxygencan be ignited with static
electricity
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PELs/IDHL
PPT-043-01 53
TWA:
Gas CAS # OSHA PEL IDLH
Methane 74-82-8
Ethane 74-84-0
Propane 74-98-6 1,000 ppm 2,100 ppm (10% LEL)Butane 106-97-8 None Not DeterminedNitrogen 7727-37-9
Oxygen 7782-44-7
Arsine 7784-42-1 0.05ppm Ca (3 ppm)
Chlorine 7782-50-5 1 ppm 10 ppm
(*Note: to convert ppm into percent by volume, divide the number given in ppmby 10,000; this will give you the percentage by volume)
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Effects of Exposure
PPT-043-01 54
Explosive rupture ofcontents which candestroy vehicles
Cylinders may gothrough barriers orwalls
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Other Gas Accidents
PPT-043-01 55
Flammability Chemical burns
Handling safety requiresan understanding of the
gas properties and use ofpersonal protectiveequipment (PPE):
Gloves
Eye protection
Respirator
Foot/body protection
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Safe Handling & Storage
PPT-043-01 56
Determine safe handlingand storage needsbased on your industry
and the gases withwhich you work
Create or follow checklists to best ensure acontinuous safetyprogram
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Proper Handling
PPT-043-01 57
Use proper hand trucks - donot roll the cylinder on itsside
Provide a forklift cylinder
change-out area whichmaximizes safety for theoperator and other staff
Provide:
Ventilation Fire extinguisher
PPE
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Handling
PPT-043-01 58
Take time to planwhat you are going todo with a cylinderand how you aregoing to do it
Always decide onthe side of personalsafety
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Storage
PPT-043-01 59
Proper ventilation
Out of the weather
Not subject totemperature extremes
Segregate gas types toeliminate fire orchemical reactionhazards
Use good house keepingpractices
Post signage
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Lab Ventilation
PPT-043-01 60
Critical for safe and healthy operation
Occupied lab air exchange rates should be sixto 10 times an hour per applicable standards
Unoccupied lab air exchange rates includingstorerooms should be four times in one hour
(NFPA 45) Air supplies to labs, storerooms, prep rooms
should never be recycled to any other part ofthe building, offices
Only conduct experiments the ventilationsystem can handle without a fume hood
HVAC filters should be changed quarterly
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Fume Hood
PPT-043-01 61
Provides local exhaust ventilation Essential in exhausting hazardous gases,
particulates, vapors, etc.
Use hood to remove airborne chemicals (e.g.
aerosols, dusts, fumes, vapors) Do not store items within fume hoods
Place apparatus far back to rear of hood forefficient air flow
Ensure only necessary materials are underhood during an operation
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Fume Hoods
PPT-043-01 62
Always keep the sash between the face andexperiment sash should be lowered
Check air flow before and during operation(face velocity of 80-120 fpm)
Compressed Gas Cylinders
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Compressed Gas Cylinders Storage, Maintenance, Handling
PPT-043-01 63
Isolate threats:
Hourly fire rated walls
Distances
Methods of securing:
Adjustable bay rack
Individually supported
Eye bolts, chain and latch
Compressed Gas Cylinders Storage
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Compressed Gas Cylinders Storage,Maintenance, Handling
PPT-043-01 64
Compressed gases can be hazardous because
each cylinder contains large amounts of energyand may also have high flammability and toxicitypotential - think safety:
Ensure the contents of all compressed gas cylindersare clearly stenciled or stamped on the cylinder ordurable label
Do not identify a gas cylinder only by themanufacturers color code
Never use cylinders with missing
or unreadable labels
Compressed Gas Cylinders Storage,
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Compressed Gas Cylinders Storage,Maintenance, Handling
PPT-043-01 65
Check all cylinders for damage before use
Be familiar with the properties and hazards ofthe gas inside the cylinder before use
Wear appropriate PPE before handling/use
Check for leaks after attaching a cylinder byusing a soap solution, snoop liquid or gasdetector
Label empty cylinders as EMPTY or MT
Always attach safety caps when storing ormoving cylinders
Compressed Gas Cylinders Storage
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Compressed Gas Cylinders Storage,Maintenance, Handling
PPT-043-01 66
Larger cylinders should be secured to a wall or lab
bench by a clamp or chain Store cylinders by gas type; separate oxidizing
gases from flammable gases by either 20 feet or a30 minute 5 foot high firewall
Store cylinders in a cool, dry, well-ventilated areaaway from incompatible materials and ignitionsources
Store empty cylinders separately from full ones
Do not subject any part of a cylinder totemperatures higher than 125F or lower than50F
H ti
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Heating
PPT-043-01 67
Use only approvedmethods to heatcylinders to guardagainst a rapid rise in
temperature andpressure in cylinder
Do NOT heat withsalamander heaters or
direct impingementheaters
Inspection
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Inspection
PPT-043-01 68
Physical:
Rust, chemical reactions,fire or heat impact
Leaking Bulging, distortions
Paint changes due tochemical reaction or heat
Inspection
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Inspection
PPT-043-01 69
Fatigue or stress
Dents, gouges, impactpoints
Internal problems Repair methods and
correctness
Protective valve caps
Inspect
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Inspect
PPT-043-01 70
For leaking fittingsand correctconnections
Know what to do
when finding suchsituations:
Handle alone?
Call a co-worker?
Call the supervisor? Evacuate?
Checking Connections
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Checking Connections
PPT-043-01 71
Ensure proper valveshave been used
Snoop connections toeliminate leakage of gasto surrounding areas*
* Snooping uses a soap solution on
a compatible gas connection to
determine leakage; no bubbles = no
leakage
Welding Gases
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Welding Gases
PPT-043-01 72
Exercise the needed care
when dealing with dualgases such as oxygen andacetylene
Practice storage and use
safety Secured and capped
Not taken into confinedspaces or work areas
Segregated fromcombustibles
Inspect Set Ups
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Inspect Set Ups
PPT-043-01 73
Check:
Valves
Hoses
Flashback arrestor
Confirm operatingpressures
Connections are secure
Personal protectiveequipment is in use
Area secured from otherhazards
Hydrostatic Testing (Hydro)
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Hydrostatic Testing (Hydro)
PPT-043-01 74
Pressurizing a cylinder for aperiod of time thendetermining if the shellreturns to a percentage ofits normal shape within a
set time period Determines serviceability of
the cylinder
Determine hydro schedule
for your cylinders and keepa record on file
Hydro Test Intervals
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Hydro Test Intervals
PPT-043-01 75
Hydro test intervalsare based on thecomposition of thecylinder
Retesting of cylinders
can be found in 49 CFR 173.34, and
CGA C-1 Methods forHydrostatic Testing ofCompressed GasCylinders
Emergency Response
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Emergency Response
PPT-043-01 76
Gas emergency responsewould fall under HazardousMaterials response per 29CFR 1910.120(q)
Certain likely events mayresult from the gases youuse and the methods oftransport, storage or
handling
Possible Gas Accidents
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Possible Gas Accidents
PPT-043-01 77
LP gas tank fire
Gas pipeline explosion
Release Events
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Release Events
PPT-043-01 78
Detection Monitoring
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Detection Monitoring
PPT-043-01 79
To determine leaks, use
various detectors: Combustible gas
indicators (CGI), or
Gas detector (gas
specific)
You will need to know:
Gas LEL/UEL and
IDLH limits before
monitoring for gas
Detection
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Detection
PPT-043-01 80
Portable leak detector
Broom used to detectburning hydrogen,
which burns light blueto almost invisible
Detection
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Detection
PPT-043-01 81
Similar broom method may also be used:
If attempting to detect presence of chlorine
Wrap clean cloth around broom
Put ammonia on cloth and wave in suspected chlorine cloud
If cloth fumes, you have detected presence of chlorine
If looking for ammonia leaks Wrap cloth treated with chlorine bleach around broom
Wave in suspect area
If fuming occurs, ammonia is present
Both methods rely on chemical reactions youll needtraining and PPE: USE CAUTION
Emergency Response Methods
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Emergency Response Methods
PPT-043-01 82
An extraction hood used fordaily operations may beused to vent escaping gasfrom a cylinder up through afilter
Hoods and vents may alsobe equipped with ascrubber to neutralizevarious gases
Some poison gases may bescrubbed this way
Response
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Response
PPT-043-01 83
Do you have a trainedteam?
Or will you call specialtyresponders?
Will special responseequipment be needed?
Special precautions arerequired for spontaneously
combustible gases such assilane
Recovery Vessel
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Recovery Vessel
PPT-043-01 84
Recovery vessel is a DOTexempt containment vessel
It can handle large cylinders
as well as smaller Service pressures vary
It may be the mostexpedient means to control
a leaking cylinder
Containment
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Containment
PPT-043-01 85
Containment is a team effort
Remote openers also existfor containers which may be
suspect so responders arenot subjected to pressureinjuries
Chlorine A Kit
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Chlorine A Kit
PPT-043-01 86
Chlorine A kit to beused for leakingchlorine cylinders
The pressures of somegases may limit the kitsuse to chlorine
Teams should betrained in proper use
Chlorine B Kit
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Chlorine B Kit
PPT-043-01 87
B kit is used to controlleaks on one toncontainers of chlorine
Where contents can not be
pumped out of a container,the container might beable to be drilled
Drilling requires pressure
reduction (cooling) andhighly trained responders
Response
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p
PPT-043-01 88
Determine if you willhandle an event aloneor with off-site help
Pre-plan potential zonesof harm should yourfacility have a release
Practice safety and besafe in handling, use,storage and response to
gas incidents
Some Standards to Aid You
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The following 29 CFR 1910 Standards mayguide you in developing your own program:
1910.101 Compressed Gases (GeneralRequirements)
1910.102 Acetylene
1910.103 Hydrogen
1910.104 Oxygen
1910.111 Storage and Handling of LP Gas
Compressed Gas Assn., Inc., 14501 George
Carter Way, Suite 103, Chantilly, VA 20151
Questions
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Q