HAZARDOUS MATERIALS
TRAINING FOR
HIGH PRESSURE CYLINDERS
Handling
Filling
Compressor Operation
Goal of This Training
• To increase your safety and the safety of
those around you by familiarizing you with
the policies and proper procedures for
handling and filling cylinders containing
high pressure gas,
THE CODE OF FEDERAL REGULATIONS
(CFR Title 49: 172.700) MANDATES THAT
ALL INDIVIDUALS WHO HANDLE
COMPRESSED GAS CYLINDERS SHALL
RECEIVE APPROPRIATE SAFETY
TRAINING. TRAINING SHOULD OCCUR
EVERY THREE YEARS.
• By law you should receive this training
within 90 days of hiring
THE US DEPT. OF
TRANSPORTATION REGULATES
TRANSPORT OF HIGH PRESSURE
CYLINDERS.
• A CODE IS STAMPED ON THE NECK
AREA OF THE CYLINDER.
• THE CODE: DOT, CTC, OR ICC MUST
APPEAR ON THE CYLINDER.
• STEEL - DOT 3AA 2250 12345B PST
7C 89 +
ALUMINUM CYLINDER
CODE
• DOT 3AL 3000
• P123456 LUXFER 06 A 00 S80
THE US DEPT. OF LABOR,
OCCUPATIONAL SAFETY HEALTH
ADMINISTRATION (OSHA)
REGULATES SAFETY IN THE
WORK PLACE
DIVING CYLINDERS AND
ASSOCIATED PLUMBING ARE
MANUFACTURED TO STANDARDS
THAT ENSURE THAT THEY ARE
EXTREMELY SAFE.
• After manufacture, the history of a
cylinder is difficult to document
EACH YEAR, SEVERAL DIVING
CYLINDERS EXPLODE RESULTING
IN INJURIES AND DEATHS.
• Often the circumstances are hidden or
the incident is exploded on the internet.
AN 80 CUBIC FT CYLINDER
FILLED TO 3000 PSI HAS IN
EXCESS OF ONE MILLION
POUNDS OF KINETIC ENERGY THIS IS SUFFICIENT POWER TO
BLOW APART BRICK WALLS AND
DESTROY VEHICLES.
• One cylinder destroyed a fire truck and
severely damaged the fire house.
ABOUT 90 PERCENT OF
EXPLOSIONS OCCUR
DURING FILLING
• Operator error is the major cause of
cylinder explosions.
• Read and understand the codes to insure
your safety
SAFE HANDLING
PROCEDURES.
• Simple, but important actions
DO NOT DROP CYLINDERS.
• Treat with respect
SECURE CYLINDERS
DURING STORAGE AND
TRANSPORT.
• Do not let them roll around in the back of
your vehicle or boat.
CYLINDERS ARE HEAVY
AND AWKWARD, USE
PROPER LIFTING
TECHNIQUES.
• Wear shoes
• Have a clear path
CYLINDERS ARE TYPICALLY
LIFTED BY USING THE
VALVE AS A HANDLE.
• The valve is an easy grasping point;
however, some valves are difficult to obtain
a comfortable grip.
CYLINDERS SHOULD BE
STORED IN TEMPERATURES
NOT EXCEEDING 130 F.
• The cylinder burst disks may open due to
increased pressure.
CYLINDERS IN TRANSPORT
SHOULD BE STORED SO
THE CYLINDER IS
STANDING UPRIGHT.
• If an explosion were to occur, a cylinder in
a vertical position will probably go up and
out.
OPEN THE CYLINDER VALVE SLOWLY
DO NOT PUT YOUR BODY IN THE AIR STREAM
HIGH PRESSURE AIR MAY BREAK THE SKIN AND
CAUSE AN EMBOLISM (AIR BUBLES IN THE
CIRCULATORY SYSTEM).
• Injuries of this nature are not uncommon,
so, please keep hands and arms out of harms
way.
CYLINDERS THAT APPEAR
TO BE DAMAGED BY FIRE
OR PHYSICAL ABUSE
SHOULD BE REMOVED
FROM SERVICE.
• Put a tag on the cylinder and notify the Dive
Safety Officer
ALL DIVING CYLINDERS
SHOULD RECEIVE VISUALL
INSPECTIONS ANNUALLY.
• If the cylinder has signs of damage or it was
totally empty, it should receive a visual
inspection before being put back in service.
A CYLINDER THAT IS
CONDEMNED MAY NEVER
BE RETURNED TO SERVICE.
• Condemned cylinders should be made
unserviceable, cut in two, or a hole drilled
in the wall.
DO NOT USE ANY DIVING
CYLINDER:
THAT IS AL & HAS A ROUNDED BOTTOM
WITH THE CODES: SP6576, SP6688, SP890,
CYLINDERS WITH LARGE DENTS, BULGES,
LINE CORROSION
WITH VALVES THAT DO NOT HAVE
PRESSURE RELIEF DEVICES.
DO NOT USE CYLINDERS THAT
HAVE THE FOLLOWING CODES
UNLESS THEY ARE ALSO
STAMPED WITH 3AL CODE:
SP6498, E6498, SP7042, E7042
• These were special alloys that were given
the 3AL rating at a later date.
DO NOT EMPTY A CYLIDER
TO ZERO PRESSURE
WITHOUT CAUSE.
• Always try to leave 300 to 500 psi in the
cylinder.
• Empty cylinders require internal visual
inspection prior to re-filling.
FILL STATION AND
COMPRESSOR OPERATORS
• The Fill Station Operator has the
responsibility to reject cylinders that do not
meet standards.
INSPECTION OF A CYLINDER
BEFORE FILLING
• Before you refill a cylinder, you should do
an inspection to satisfy safety issues.
• Cylinders used in diving have pressures
ranging from 1,800 to 3,500, this is an
important detail.
Verifying The Cylinder
•
•
•
•
•
•
Valid ICC or DOT stampings
Current Hydrostatic Test Stamp
Current Evidence of Visual Inspection
Valve has a pressure relief device
Air in cylinder
No visual signs of dents, bulges, scrapes,
or line corrosion.
REJECTING A CYLINDER
THAT WAS RECALLED
REJECT THE FOLLOWING CYLINDERS
• SP6576
• SP6688, SP890
• SP6498, E6498, SP7042, E7042
• All round bottom aluminum cylinders
• Steel, non-galvanized, vinyl coated.
Looking for Problems
•
•
•
•
Check O-Rings
Check Pressure in Cylinder
Check The Valve Handle
On steel cylinders, strike the cylinder
with a blunt object- It should sound like a
bell, if not, don’t fill.
• Verify the rated pressure of the cylinder
Nitrox Cylinders
• To change gas type (air to Nitrox or
reverse), the original gas content must be
removed and the labeling must be
corrected before filling.
SETTING UP FOR FILLING
• Open cylinder valve to blow out
dust/water
• Attach the fill whip to the valve
• Close the whip bleed valve
• Open cylinder valve and check the
pressure in the cylinder
• Open the fill whip valve
• Open supply valve (cascade system)
VALVE TYPES
• Metering Valve, provides for slow and
controlled pressure adjustments
• Ball Valve, rapid turn on and turn off
(Use Caution when opening)
Pipes and hoses
• Pipes and hoses that carry high pressure
gas should be secured with hardware
approximately every two feet.
• Inspect for wear and correct problems
FILLING A CYLINDER
• Once the panel is pressurized and the line
is open to the cylinder, the procedure is to
fill the cylinder to rated pressure.
• Fill at 300 to 600 psig/minute
• A 3000 psi cylinder should take 5 to 10
minutes to fill.
• Do not fill beyond rated pressure
GAUGES
• Gauges that are used on the fill whips
and yokes are not calibrated or tested.
• Gauges in the fill panel are tested and
calibrated.
CYLINDER STORAGE
• Vertically and secured to a wall with a
chain
• Below 130 F
• Away from flammable materials
CASCADE OR BANK
STORAGE CYLINDERS
• Large, storage units with a valve on the
top
• Filled to 4,500 psig
• Interconnected with stainless steel
plumbing
• Secured in a metal frame
CASCADE FILLING
PROCEDURES
• Cascade filling is the most economical use of
banked gas.
• To fill from a bank, the pressure in the bank
must be higher than the cylinder being filled.
• Start filling from the bank containing the
lowest pressure in excess of the pressure in the
cylinder being filled.
• After the pressure equalizes, close the bank and
open the next highest bank in the chain.
Continue in this mode until the cylinder
working pressure is reached.
SUMMARY
• Handle HP Cylinders with care
• Perform an inspection of all cylinders
before filling
• Do not overfill cylinders
• Inspect fill station and compressor prior to
use
Safety Strategy
WORK SMART
BE CAREFUL
SAFETY FIRST