COMPRESSED GAS SAFETY
CORPORATE SAFETY TRAINING
OSHA 29 CFR 1910.101
WELCOME
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YOUR INSTRUCTOR
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COURSE OBJECTIVES
 Discuss Compressed Gas Program Requirements.
 Discuss Safety Inspection Requirements.
 Discuss The Types of Compressed Gases.
 Discuss Properties of Compressed Gases.
 Discuss Basic Skills in Hazard Recognition & Control.
 Discuss OSHA’s Requirements for Gas Safety.
 Discuss the Compressed Gas Association’s involvement.
 Discuss Use, Storage and Maintenance Requirements.
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BASIS FOR THIS COURSE
 Employers are Responsible for Compressed Gas Safety.
 Compressed Gases Contain a Variety of Hazards.
 Compressed Gases are Maintained Under High Pressure.
 Compressed Gases are Extremely Hazardous
 Training Greatly Lessens the Probability of Disaster.
 This Training Helps Improve:
 Safety
 Morale
 Productivity
 Employee well-being
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COURSE ATTENDEES
 Gas Users
 Safety Committees
 Purchasing Agents
 Department Managers
 First Line Supervisors
 Maintenance Managers
 Shipping and Receiving Employees
 Accident Investigation Team Members
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FORWARD
REGARDING COMPRESSED GAS SAFETY -
Know the gas you are using, or don’t use it! “Never
let your name, and the word “dead” be used in the
same sentence.”
Billy N. Ring, Fire Captain
Dayton Regional HAZMAT Coordinator
27 Years Experience
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REGULATORY STANDARD
THE GENERAL DUTY CLAUSE
FEDERAL - 29 CFR 1903.1
EMPLOYERS MUST: Furnish a place of employment
free of recognized hazards that are causing or are likely
to cause death or serious physical harm to employees.
Employers must comply with occupational safety and
health standards promulgated under the WilliamsSteiger Occupational Safety and Health Act of 1970.
OSHA ACT OF 1970
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APPLICABLE REGULATIONS
29CFR - SAFETY AND HEALTH STANDARDS
1910 - INDUSTRIAL SAFETY
101 - COMPRESSED GASES (GENERAL)
DANGER
COMPRESSED
GAS
STORAGE AREA
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CONSENSUS STANDARDS
COMPRESSED GAS ASSOCIATION
CGA P-1 - SAFE HANDLING OF COMPRESSED GASES
- Over 100 Other CGA Safety Manuals
DANGER
COMPRESSED
GAS
STORAGE AREA
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OSHA CIVIL PENALTIES POLICY
BEFORE MARCH 1, 1991:
VIOLATION NARRATIVE: TEN (10) EMPLOYEES WERE
NOTED NOT WEARING EYE PROTECTION IN AREAS
WHERE A REASONABLE PROBABILITY OF EYE INJURY
COULD OCCUR.
PENALTY: $500
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OSHA CIVIL PENALTIES POLICY
(Continued)
AS OF MARCH 1, 1991:
CHANGES IN PENALTY COMPUTATION:
1. PENALTIES BROKEN OUT INDIVIDUALLY.
2. PENALTIES INCREASED SEVEN FOLD.
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OSHA CIVIL PENALTIES POLICY
(Continued)
AS OF MARCH 1, 1991:
VIOLATION NARRATIVE: TEN (10) EMPLOYEES WERE
NOTED NOT WEARING EYE PROTECTION IN AREAS
WHERE A REASONABLE PROBABILITY OF EYE
INJURY COULD OCCUR.
$ 10 VIOLATIONS TIMES $500 = $5000
$ 5000 TIMES SEVEN = $35,000
PENALTY: $35000
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BEFORE MARCH, 1991:
$500
AS OF MARCH, 1991: $35,000
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GENERAL PROGRAM REQUIREMENTS
ALL EMPLOYERS MUST:
 Assign Responsibility
GAS
SAFETY
PROGRAM
 Establish a Written Program
 Conduct Gas Safety Training
 Develop Safe-Use Procedures
 Conduct Work Area Inspections
 Maintain a Safe Work Environment
 Conduct Regular Program Evaluations
 Ensure Proper Storage and Maintenance
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TRAINING REQUIREMENTS
THE EMPLOYER MUST PROVIDE TRAINING:

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

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

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
Properties of the Gases Being Handled.
Explain Why a Particular Gas is Required.
Conduct Training Prior to Job Assignment.
Precautions to be Taken in Using Cylinders.
Precautions to be Taken in Storing Cylinders.
Precautions to be Taken in Moving Cylinders.
Explain Proper Maintenance and Storage of Gases.
Explain the Potential Hazards Associated with Gases.
Explain The Nature, Extent and Effects of Gas Hazards.
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RETRAINING REQUIREMENTS
REQUIRED WHEN THERE IS A:


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


New Hazard or Gas.
Program Related Injury.
Change in Job Assignment.
New Hazard Control Methods.
Failure in the Safety Procedures.
Reason to Doubt Employee Proficiency.
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GAS
SAFETY
PROGRAM
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TRAINING IS IMPORTANT
A GOOD PROGRAM WILL HELP:





Reduce injury and illness rates.
SAFETY
Acceptance of high-turnover jobs.
STATISTICS
Workers feel better about their work.
Reduce workers’ compensation costs.
Elevate OSHA compliance to a higher level.
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PROGRAM IMPLEMENTATION
IMPLEMENTATION OF A COMPRESSED
GAS SAFETY PROGRAM REQUIRES:
 DEDICATION
 PERSONAL INTEREST
 MANAGEMENT COMMITMENT
NOTE:
UNDERSTANDING AND SUPPORT FROM THE WORK FORCE
IS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!
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PROGRAM IMPLEMENTATION
Continued
DEVELOPMENT SEQUENCE:

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


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

Establish responsibility.
DANGER
Conduct employee training.
COMPRESSED
GAS
Periodically review the program.
STORAGE AREA
Perform inspections and maintenance.
Modify policies and rules as appropriate.
Eliminate hazardous gases where possible.
Establish a corporate policy and develop rules.
Substitute nonhazardous gases where possible.
Conduct a compressed gas safety survey of the facility.
Provide protection where hazard elimination is not possible.
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IMPLEMENTATION STRATEGY
 RECOGNITION
 EVALUATION
 IMPLEMENTATION
 CONTROL
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IMPLEMENTATION STRATEGY
Continued
 RECOGNITION
ASSESSMENT OF GAS HAZARDS:
 Known jobs/areas having gas usage.
 Jobs/areas with new equipment or processes.
 New jobs having little or no statistical injury data.
 Jobs/areas having had recent operational changes.
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IMPLEMENTATION STRATEGY
Continued
 RECOGNITION
 EVALUATION
 IMPLEMENTATION
 CONTROL
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IMPLEMENTATION STRATEGY
Continued
 EVALUATION






SAFETY
PROGRAM
Facility audit data.
Employee surveys.
Accident investigations.
Logs of employee complaints.
Statistical evidence of known/potential hazards.
Injury and illness data of known/potential hazards.
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IMPLEMENTATION STRATEGY
Continued
 RECOGNITION
 EVALUATION
 IMPLEMENTATION
 CONTROL
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IMPLEMENTATION STRATEGY
Continued
 IMPLEMENTATION
 Written program.
 Training program.
 Employee involvement.
 Supervisor involvement.
 Corrective action program.
 Job hazard analysis program.
 Safety in purchasing (new gases, substitutes etc.)
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IMPLEMENTATION STRATEGY
Continued
 RECOGNITION
 EVALUATION
 IMPLEMENTATION
 CONTROL
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IMPLEMENTATION STRATEGY
Continued
 CONTROL




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

Periodic facility audits.
SAFETY
Written program reviews.
PROGRAM
Employee feedback surveys.
Job hazard analysis reviews.
Recurrent training programs.
Supervisor feedback surveys.
Periodic statistical evaluations.
Corrective action follow-up measures.
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IMPLEMENTATION STRATEGY
Continued
 CONTROL MEASURES CONSIDERATIONS:
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Capital improvement plan to eliminated hazards.
Costs involved in purchasing substitutes gases.
Length of time necessary for implementation.
Level of urgency in implementation.
Compatibility with existing processes or controls.
Anticipated problems with employee use.
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IMPLEMENTATION STRATEGY
Continued
 PRIORITIZATION CONSIDERATIONS:
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
Severity of injuries as a result of hazards.
Consequences of an injury at the worksite.
Likelihood that the operation will have an injury.
The length of exposure to the hazard.
Long-term effects of hazardous gas use.
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THE SUPERVISOR’S ROLE
 CONSIDER THE FOLLOWING:
1. KNOW THE GASES YOU USE!
2. GET INVOLVED IN THE HAZARD ASSESSMENTS.
3. OBTAIN ASSISTANCE (IF NEEDED) FROM YOUR SUPPLIERS.
4. OBTAIN ASSISTANCE (IF NEEDED) FROM EXPERTS IN THE
FIELD OF GAS SAFETY, CGA (703) 412-0900.
5. COMPLETE THE PAPERWORK (WORK ORDERS, POLICY
CHANGES, ETC.) TO MAKE CORRECTIVE ACTIONS.
6. ATTEND THE SAME TRAINING AS YOUR WORKERS.
7. FOLLOW-UP ON THE ACTIONS YOU TOOK.
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COMPRESSED GAS HAZARDS

PRINCIPAL HAZARDS:
 Extremely High Pressure.
 Toxicity.
 Reactivity.
 Instability.
 Flammability.
 Extreme Low Temperature.
 Asphyxiation.
 Radioactivity.
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COMPRESSED GAS HAZARDS
Continued

WHEN THINGS GO WRONG:
 Have Flown Over a Half Mile.
 Penetrated Brick Walls.
 Can Displace Oxygen in Extremely Large Areas.
 Can Oxygen-Enrich Extremely Large Areas.
 Can Spin and Ricochet Completely Out of Control.
 Can Immediately Freeze Exposed Skin.
 Can Explode With Tremendous Force.
 Can be Virtually Unstoppable.
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COMPRESSED GAS HAZARDS
Continued

THE TYPICAL COMPRESSED GAS CYLINDER:
 175 Pounds.
 2,000 to 2,640 psig (some to 6,000 psig).
 Wall Thickness of About 1/4 Inch.
 57 Inches Tall.
 9 Inches In Diameter.
 Easily Toppled.
 Easily Corroded.
 Devastatingly Hazardous.
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BASIC SAFETY RULES
I’LL GET THE
RUST OFF
OF THIS THING
ONE WAY
OR ANOTHER!
KIDS DON’T TRY
THIS AT HOME!
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BASIC SAFETY RULES
Continued

THE BIG THREE:
 Oxidizers: Must not be used in contact with
oils, greases or other hydrocarbons.
 Flammables: Must not be exposed to flames,
sparks or arcs including static electricity, hot
surfaces or oxidizers.
 NonFlammables: Must not be allowed to
displace air in confined work spaces so that
there is insufficient oxygen for breathing.
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BASIC SAFETY RULES
Continued

FILLING OF CYLINDERS:
 Cylinders may not be filled except by the
supplier of the cylinder or with the supplier’s
consent.
 Where filling is authorized it must be
accomplished in strict accordance with DOT,
OSHA and CGA regulations.
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BASIC SAFETY RULES
Continued

CONTENT IDENTIFICATION:
 Never assume you know what it is!
 Assuming (with gases) gets you dead!
 Labels must be legible at all times.
 Labels may not be altered or removed.
 Labels may not be bypassed, ignored, or
otherwise defeated.
 Labels must be understood by all.
 Nonlegible/missing labels must be reported.
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BASIC SAFETY RULES
Continued

CONTENT IDENTIFICATION:
Continued
 Labels and their means of attachment must
withstand their normal operating environment.
 Labels may evoke a false sense of security,
and their meaning needs to be understood.
 Labels must be securely attached to cylinders
so that they cannot be inadvertently or
accidentally detached during use.
 Each container must bear the proper label for
the gas contained.
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BASIC SAFETY RULES
Continued

PAINTING CONTAINERS:
 Containers may not be painted.
 Painting may cover cylinder defects.
 Containers showing signs of corrosion must
be removed from service and returned to the
supplier.
 Never rely solely on the cylinder color for
identification.
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BASIC SAFETY RULES
Continued

LEAKING AND DEFECTIVE CYLINDERS:
 Never underestimate the hazard!
 Notify co-workers of the hazard.
 Consider evacuation of the area.
 Evacuate to open air, up-wind or side-wind.
 Report the contents, location, situation.
 Begin role call to account for co-workers.
 Do not return to work until all-clear is given.
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BASIC SAFETY RULES
Continued

CYLINDER USAGE REQUIREMENTS:
 Verify contents before transporting or using.
 Keep cylinder caps on until ready to connect.
 Keep valve caps on until ready to use.
 Never use as a door stop.
 Never underestimate the hazard.
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BASIC SAFETY RULES
Continued

MOVEMENT OF COMPRESSED GAS CYLINDERS:
 Never handle roughly.
 Never use magnetic lifting devices.
 Never lift by valves or cylinder caps.
 Never roll, drag, or slide the cylinder.
 Always use a hand-truck, fork truck etc.
 Cradles, ropes, chains, or slings are prohibited
from use unless lugs or lifting attachments are
provided by the manufacturer.
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BASIC SAFETY RULES
Continued

STORAGE REQUIREMENTS (GENERAL):

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“No Smoking” signs must be posted.
The name of the gas must be posted.
Specific hazards must be posted.
Containers must be stored up right.
Gases must be stored with like gases.
Do not intermingle full and empty containers.
The oldest material must be used first.
Stored only on stable surfaces.
Some gases must always be shaded from sun.
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BASIC SAFETY RULES
Continued

STORAGE ROOMS (GENERAL):
 Must be dry.
 Must not exceed 125 F.
 Must be well ventilated.
 Should be protected from tampering.
 Local fire inspectors should evaluate.
 NFPA guidelines should be reviewed.
 Subsurface storage should be avoided.
 Should be of fire-resistive construction.
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BASIC SAFETY RULES
Continued

STORAGE ROOMS (GENERAL):
 Cylinders
- Must not impede emergency egress.
- Cannot be located near exits.
- Cannot be located near stairs.
 Must be secured to prevent toppling.
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BASIC SAFETY RULES
Continued

OUTDOOR STORAGE (GENERAL):
 Bottoms must be protected from corrosion.
 Must be secured to prevent toppling.
 Must be shaded in extreme temperatures.
 Some gases must always be shaded from sun.
 Should be of fire-resistive construction.
 Should be protected from tampering.
 Local fire inspectors should evaluate.
 NFPA guidelines should be reviewed.
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BASIC SAFETY RULES
Continued
 NAME
 PRECAUTIONS
 RESTRAINED ABOVE
MIDPOINT
DANGER
ACETYLENE
NO SMOKING
NO FUMAR
1
4
3
GAS
INSPECTION
CHECKLIST
 EMERGENCY & USE
PROCEDURES
 AWAY FROM
COMBUSTIBLES
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BASIC SAFETY RULES
Continued

GENERAL INSPECTION CRITERIA:
INSPECT FOR:
POSSIBLE RESULT:
Dents
Crevice Corrosion
Bulges
ARC/ Torch Burns
Cuts, Gouges or Digs
Corrosion
Pitting
Neck Defects
Valve Ease-Of-Movement
Valve Thread Serviceability
Weakening of cylinder wall
Weakening of cylinder wall
Weakening of cylinder wall
Weakening of cylinder wall
Decrease in wall thickness
Decrease in wall thickness
Decrease in wall thickness
Leak or cylinder explosion
Corrosion leading to leak
Leak during operation
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BASIC SAFETY RULES
Continued

PRE-OPERATION SAFETY RULES:
 If you’re not trained don’t touch it!
 Read the Material Safety Data Sheet before use.
 Ensure an “In Use” label is present.
 Ensure all labels/warnings are readable.
 Place upright on stable dry surface.
 Ensure cylinder is restrained above midpoint.
 Keep heat, flame, & electrical sources from gas.
 Use in accordance with established procedures.
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BASIC SAFETY RULES
Continued

POST-OPERATION SAFETY RULES:
 If you’re not trained don’t touch it!
 Read the Material Safety Data Sheet.
 Ensure an “Empty” label is present.
 Close valve completely and cap cylinder.
 Remove from operation (established procedures).
 Transport cylinder using a handtruck.
 Place in “Empty Container” storage area.
 Ensure “Empty” label is readable.
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STORAGE RULES
STORAGE VARIES
GREATLY,
HERE ARE A FEW
EXAMPLES OF COMMON
STORAGE REQUIREMENTS.
ASK YOUR LOCAL FIRE
INSPECTOR TO HELP YOU
WITH YOUR SPECIFIC
TYPES OF GASES.
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STORAGE
RULES
Continued
USE OLDEST STOCK FIRST!
DANGER
FULL
CYLINDERS
NO
SMOKING!
ACETYLENE
DANGER
4
COMPRESSED
GAS
STORAGE AREA
1
3
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GAS
STORAGE
CHECKLIST
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STORAGE RULES
Continued

FULL CYLINDER STORAGE RULES:
 If you’re not trained don’t touch it!
 Read the Material Safety Data Sheet.
 Do not smoke.
 Mark cylinder with date of storage.
 Rotate oldest product to front.
 Rotate oldest product to front and use first.
 Inspect cylinder for damage before storage.
 Store with like kind of gas.
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STORAGE RULES
Continued

FULL CYLINDER STORAGE RULES:
Continued
 Ensure all labels are readable.
 Ensure valve assembly is tightly capped.
 Ensure cylinder is restrained above midpoint.
 Store upright on stable dry surface.
 Keep electrical devices away from gas.
 Keep combustible materials away from gas.
 Keep heat, flame and ignition sources from gas.
 Never underestimate the hazard.
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STORAGE RULES
Continued

EMPTY CYLINDER STORAGE RULES:
 If you’re not trained don’t touch it!
 Read the Material Safety Data Sheet.
 Do not smoke.
 Ensure the cylinder is empty.
 Ensure valve assembly is closed tightly.
 Ensure valve assembly is capped tightly.
 Inspect cylinder for damage before storage.
 Store with like kind of gas cylinders.
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STORAGE RULES
Continued

EMPTY CYLINDER STORAGE RULES:
Continued
 Ensure all labels are readable.
 Ensure cylinder is restrained above midpoint.
 Store upright on a stable dry surface.
 Keep electrical devices away from gas.
 Keep combustible materials away from gas.
 Keep heat and flame away from gas.
 Never underestimate the hazard.
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SPECIFIC TYPES OF GASES
THERE ARE HUNDREDS OF
GASES USED IN INDUSTRY.
HERE ARE A FEW
EXAMPLES OF COMMONLY
USED GASES. ASK YOUR
SUPPLIER TO HELP YOU
WITH YOUR SPECIFIC
TYPES OF GASES.
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SPECIFIC TYPES OF GASES
Continued

OXYGEN (INCLUDING OXIDIZING GASES):

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Oxygen and oxidizers can be deadly.
Cleanliness is absolutely essential!!!
Explosion results upon contact with hydrocarbons.
Keep oil, grease, and other hydrocarbons away!
Ensure process or system is compatible with oxygen.
Assess compatibility of equipment and materials.
Separate from combustible materials.
Oxygen can “fuel enrich” permeable materials.
Oxygen enriched materials burn tremendously.
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SPECIFIC TYPES OF GASES
Continued
THE pH of ACIDS AND BASES
pH IS THE NUMERICAL MEASURE OF ITS RELATIVE
ACIDITY OR ALKALINITY. THE RANGE IS FROM 0 - 14
WITH A NEUTRAL LEVEL EXPRESSED AS A pH OF 7.0.
pH ABOVE 7.0 - MORE ALKALINE OR BASIC.
pH BELOW 7.0 - MORE ACIDIC.
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SPECIFIC TYPES OF GASES
Continued
CHECK FOR COMPATIBILITY!
LOW pH
ACID
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BASE
HIGH pH
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SPECIFIC TYPES OF GASES
Continued

ACID & ALKALINE GASES:



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
Avoid contact with all bodily routes of entry.
Wear goggles and suitable skin protection.
Consider effects on the respiratory tract.
Long sleeves and trousers are mandatory.
Open toed shoes or sneakers are prohibited.
Gas masks/SCBA must be immediately available.
 SCBA must be used when the concentration could
exceed the rating of the gas mask canister or if the
gas could displace oxygen to below 19 percent.
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SPECIFIC TYPES OF GASES
Continued

ACID & ALKALINE GASES:




Continued
Emergency showers/eyewashes must be available.
Quantities on-site must be limited.
Ventilation must be adequate in the work area.
Common corrosive and toxic gases include:
- Boron Trichloride
- Chlorine Trifluoride
- Iodine Pentafluoride
- Sulfur Tetrafluoride
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- Bromine Trifluoride
- Hydrogen Fluoride
- Silicon Tetrafluoride
- Tungsten Hexafluoride
CG - ‹#›
SPECIFIC TYPES OF GASES
Continued
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BHOPAL, INDIA:
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Over 2000 people died.
Methyl isocyanate released.
Occurred in December 1984.
SARA Title III initially proposed as a result.
The Union Carbide Facility was not unique.
The accident could have occurred anywhere.
Most were inhabitants in the area of the plant.
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CG - ‹#›
SPECIFIC TYPES OF GASES
Continued
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HIGHLY TOXIC GASES:
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Remember Bhopal India!
Training is critical.
The specific hazards must be understood.
Threshold Limit Values must be determined.
Storage is critical and must be assessed.
Ventilation is critical and must be assessed.
Gas discharges must be scrubbed.
Discharges must be neutralized.
On-site quantities must be limited.
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CG - ‹#›
SPECIFIC TYPES OF GASES
Continued
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HIGHLY TOXIC GASES:
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Continued
Medical services should be pre-planned.
Suppliers/manufacturers should be consulted.
Emergency responders should consulted.
Common highly toxic gases include:
- Arsine
- Bromine Trifluoride
- Chlorine
- Germane
- Hydrogen Selenide
- Nitric Oxide
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- Boron Trichloride
- Bromine Pentafluoride
- Fluorine
- Hydrogen Cyanide
- Hydrogen Sulfide
- Phosgene
CG - ‹#›
SPECIFIC TYPES OF GASES
Continued
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CRYOGENIC LIQUEFIED GASES:
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In liquid form at relatively low pressures.
Extremely low temperatures.
Usually below - 238F (- 150C).
Handled in heavily insulated containers.
Insulated containers minimize evaporation.
Proper operation of venting systems is essential.
High expansion rate on vaporization.
Can cause extreme bodily damage on contact.
Full body protection must be utilized.
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CG - ‹#›
SPECIFIC TYPES OF GASES
Continued
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CRYOGENIC LIQUEFIED GASES:
Continued
Oxygen
Rate of Expansion
3
3
1ft
875 ft
+65F
- 238F
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CG - ‹#›
SPECIFIC TYPES OF GASES
Continued
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CRYOGENIC LIQUEFIED GASES:
Continued
 Use only hardware designed for cryogenics.
 Pain is not immediate.
 Tissue solidifies over time.
LOX
 Blood circulation is arrested.
 Serious skin burns may result.
 Blood clots are highly probable.
 Skin highly vulnerable to infection.
 Flush with tepid water.
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CG - ‹#›
SPECIFIC TYPES OF GASES
Continued

INERT GASES:
 Can displace oxygen leading to asphyxiation.
 SCBA or airline systems must be used.
 Oxygen content below 19 percent is dangerous.
 Common highly inert gases include:
- Argon
- Helium
- Nitrogen
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- Carbon Dioxide
- Neon
- Xenon
CG - ‹#›
SPECIFIC TYPES OF GASES
Continued

GENERAL SAFETY CONSIDERATIONS
Don’t be afraid to ask people to wait!
Limit conversation while using gases.
Know that you could be seriously injured.
Know that no one ever expected to get injured.
Know that none of us is immune to injury.
Know the safe procedures before starting work.
Know the location of first aid kits.
Avoid horseplay - don’t tolerate it from others.
Think about going home in the same shape.
Know your gas!
CG - ‹#›
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INSPECTION AND CARE OF GASES
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INSPECTION CONSIDERATIONS:
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INSPECTION
CHECKLIST
Develop a detailed inspection policy.
Document each inspection.
Inspect all gases before issue or use.
Tag as unusable, damaged cylinders.
Inspect cylinders before each use (without exception).
Separate damaged cylinders from serviceable cylinders.
Consider the effects on gases stored for long periods.
Remove damaged cylinders from service immediately.
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CG - ‹#›