HAZARDOUS MATERIALS TRAINING FOR HIGH PRESSURE CYLINDERS Handling Filling Compressor Operation Goal and Objective • Safe handling and filling of Scuba cylinders. • Understanding potential hazards of working with high pressure cylinders. 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, OR ICC MUST APPEAR ON THE CYLINDER. • STEEL - ICC 3AA 2200 12345 M8303 1989 ALUMINUM CYLINDER CODE • DOT 3AL 3000 • P123456 M4002 06/91 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 disk 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 VISUAL 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 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 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. INSPECT 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 yoke to the valve • Close the bleed valve • Open cylinder valve and check the pressure in the cylinder • Open the fill yoke valve • Open supply valve (cascade system) 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 CASCADE OR BANK STORAGE CYLINDERS • Large, storage units with a valve on the top • Filled to 3500 - 4,500 psig • Interconnected with stainless steel plumbing • Secured in a metal frame CASCADE FILLING PROCEDURES • • • • Bank Cylinders are numbered 1, 2, 3, 4, 5 Start with all Bank Cylinders closed Open Cylinder 1 to start filling When #1 is at a pressure less than the rated pressure to fill a cylinder, close #1 and open #2. Continue in this mode until working pressure is obtained. VALVE TYPES • Metering, provide 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 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 in a secure place • Below 130 F • Away from flammable materials SUMMARY • Handle HP Cylinders with care • Perform visual inspection of all cylinders before filling • Do not overfill cylinders • Inspect fill station and compressor prior to use