Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
COMPRESSED AIR EQUIPMENT
TABLE OF CONTENTS
[Alt + Right/Left = Page Forward/Back]
PURPOSE .................................................................................................................................................................... 1
SCOPE ......................................................................................................................................................................... 2
APPLICATION ........................................................................................................................................................... 2
DEFINITIONS ............................................................................................................................................................ 2
1.0 GENERAL REQUIREMENTS ........................................................................................................................ 2
1.1
2.0
2.1
2.2
3.0
3.1
3.2
3.3
3.4
3.5
3.6
4.0
5.0
Whip Check...................................................................................................................................... 2
PRESSURIZED/COMPRESSED AIR EQUIPMENT ..................................................................................... 3
Inspections ....................................................................................................................................... 3
Cleaning ........................................................................................................................................... 3
Compressed gas cylinders ................................................................................................................................. 4
Procurement Specifications and Limits ........................................................................................... 4
Transporting and Moving Cylinders ................................................................................................ 4
Placing Cylinders ............................................................................................................................. 5
Storing Cylinders ............................................................................................................................. 5
Using Cylinders ................................................................................................................................ 6
Refilling Gas Cylinders .................................................................................................................... 8
MANIFOLDS ................................................................................................................................................... 8
REFERENCES ................................................................................................................................................. 9
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 1
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
PURPOSE
This practice defines the requirements for operating or using pressurized or compressed air equipment.
SCOPE
This practice includes the following major sections:




General Requirements
Pressurized/Compressed Air Equipment
Compressed Gas Cylinders
Manifolds
APPLICATION
This practice applies to work activities and employees under the control of P2S and its contractors.
DEFINITIONS
Pressurized Equipment  Includes but is not limited to any equipment, such as line, hose, vessel, or container,
which is subjected to pressure above or below that of one atmosphere.
GENERAL REQUIREMENTS
All connections on pressurized/compressed air hoses or lines must have a positive means of coupling to prevent the
connection from uncoupling.
All hoses will have a containment device fitted to prevent whipping should it become detached.
Whip Check
If inadequately restrained or “whip-checked,” the resulting whipping effect may, and has previously, caused
equipment damage and significant injury to, or death of, employees. Consequently, all pressurized equipment must
be restrained, or whip-checked through the use or combined use of the following:





Single leg cable stocking
Sling (such as 1 or 2 leg slings)
Internal reinforcement
Double or 2-leg cable stocking, or
Proprietary fittings or fixtures
Particular attention must be given to the securing and whip checking of:




Hydraulic lines and pressure units
High-pressure water lines, pumps, and vessels
Air compressors and lines
Associated tools and accessories
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 2
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
PRESSURIZED/COMPRESSED AIR EQUIPMENT
Only certified pressure vessels are permitted.
Employees required to use pressurized equipment must be trained in the use of such equipment and fully conversant
with the hazards associated with pressurized equipment.
Most pressurized equipment fails through:






Mistreatment
Sharp edges
Poor handling techniques
Incorrect installation or fitting
Incorrect fitting of whip-check system
Incorrect flow rate
Before compressed air equipment is brought to the project/site, it must be inspected and deemed fit for the intended
purpose.
Certificates of inspection for air receivers must be provided before arriving on the project/site. Bleed-/pressurerelief valves, as well as air diffusers, must be fitted to air-powered equipment.
Air lines must be protected from being driven over by machinery and kept away from walkways and supported by
cable stands where practicable.
Inspections
Pressure vessels must be inspected/certified according to the manufacturer’s recommendations, and applicable
codes/standards (such as ASTM, ASME, and in-country).
Air compressors and similar equipment will be inspected daily with results documented on Form 000.653.F0107z,
Inspection Report – General Line Equipment: Air Compressors; and monthly with results documented on Form
000.653.F0108, Monthly Inspection Report – Construction Equipment and Light Vehicles.
Note: Forms used to document inspections (000.653.F0107 series) and performance
evaluations (000.653.F0218 series) are specific to the machine. Both forms have a
sub-letter designation for nearly every type of machine. For example, F0107 “b”
and F0218 “b” are used for aerial lifts; F0107 “c” and F0218 “c” are used for
scissor lifts; F0107 “x” is used for a welding machine; and F0107z is used for an
air compressor.
Cleaning
Compressed air must not be used for cleaning purposes unless the pressure is reduced to less than 30 psi — and
then only with effective chip guarding and adequate personal protective equipment.
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 3
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
Compressed gas cylinders
Procurement Specifications and Limits
Requisitions for cylinders and hardware will include the following specifications when applicable:


Portable cylinders used to store and ship compressed gas will be constructed and
maintained in accordance with U.S. Department of Transportation (DOT) regulations,
Title 49 Code of Federal Regulations, Parts 171-179, or applicable in-country
standards.
Devices used on compressed gas cylinders must comply with applicable Compressed
Gas Association (CGA) Standards, or applicable in-country standards.
Transporting and Moving Cylinders
When compressed gas cylinders are hoisted, they must be secured on a cradle, cylinder truck/dolly, sling board, or
pallet; cylinders must not be hoisted using slings choked around the body nor with unapproved devices or
attachments.
When cylinders are moved with powered vehicles, they will be secured in a vertical position, regulators will be
removed, and valve protection caps put in place.
When cylinders are manually handled, unless cylinders are firmly secured on a cylinder truck, regulators will be
removed and valve protection caps put in place before cylinders are moved in any fashion or by any means.
Whenever cylinders are moved, the valve will be in a closed position.
Regulators must be removed and, when provided for, valve-protection caps put back in place before moving
cylinders.
Proper support racks will be provided in vehicles used to transport cylinders.
The driver/operator will ensure cylinders filled for transportation (bulk loads) comply with DOT regulations or
applicable in-country standards, on the following subjects:






Ownership and authorization to fill
Type of shipping cylinders for each gas
Charging cylinders – amount of gas and conditions of filling
Marking and labeling
Placarding transport vehicles
Type(s) of pressure relief devices, where required
Compressed gas cylinders must not be transported in automobiles or in closed-bodied
vehicles.
Shipping compartments will be adequately ventilated.
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 4
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
Placing Cylinders
Cylinders will be secured in an upright position, even when being hoisted or moved.
Cylinders will be placed where they cannot become part of an electrical circuit and will be kept away from piping
systems and layout tables that may be used for grounding electrical circuits.
When cylinders are in use, they will be placed with the valve end up, and a steadying device used to keep them
from being knocked over. Cylinders will not be placed where they will be exposed to open flames, hot metal, or
other sources of heat.
Note: This requirement does not apply to cylinders as follows (as prescribed in CGA and
National Fire Protection Association (NFPA) standards:



Cylinders designed to remain stable without being secured (for example, LPG
cylinders commonly used with gas grills and weed burners)
Cylinders with a maximum water capacity < 2.7 pounds
Compressed gas and oxygen cylinders must not be placed in confined/enclosed or
non-ventilated areas.
Storing Cylinders
Compressed gas cylinders must be stored in areas that are safe, dry, well-ventilated, and protected from direct sun
and weather conditions; do not expose cylinders to temperatures above 125 F (51 C).
Compressed gas cylinder storage areas will be clearly identified and posted with the name(s) of the gas(es) stored in
the area.
The quantity of gas in cylinders allowed in storage (inside or outside) will be in accordance with NFPA
Standards 51 and 55.
Cylinders will not be stored near elevators, gangways, stairwells, or any other place where they are likely to be
knocked down or interfere with traffic.
Empty cylinders will be segregated from other cylinders and labeled or tagged “Empty” or “MT.”
Oxygen cylinders not in use must not be stored within 20 feet (6.1 meters) of cylinders containing flammable gases
unless separated by a fire wall at least 5 feet (1.5 meters) tall and having a fire-resistance rating of at least 1/2 hour.
Cylinders containing oxidizing gases must be stored away from flammable substances such as oil and volatile
liquids.
Smoking is prohibited within 20 feet of flammable gas cylinder storage areas. NO SMOKING signs must be
posted in storage areas containing flammable gases.
Valves on empty cylinders will be closed and capped.
Storage areas will be constructed so that they are dry, well-ventilated, and made with noncombustible materials;
ensure shelves are able to support cylinders.
Dry vegetation and combustible materials must be cleared for a minimum distance of 15 feet (4.6 meters) from
around the storage area.
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 5
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
Physical protection (barriers) will be provided to prevent damage from vehicles.
Using Cylinders
Gas welding and cutting equipment must be inspected by the user at the beginning of each shift to identify any of
the following defects:




Leaking or damaged hose or hose couplings
Leaking or damaged fuel-gas pressure regulators and gauges and related connections
Leaking or damaged torch heads or shutoff valves and related connections
Clogged tip openings
Before connecting a regulator to the valve, the valve will be opened slowly to clear debris from the valve nozzle
and closed immediately. This action will be taken in an area where there are no possible sources of ignition, and
the employee will stand to one side when taking this action.
Safety devices will not be tampered with.
Cylinders must be clearly identified as to their contents in accordance with local hazardous substance legislation.
Do not strike an arc on a cylinder.
Hoses from compressed gas cylinders must be removed from confined spaces when not in use and during breaks.
Flashback devices must be installed at both the regulator and torch end, on both lines, of oxygen/fuel gas systems.
Regulators and hoses used with flammable compressed gas cylinders will be leak tested immediately after they are
connected to the cylinders.
Cylinders must be kept far enough away from the actual welding/cutting operation to prevent sparks, hot slag, and
flames from reaching them.
Acetylene cylinder valves will be opened 3/4 of a turn or less; do not open acetylene cylinder valves more than
1-1/2 turns.
Acetylene regulators will be adjusted so the low-pressure gauge indicates a delivery pressure of less than 100 kPa
(15psig) to the hose and torch.
Cylinders will be considered full and must be handled accordingly.
Approved reducers and regulators must be used; do not use gas directly from cylinders without pressure being
reduced through specifically approved regulators; do not tamper with safety devices on regulators or on cylinder
valves.
Cylinders will be protected from damage; do not drag, drop, or strike; do not use cylinders with signs of damage.
Cylinders will not be used as rollers or supports or for any purpose other than to store and dispense the original
contents.
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 6
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
Oxygen cylinders and fittings must be kept away from oil, grease, and other combustible/flammable materials; keep
cylinders, cylinder caps and valves, couplings, regulators, hoses, and apparatus free from oil and greasy substances,
and do not handle with oily hands or gloves; do not direct oxygen at oily surfaces or greasy clothes.
Gaseous hydrogen systems will be equipped with pressure-relief devices and protected from tampering. Relief
devices will be arranged so that if actuated, they have an unobstructed upward vent path to open air.
Users will verify that compressed gas cylinders indicate the following:


Date the last hydrostatic test was performed (stamp).
Cylinder contents (label with either chemical or trade name).
Cylinder tags or markings will not be removed or altered.
Mixing gases, transferring them from one cylinder to another, or refilling cylinders is prohibited.
Valve protective caps will be kept on the cylinder except when the cylinder is secured and connected to dispensing
equipment.
Cylinder valves must be opened slowly.
Users will ensure reverse-flow gas check valves and flashback arrestors are installed on both lines of all oxygen and
fuel-gas setups.
Special wrenches, when required, will be left in position on the stem of the valve while the cylinder is in use; in the
case of coupled cylinders or cylinders connected with a manifold, at least one such wrench must be available for
immediate use.
When the work is complete, or at the end of the shift, valves and regulators will be closed; gas lines and regulators
must be drained and the adjusting screw “backed out.”
Note: This does not apply to cylinders connected with a manifold.
Regulators and pressure gauges will be used only for the gases that they are designed and intended for. Repair,
modification, or alteration on cylinders, valves, or attachments will be performed only by the
manufacturer/authorized service center.
Difficult connections must not be forced; threads on regulators must match to those on the cylinder valve outlet.
Cylinders will not be dragged, dropped, rolled, or struck in horizontal position, or allowed to strike each other or
another surface violently.
When transporting cylinders, a suitable hand truck, forklift, or similar handling device will be used with the
cylinder properly secured to the device and the valve cap on.
Cylinders may be rolled only for short distances, using the curved bottom edge of the cylinder.
Cylinders will not be lifted using the protective cap or with a magnet.
When disconnecting regulators and hose, the valve must be closed and the hoses purged before removing the
regulators, and storing.
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 7
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
Torches and hoses will be completely depressurized (bled) before storage, or at the end of each shift.
Torch, hose, and regulators must be completely contained within any box for storage. Storage of torches or hose
with one end out of the box is strictly prohibited, regardless of the regulators being connected to a compressed gas
cylinder.
Refilling Gas Cylinders
Compressed gas cylinders may only be refilled by the owner or authorized employees in compliance with
applicable standards.
MANIFOLDS
Use manifolds and manifold parts only for the gas(es) they are designed for.
Cylinder manifolds are installed under the supervision of an employee who is familiar with the uses of the gas at
that facility. Installations comply with applicable standards for construction and use.
Ensure compressed gas manifolds are designed to meet NFPA Standard 51.
Ground and bond flammable gas piping systems in accordance with NFPA Standard 51.
When acetylene cylinders are connected by a manifold, approved flash arrestors are installed between each cylinder
and the coupler block. One flash arrestor installed between the coupler block and regulator is acceptable only for
outdoor use or if the number of cylinders coupled does not exceed 3.
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 8
Origination Date:
October 7, 2011
Revision Date:
Release Authorized by:
Danny Trahan, Safety Director
June
2012
Manual Rev 4
COMPRESSED AIR EQUIPMENT
REFERENCES
Document ID
Document ID
Forms:
000.653.F0107z
Inspection Report – General Line Equipment: Air
Compressors
000.653.F0108
Monthly Inspection Report – Construction
Equipment and Light Vehicles
Non-P2S Documents
49 CFR Parts 171-179
Department of Transportation Regulations
(Hazardous Materials and Carriage)
NFPA Standard 51
Design and Installation of Oxygen and Fuel Gas
Systems for Welding, Cutting, and Allied
Processes
NFPA Standard 55
Compressed and Liquefied Gases in Portable
Cylinders
P2S Health, Safety & Environmental
Copyright © 2012, P2S. All Rights Reserved.
Page 9