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GAS - SLIDE 1 OF 72© Copyright Compliware 1999
WELCOME
OSHA 29 CFR 1910.101 and 1926.350-354
COMPRESSED GAS SAFETY
SAFETY TRAINING
GAS - SLIDE 2 OF 72© Copyright Compliware 1999
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
GAS - SLIDE 3 OF 72© Copyright Compliware 1999
REGULATORY STANDARDTHE 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 Williams-Steiger Occupational Safety and Health Act of 1970.
OSHA ACT OF 1970
GAS - SLIDE 4 OF 72© Copyright Compliware 1999
29CFR - SAFETY AND HEALTH STANDARDS
1910 - INDUSTRIAL SAFETY & 1926 - CONSTRUCTION SAFETY
1910-101 - COMPRESSED GASES (GENERAL) 1926-350-354 - WELDING & CUTTING
APPLICABLE REGULATIONS
DANGER
COMPRESSEDGAS
STORAGE AREA
GAS - SLIDE 5 OF 72© Copyright Compliware 1999
COMPRESSED GAS ASSOCIATION
CGA P-1 - SAFE HANDLING OF COMPRESSED GASES - Over 100 Other CGA Safety Manuals
CONSENSUS STANDARDS
DANGER
COMPRESSEDGAS
STORAGE AREA
GAS - SLIDE 6 OF 72© Copyright Compliware 1999
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
GAS - SLIDE 7 OF 72© Copyright Compliware 1999
OSHA CIVIL PENALTIES POLICY
AS OF MARCH 1, 1991:
CHANGES IN PENALTY COMPUTATION:
1. PENALTIES BROKEN OUT INDIVIDUALLY.
2. PENALTIES INCREASED SEVEN FOLD.
(Continued)
GAS - SLIDE 8 OF 72© Copyright Compliware 1999
OSHA CIVIL PENALTIES POLICY
AS OF MARCH 1, 1991:
VIOLATION NARRATIVE: TEN (10) EMPLOYEES WERENOTED 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 BEFORE MARCH, 1991: $500 AS OF MARCH, 1991: $35,000
(Continued)
GAS - SLIDE 9 OF 72© Copyright Compliware 1999
GENERAL PROGRAM REQUIREMENTS
Assign Responsibility
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
ALL EMPLOYERS MUST:GASSAFETYPROGRAM
GAS - SLIDE 10 OF 72© Copyright Compliware 1999
TRAINING REQUIREMENTS
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.
THE EMPLOYER MUST PROVIDE TRAINING:
GAS - SLIDE 11 OF 72© Copyright Compliware 1999
REQUIRED WHEN THERE IS A:
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.
RETRAINING REQUIREMENTS
GASSAFETYPROGRAM
GAS - SLIDE 12 OF 72© Copyright Compliware 1999
IMPLEMENTATION STRATEGY
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.
RECOGNITION
ASSESSMENT OF GAS HAZARDS:
GAS - SLIDE 13 OF 72© Copyright Compliware 1999
IMPLEMENTATION STRATEGY
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.
SAFETYPROGRAM
Continued
EVALUATION
GAS - SLIDE 14 OF 72© Copyright Compliware 1999
Written program. Training program. Employee involvement. Supervisor involvement. Corrective action program. Job hazard analysis program. Safety in purchasing (new gases, substitutes etc.)
IMPLEMENTATION STRATEGYContinued
IMPLEMENTATION:
GAS - SLIDE 15 OF 72© Copyright Compliware 1999
IMPLEMENTATION STRATEGY
Periodic facility audits. Written program reviews. Employee feedback surveys. Job hazard analysis reviews. Recurrent training programs. Supervisor feedback surveys. Periodic statistical evaluations. Corrective action follow-up measures.
SAFETYPROGRAM
Continued
CONTROL:
GAS - SLIDE 16 OF 72© Copyright Compliware 1999
COMPRESSED GAS HAZARDS
Extremely High Pressure. Toxicity. Reactivity. Instability. Flammability. Extreme Low Temperature. Asphyxiation. Radioactivity.
PRINCIPAL HAZARDS:
GAS - SLIDE 17 OF 72© Copyright Compliware 1999
COMPRESSED GAS HAZARDS
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.
WHEN THINGS GO WRONG:
Continued
GAS - SLIDE 18 OF 72© Copyright Compliware 1999
COMPRESSED GAS HAZARDS
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.
THE TYPICAL COMPRESSED GAS CYLINDER:
Continued
GAS - SLIDE 19 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
I’LL GET THE RUST OFF
OF THIS THING ONE WAY
OR ANOTHER!
KIDS DON’T TRY THIS AT HOME!
GAS - SLIDE 20 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
THE BIG THREE:
Continued
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.
GAS - SLIDE 21 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
FILLING OF CYLINDERS:
Continued
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.
GAS - SLIDE 22 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
CONTENT IDENTIFICATION:
Continued
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.
Non-legible/missing labels must be reported.
GAS - SLIDE 23 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
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.
Continued
GAS - SLIDE 24 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
PAINTING CONTAINERS:
Continued
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.
GAS - SLIDE 25 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
LEAKING AND DEFECTIVE CYLINDERS:
Continued
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.
GAS - SLIDE 26 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
CYLINDER USAGE REQUIREMENTS:
Continued
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.
GAS - SLIDE 27 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
MOVEMENT OF COMPRESSED GAS CYLINDERS:
Continued
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.
GAS - SLIDE 28 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
STORAGE REQUIREMENTS (GENERAL):
Continued
“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.
GAS - SLIDE 29 OF 72© Copyright Compliware 1999
BASIC SAFETY RULES
OUTDOOR STORAGE (GENERAL):
Continued
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.
GAS - SLIDE 30 OF 72© Copyright Compliware 1999
NAME
PRECAUTIONS
RESTRAINED ABOVE MIDPOINT
EMERGENCY & USE PROCEDURES
AWAY FROM COMBUSTIBLES
BASIC SAFETY RULESContinued
DANGER
NO SMOKINGNO FUMAR 4
31
ACETYLENE
GASINSPECTIONCHECKLIST
GAS - SLIDE 31 OF 72© Copyright Compliware 1999
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.
GAS - SLIDE 32 OF 72© Copyright Compliware 1999
Continued
USE OLDEST STOCK FIRST!
ACETYLENE DANGER
COMPRESSEDGAS
STORAGE AREA
DANGER
FULLCYLINDERS
NOSMOKING!
431
GASSTORAGE
CHECKLIST
STORAGE RULES
GAS - SLIDE 33 OF 72© Copyright Compliware 1999
STORAGE RULES
FULL CYLINDER STORAGE RULES:
Continued
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.
GAS - SLIDE 34 OF 72© Copyright Compliware 1999
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.
Continued
STORAGE RULES
GAS - SLIDE 35 OF 72© Copyright Compliware 1999
EMPTY CYLINDER STORAGE RULES:
Continued
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.
STORAGE RULES
GAS - SLIDE 36 OF 72© Copyright Compliware 1999
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.
Continued
STORAGE RULES
GAS - SLIDE 37 OF 72© Copyright Compliware 1999
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.
SPECIFIC TYPES OF GASES
GAS - SLIDE 38 OF 72© Copyright Compliware 1999
OXYGEN (INCLUDING OXIDIZING GASES):
Continued
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.
SPECIFIC TYPES OF GASES
GAS - SLIDE 39 OF 72© Copyright Compliware 1999
ContinuedSPECIFIC TYPES OF GASES
THE pH of ACIDS AND BASES
pH IS THE NUMERICAL MEASURE OF ITS RELATIVEACIDITY OR ALKALINITY. THE RANGE IS FROM 0 - 14WITH A NEUTRAL LEVEL EXPRESSED AS A pH OF 7.0.
pH ABOVE 7.0 - MORE ALKALINE OR BASIC.
pH BELOW 7.0 - MORE ACIDIC.
GAS - SLIDE 40 OF 72© Copyright Compliware 1999
ContinuedSPECIFIC TYPES OF GASES
CHECK FOR COMPATIBILITY!
HIGH pHBASEACIDLOW pH
GAS - SLIDE 41 OF 72© Copyright Compliware 1999
ACID & ALKALINE GASES:
Continued
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.
SPECIFIC TYPES OF GASES
GAS - SLIDE 42 OF 72© Copyright Compliware 1999
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:
SPECIFIC TYPES OF GASES
Continued
- Boron Trichloride - Bromine Trifluoride- Chlorine Trifluoride - Hydrogen Fluoride- Iodine Pentafluoride - Silicon Tetrafluoride- Sulfur Tetrafluoride - Tungsten Hexafluoride
GAS - SLIDE 43 OF 72© Copyright Compliware 1999
HIGHLY TOXIC GASES:
ContinuedSPECIFIC TYPES OF GASES
Medical services should be pre-planned. Suppliers/manufacturers should be consulted. Emergency responders should consulted. Common highly toxic gases include:
- Arsine - Boron Trichloride- Bromine Trifluoride - Bromine Pentafluoride- Chlorine - Fluorine- Germane - Hydrogen Cyanide- Hydrogen Selenide - Hydrogen Sulfide- Nitric Oxide - Phosgene
Continued
GAS - SLIDE 44 OF 72© Copyright Compliware 1999
CRYOGENIC LIQUEFIED GASES:
ContinuedSPECIFIC TYPES OF GASES
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.
GAS - SLIDE 45 OF 72© Copyright Compliware 1999
CRYOGENIC LIQUEFIED GASES:
ContinuedSPECIFIC TYPES OF GASES
Continued
OxygenRate of Expansion
- 238F
875 ft3
+65F1ft3
GAS - SLIDE 46 OF 72© Copyright Compliware 1999
ContinuedSPECIFIC TYPES OF GASES
Continued
LOX
Use only hardware designed for cryogenics. Pain is not immediate. Tissue solidifies over time. Blood circulation is arrested. Serious skin burns may result. Blood clots are highly probable. Skin highly vulnerable to infection. Flush with tepid water.
CRYOGENIC LIQUEFIED GASES:
GAS - SLIDE 47 OF 72© Copyright Compliware 1999
ContinuedSPECIFIC TYPES OF 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:
INERT GASES:
- Argon - Carbon Dioxide- Helium - Neon- Nitrogen - Xenon
GAS - SLIDE 48 OF 72© Copyright Compliware 1999
GENERAL SAFETY CONSIDERATIONS
ContinuedSPECIFIC TYPES OF GASES
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!
GAS - SLIDE 49 OF 72© Copyright Compliware 1999
WORK AT WORKING SAFELY
Training is the key to success in managing safety in the work environment. Attitude is also a key factor in maintaining a safe workplace. Safety is, and always will be a team effort, safety starts with each individual employee and concludes with everyone leaving at the end of the day to rejoin their families.