Handling High Pressure Cylinders

7/29/2019 Handling High Pressure Cylinders

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HANDLING HIGH

PRESSURE CYLINDERS


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Sources

T. Joiner (ed.). 2001. NOAA DivingManual - Diving for Science andTechnology, Fourth Edition. BestPublishing Company, Flagstaff, Arizona.

Bill High, notes from PSI CylinderInspection Course

US Code of Federal Regulations Title 49:172.700


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Goal of This Training

To increase your safety and the safety ofthose around you by familiarizing youwith the policies and proper proceduresfor handling and filling cylinderscontaining high pressure gas


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Objectives

After completing this training module youwill be able to:

Identify the regulating bodies regulatinghazardous materials training for handlinghigh pressure cylinders and explain theregulations as they pertain to scientific diving

Define a high pressure cylinder as it relates todiving


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Objectives

After completing this training module youwill be able to:

Identify and explain cylinder markings forsteel and aluminum scuba cylinders

List 25 safe handling procedures for highpressure cylinders

Define the parts of a fill station and listprocedures for filling high pressure cylinderscommon to all fill stations


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Regulation

In the US: The Department of Transportation (DOT)

regulates transport of high pressure cylinders

The Department of Labor, OccupationalSafety and Health Administration (OSHA)regulates safety in the workplace


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Regulation

The Code of Federal Regulations (CFRTitle 49: 172.700) mandates employees ofcompanies involved in commerce who

handle compressed gas cylinders toreceive appropriate safety training.

A new hire should receive this training within

90 days of hiring Training should be repeated every three years


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Regulation

Discussions with US DOT havedetermined that most organizationsinvolved in scientific diving are not

involved in commerce and are exemptfrom the three year retraining updates

Local regulations or standards may re-

impose this requirement


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Regulation

AAUS and NOAA scientific divingstandards require all scientific divers toreceive hazardous materials training for

handling high pressure cylinders


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High Pressure Cylinders

The capacity of a cylinder is the amount ofgas at surface pressure that can becompressed into the cylinder at its rated

pressure This capacity is usually expressed in standard

cubic feet or standard liters of gas

Cylinders with capacities from 26 standard cubicfeet to over 100 standard cubic feet are used inscuba diving


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High Pressure Cylinders

Scuba cylinders are generally made ofsteel or aluminum

Cylinders used in diving fill to workingpressures ranging from 1,800 to 3,500 psi(124 to 241 bar) or greater


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Cylinder Markings

Data describing the cylinder must beclearly stamped on the shoulder of thecylinder

Image courtesy Best Publishing


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Cylinder Markings

The precise manufacturing specificationsof cylinders have been dictated by:

The Interstate Commerce Commission (ICC)

until 1970

The Department of Transportation (DOT)after 1970

The TC/DOT (Transport Canada and DOT)most recently dictates specifications foraluminum cylinders


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Steel Cylinder Markings



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Steel Cylinder Markings

DOT (Department of Transportation may also read ICC if cylinder predates1970)

3AA (indicates steel construction) Service pressure

Serial number

Cylinder manufacturers symbol Hydrostatic test date


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Aluminum Cylinder Markings



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Aluminum Cylinder Markings

DOT (or ICC)

3AL (indicates aluminum construction)

Service pressure Serial number

Service volume

Manufacturer Hydrostatic test date


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Safe Handling Procedures

Treat all cylinders designed to hold highpressure gas with respect

Do not drop cylinders


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Wear shoes when working aroundcylinders

Have a clear path to avoid tripping orknocking over cylinders or otherequipment


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Cylinders are heavy and awkward; useproper lifting techniques and dollies tominimize the risk of personal injury


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Handle charged cylinders carefully handling by the valve or body is preferred handling by straps or backpack may allow the

cylinder to slip or drop

Cylinders should be stored attemperatures not to exceed 130o F (54 C)


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Store charged cylinders in an uprightposition in a cool shady place and awayfrom flammable materials

Secure cylinders properly to preventfalling or rolling

PhotocourtesySteveSe

llers


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While in transit, cylinders should besecured from rolling Preferably in a rack in the upright position

PhotocourtesySteve

Sellers


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Open cylinder valves slowly

Do not put your body in the gas stream

High pressure can force gas through the skinand into the body; bubbles in the circulatorysystem could result in an embolism

Injuries of this nature are not uncommon, so

please keep out of harms way


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Cylinders that appear to be damaged byfire or physical abuse should be removedfrom service


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Scuba cylinders should receive a visualinspection by a qualified inspectorannually

A cylinder with signs of damage or thathas been totally emptied, should receive avisual inspection before being put back in

service


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Internal inspections, hydrostatic tests, andrepair work should be performed only bytrained technicians

ImagecourtesyPSI


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Remove cylinder boot frequently toinspect for corrosion Boots that inhibit rapid draining and drying

should not be used because they allow waterto remain in contact with the cylinder,forming corrosion


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A cylinder that has been condemnedduring the visual inspection or hydrostatictesting process may never be returned to

service Condemned cylinders should be made

unserviceable (i.e. cut in two, hole drilled

in the wall, threads destroyed, etc)


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Do not use any cylinder that:

Is aluminum and has a rounded bottom

Have the manufacturing codes SP6576,

SP6688, or SP890 stamped into the cylinder

Have large dents, bulges, or lines of corrosion

Do not have a proper pressure relief device

(burst disc)


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Do not use any cylinder that:

Have manufacturing codes SP6498, E6498,SP7042, or E7042 stamped into the cylinder

unless the cylinder is also stamped with thecode 3AL

These were special aluminum alloys that weregiven the 3AL rating at a later date


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Do not totally empty a cylinder withoutcause

Always try to leave 300 to 500 psi in the

cylinder Empty cylinders should be internally visually

inspected by a trained technician prior to re-

filling


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Regulators or gauges may fail when acylinder valve is opened it is importantto stand to the side rather than in the line

of discharge to avoid the blast effect incase of failure

Photos courtesy Dave Pence


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Do not look directly at the face of anypressure gauge when turning on thecylinder because of the possibility of a

blowout

PhotocourtesySteveSellers


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Fill Stations andFilling Cylinders

Diving cylinders and associated highpressure equipment are manufactured andtested to standards in order to ensure a

high degree of safety when they areproperly used and maintained


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Manufacturingstandards andmaintenance

requirements do noteliminate thepossibility of acatastrophic failure

that could result inserious injury ordeath

Photocourtesywww.sealance

rs.org

ll d


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An 80 cubic foot cylinder filled to 3000 psi(207 bar) has in excess of one millionpounds of kinetic energy; sufficient power

to blow apart brick walls or destroyvehicles

Photo courtesy connected.bc.ca/~baquatics/index.htm

ill i d


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90% of all cylinderexplosions occurduring the filling

process Operator error has

been linked to

many of theseincidents

P

hotocourtesywww.sealance

rs.org

Fill S i d


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Properly trained and attentive operatorsreduce their risk of being involved in acatastrophic incident

Be familiar with the equipment you areworking with and follow inspectionrequirements and safe operating

procedures

Fill S i d


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A fill station consists of a source of highpressure gas, high pressure lines calledwhips that connect the gas source to the

cylinders being filled, and valves andgauges to control and monitor the fillingprocess

Fill S i d


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Fill stations come in a wide variety ofconfigurations, the specifics of operating agiven system are beyond the scope of this

presentation and require additionaltraining

Fill S i d


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Compressor basics:

High pressure compressors capable ofproducing breathing grade gas intake air,

compress the air through a series of stages toincrease the pressure, and filter the gas toremove impurities and excess moisture

Photos courtesy Bauerair.com

Fill St ti d


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Compressor basics:

Each compressor has its own operational andmaintenance requirements, but items common

to all units include: Checking oil levels prior to startup

Monitoring compressor hours and filter life

Monitoring the compressor intake to assure a

proper air source, and monitoring stage pressures

Keeping a log of regular maintenance andadhering to a maintenance schedule

Fill St ti d


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Storage banks take two forms:

A series of cylinders connected by manifold toproduce a desired storage capacity

Or a single large storage cylinder such as arecycled submarine ballast tank

Cylinders connected by manifold have theadvantage of allowing cascade filling

A single large storage cylinder can offer theadvantage of not requiring periodic hydrostatictesting

Fill St ti d


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Storage banks have specific pressurelimitations and are secured to preventthem from falling

Banked pressures of 4,500 psi (310 bar) arecommon

PhotocourtesySteveSelle

rs

Fill St ti d


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Cascade filling involves equalizing thepressure in the cylinder being filled withthe pressure in a single cylinder in a series

of storage cylinders, moving to the nextcylinder in the series and repeating theprocess until the desired pressure is

reached Cascade filling is the most economical use

of banked gas

Fill St ti d


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Fill station valves can be of a metering orball valve design

A metering valve provides for slow and

controlled pressure adjustments A ball valve is either open or closed

PhotoscourtesyGlobalMfg.Corp.

Metering Valve Ball Valve

Fill St ti d


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Caution should be taken when using fillpanels employing ball valves, a rapidpressure spike can increase the risk of a

fire in the presence of gases with highoxygen content


Fill St ti d


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High pressure lines:

Pipes and hoses that carry high pressure gasshould be secured approximately every two

feet and regularly inspected

PhotocourtesySt

eveSellers

Fill St ti d


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Gauges:

Gauges that are used on the fill whips andyokes are not calibrated or tested

Gauges in the fill panel are tested and

calibrated

PhotoscourtesySteveSellers

Fill St ti d


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The Fill Station Operator has theresponsibility to reject cylinders that donot meet standards

P

hotocourtesySteveSellers

Fill St ti d


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Before filling a cylinder:

Verify it has valid ICC or DOT stampings

Check for a current Hydrostatic Test Stamp

Hydrostatic testing must be done every five years

Photos courtesy Steve Sellers

Fill Stations and


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Verify a current visual inspection sticker

Verify it has a valve with a pressure reliefdevice

Check that there is air/gas in the cylinder


Fill Stations and


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Check the rated pressure of the cylinder

Verify it has a valve O-Ring (yoke stylevalves)


Fill Stations and


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Determine if the cylinder has a yoke or DINvalve and that the fill station has the

necessary adaptors to allow for filling


Fill Stations and


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Check the pressure in the cylinder and itscontents (air, nitrox, etc.)

Cylinders containing gas mixtures other than airshould not be allowed to equalize pressurethrough the fill whips with cylinders notcontaining the same gas; doing so modifies gas

mixtures in all the cylinders and couldcompromise the safety of unsuspecting diversusing them

Fill Stations and


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Verify the general condition of the cylinder

On steel cylinders, strike the cylinder with a blunt

object; it should sound like a bell, if not, dont fill it No visual signs of dents, bulges, scrapes, or line

corrosion

Verify the fill setting on the fill panel

regulator (if present)

Ph

otocourtesySteveSellers

Fill Stations and


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Do not fill high-pressure cylinders if thedate of the last hydrostatic test has expired(five years for steel and aluminumcylinders) or if more than one year haspassed since the last formal visualinspection


Fill Stations and


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Reject cylinders with the followingmarkings or conditions:

SP6576

SP6688, SP890

SP6498, E6498, SP7042, E7042

All round bottom aluminum cylinders

Steel, non-galvanized, vinyl coated cylinders

Fill Stations and


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Only individuals trained in the handlingand filling of high pressure cylindersshould be in the room when cylinders are

being filled Maintain an organized fill area, keep a

clear path in and out and secure cylinders

after filling

Fill Stations and


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Preparing to fill: Open cylinder valve to blow out dust/water

Attach the fill whip to the valve

Close the whip bleed valve and open thecylinder valve

If filling multiple cylinders containing the samegas, open all cylinder valves and equalize the

pressure between cylinders Open the fill whip valve

Open supply valve


Fill Stations and


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Charge cylinders at 300-600 psig/min (20-41 bar/min) to prevent excessive heatbuildup

Never exceed the maximum allowablepressure for any particular cylinder

Never perform maintenance or repairs ona cylinder valve while the cylinder is

charged


Fill Stations and


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A 3000 psi (207 bar) cylinder should take 5to 10 minutes to fill

Aluminum alloy cylinders should never

be filled in excess of marked servicepressure, and steel cylinders without aplus (+) after the current hydrostatic test

date should also not be filled over theirmarked service pressure

Fill Stations and


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Assure any cylinders filled are properlylabeled with appropriate contents labelsand that any logs have been filled out as

required by local procedures or standards

Fill Stations and


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When the filling process is complete, bleedexcess pressure from the fill whips, closeall valves, shut off power to the

compressor, and secure the fill station perlocal procedures

Fill Stations and


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To help ensure safety during the fillingprocess, considered the following: Placing the fill station away from work areas

Consulting with an engineer beforeconstructing a cylinder explosion diversiondevice

Configuring controls away from the cylinder

fill area

Fill Stations and


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Safety considerations continued: Secure high-pressure hoses and fittings at

close intervals

Locate the fill station away from criticalbuilding structural support and walls;provide a physical barrier between fill stationoperator and cylinders during filling

Use an energy deflector to send explosiveforce in a safe direction

Fill Stations and


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Safety considerations continued:

Regularly inspect compressor filters andpiping

Allow only trained, authorized persons towork at the fill station

Post operating procedures and safety

instructions Proper labeling of all valves, gauges, etc


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Study Questions

Use the following study questions toreview some of the information presentedin this self study module. When you are

finished you can print out your studyquestions results.


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Self Study Questions

_____ require all scientific divers to receivehazardous materials training for handlinghigh pressure cylinders.

AAUS and NOAA scientific divingstandards

CFR Title 29: 1910 Sub Part T

OSHA

Individual State's Department ofTransportation


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_____ require all scientific divers to receivehazardous materials training for handlinghigh pressure cylinders.

AAUS and NOAA scientific divingstandards

CFR Title 29: 1910 Sub Part T

OSHA Individual State's Department of

Transportation


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DOT regulations found in 49 CFR 172.700mandate training requirements foremployees of companies involved in

commerce who handle compressed gascylinders.

A. True

B. False


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DOT regulations found in 49 CFR 172.700mandate training requirements foremployees of companies involved in

commerce who handle compressed gascylinders.

A. True

B. False


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The codes 3AA 2250 PST 4~08+stamped into the neck of a cylinderindicate:

This is a steel cylinder with a rated working pressure of 2250 psi,

manufactured by Pressed Steel, hydrostatically tested in April of2008, and capable of being over filled by 10%.

This is an aluminum cylinder with a rated working pressure of 2250psi, manufactured by Pacific Scuba Tanks, hydrostatically tested inApril of 2008, and capable of being over filled by 10%.

The serial number of the cylinder. This is a steel cylinder with a rated working pressure of 2250 psi,

manufactured by Pressed Steel; last visually inspected in April of2008, and capable of being over filled by 10%.

lf d


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The codes 3AA 2250 PST 4~08+stamped into the neck of a cylinderindicate:

This is a steel cylinder with a rated working pressure of 2250 psi,

manufactured by Pressed Steel, hydrostatically tested in April of2008, and capable of being over filled by 10%.

This is an aluminum cylinder with a rated working pressure of 2250psi, manufactured by Pacific Scuba Tanks, hydrostatically tested inApril of 2008, and capable of being over filled by 10%.

The serial number of the cylinder. This is a steel cylinder with a rated working pressure of 2250 psi,

manufactured by Pressed Steel; last visually inspected in April of2008, and capable of being over filled by 10%.

lf d


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It is June 2008; a fill station operator conducting a pre-fillingsurvey of a cylinder finds the hydrostatic test dates of 2 98+and 10 04. The cylinder has a current VIP sticker, all otherrequired markings, and shows no signs of dents, bulges,scrapes or line corrosion. The fill station operator:

can fill the cylinder, but only to the rated working pressuresince the current hydrostatic test mark does not have a +.

should not fill the cylinder because the current hydrostatictest mark does not have a +.

should not fill the cylinder because the current hydrostatictest has passed the five year limit for the test.

can fill the cylinder to a pressure 10% greater than thecylinder's rated working pressure because of the presence ofthe + on the cylinder.

S lf S d Q i


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It is June 2008; a fill station operator conducting a pre-fillingsurvey of a cylinder finds the hydrostatic test dates of 2 98+and 10 04. The cylinder has a current VIP sticker, all otherrequired markings, and shows no signs of dents, bulges,scrapes or line corrosion. The fill station operator:

can fill the cylinder, but only to the rated working pressuresince the current hydrostatic test mark does not have a +.

should not fill the cylinder because the current hydrostatictest mark does not have a +.

should not fill the cylinder because the current hydrostatictest has passed the five year limit for the test.

can fill the cylinder to a pressure 10% greater than thecylinder's rated working pressure because of the presence ofthe + on the cylinder.

S lf S d Q i


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It is November 2008; a fill station operator conducting a pre-fillingsurvey of a cylinder finds the hydrostatic test dates of 2 97 and 1003. The cylinder has a VIP sticker dated 10/07. It has the stamp3AL, along with all other required markings, and shows no signsof dents, bulges, scrapes or line corrosion. (Select all that apply)

The cylinder is "out of hydro"; it has been longer than five yearssince the last hydrostatic test.

This cylinder is within its second hydrostatic test period.

The cylinder does not have a current VIP.

This is a steel cylinder.

This is an aluminum cylinder. The cylinder has a current VIP.

The fill station operator should fill this cylinder.

The fill station operator should not fill this cylinder.

S lf S d Q i


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It is November 2008; a fill station operator conducting a pre-fillingsurvey of a cylinder finds the hydrostatic test dates of 2 97 and 1003. The cylinder has a VIP sticker dated 10/07. It has the stamp3AL, along with all other required markings, and shows no signsof dents, bulges, scrapes or line corrosion. (Select all that apply)

The cylinder is "out of hydro"; it has been longer than five yearssince the last hydrostatic test.

This cylinder is within its second hydrostatic test period.

The cylinder does not have a current VIP.

This is a steel cylinder.

This is an aluminum cylinder.

The cylinder has a current VIP.

The fill station operator should fill this cylinder.

The fill station operator should not fill this cylinder.



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Self Study QuestionsSafe handling procedures for high pressure

cylinders include: (select all that apply) Wear shoes when working around cylinders. Store charged cylinders in an upright position in a cool shady

place and away from flammable materials. Handling cylinders by straps or backpack is preferred to

handling cylinders by the valve. Cylinders that appear to be damaged by fire or physical abuse

should be removed from service. Scuba cylinders should receive a visual inspection by a

qualified inspector annually.

Internal inspections, hydrostatic tests, and repair work shouldbe performed only by trained technicians. A cylinder that has been condemned during the visual

inspection or hydrostatic testing process may be returned toservice after repairs have been completed.



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Self Study QuestionsSafe handling procedures for high pressure

cylinders include: (select all that apply) Wear shoes when working around cylinders. Store charged cylinders in an upright position in a cool shady

place and away from flammable materials. Handling cylinders by straps or backpack is preferred to

handling cylinders by the valve. Cylinders that appear to be damaged by fire or physical abuse

should be removed from service. Scuba cylinders should receive a visual inspection by a

qualified inspector annually.

Internal inspections, hydrostatic tests, and repair work shouldbe performed only by trained technicians. A cylinder that has been condemned during the visual

inspection or hydrostatic testing process may be returned toservice after repairs have been completed.

S lf St d Q ti


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_____ is the most economical use of bankedgas.

Cascade filling

Single bank filling

Filling directly from the compressor

The use of high pressure scuba cylinders

S lf St d Q ti


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_____ is the most economical use of bankedgas.

Cascade filling

Single bank filling

Filling directly from the compressor

The use of high pressure scuba cylinders

S lf St d Q ti


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Select all that apply to the valve picturedhere:

This is an example

of a Ball valve

This is an exampleof a Metering valve

This valve provides for slow

and controlled pressure adjustments

This valve is either open orclosed providing no means

of pressure adjustments

S lf St d Q ti


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Select all that apply to the valve picturedhere:

This is an example

of a Ball valve

This is an exampleof a Metering valve

This valve provides for slow

and controlled pressure adjustments

This valve is either open orclosed providing no means

of pressure adjustments

S lf St d Q ti


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Match the item with its counterpart:A. Cascade fillingB. A ball valveC. A metering valveD. 4,500 psiE. Allows for cascade fillingF. A single large storage cylinder such as a recycled submarine ballast tank

G. 300-600 psi or 20-41 barH. 5 to 10 minutesI. About 30 minutes Equalizing the pressure in the cylinder being filled with the pressure in a single cylinder in

a series of storage cylinders, moving to the next cylinder in the series and repeating theprocess until the desired pressure is reached.

Is either open or closed.

Provides for slow and controlled pressure adjustments. 310 bar A series of storage cylinders connected by manifold to produce a desired storage capacity. Can offer the advantage of not requiring periodic hydrostatic testing. The rate per minute for filling cylinders. The amount of time it should take to properly fill a 3000 psi (207 bar) cylinder. The amount of time it will take someone with a surface air consumption of 20 psi/minute

to breathe 2500 psi from a scuba cylinder while diving in 99 feet of seawater.

S lf St d Q ti


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Select all of the items listed that the fill stationoperator should do before filling a cylinder:

Verify the cylinder has valid ICC or DOT stampings Check for a current Hydrostatic Test Stamp Verify a current visual inspection sticker (within the past year)

Verify the cylinder has a valve with a pressure relief device Check that there is air/gas in the cylinder Check the rated pressure of the cylinder Check the pressure in the cylinder and its contents (air, nitrox, etc.) Verify the general condition of the cylinder

Open the bleed valve on the fill whip Close the cylinder valve



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Select all of the items listed that the fill stationoperator should do before filling a cylinder:

Verify the cylinder has valid ICC or DOT stampings Check for a current Hydrostatic Test Stamp Verify a current visual inspection sticker (within the past year)

Verify the cylinder has a valve with a pressure relief device Check that there is air/gas in the cylinder Check the rated pressure of the cylinder Check the pressure in the cylinder and its contents (air, nitrox, etc.) Verify the general condition of the cylinder

Open the bleed valve on the fill whip Close the cylinder valve



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Putting part of your body in the air streamof an open high pressure cylinder valvecan lead to embolism.

A.True

B.False



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Putting part of your body in the air streamof an open high pressure cylinder valvecan lead to embolism.

A.True

B.False



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Preferably, cylinders should be transportedand stored in a secure, upright position.

A.True

B.False



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Preferably, cylinders should be transportedand stored in a secure, upright position.

A.True

B.False



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Caution should be taken when using fill panelsemploying _____ valves, a rapid pressurespike can increase the risk of a fire in thepresence of gases with high oxygen content.

metering

ball J K yoke DIN



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Caution should be taken when using fill panelsemploying _____ valves, a rapid pressurespike can increase the risk of a fire in thepresence of gases with high oxygen content.

metering

ball J K yoke DIN



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Fill Station Operator has the responsibilityto reject cylinders that do not meetstandards.

A.True

B.False



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Fill Station Operator has the responsibilityto reject cylinders that do not meetstandards.

A.True

B.False



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Only individuals _____ in the handling andfilling of high pressure cylinders shouldbe in the room when cylinders are being

filled. trained

interested

participating tasked



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Only individuals _____ in the handling andfilling of high pressure cylinders shouldbe in the room when cylinders are being

filled. trained

interested

participating tasked

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Handling High Pressure Cylinders

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