WELCOME

1. COMPRESSED GAS SAFETY CORPORATE SAFETY TRAINING OSHA 29 CFR 1910.101 WELCOME

2. 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.

3. 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

4. COURSE ATTENDEES • Gas Users • Safety Committees • Purchasing Agents • Department Managers • First Line Supervisors • Maintenance Managers • Shipping and Receiving Employees • Accident Investigation Team Members

5. 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

6. APPLICABLE REGULATIONS 29CFR - SAFETY AND HEALTH STANDARDS 1910 - INDUSTRIAL SAFETY 101 - COMPRESSED GASES (GENERAL)

7. DANGER COMPRESSED GAS STORAGE AREA CONSENSUS STANDARDS COMPRESSED GAS ASSOCIATION CGA P-1 - SAFE HANDLING OF COMPRESSED GASES - Over 100 Other CGA Safety Manuals

8. GENERAL PROGRAM REQUIREMENTS ALL EMPLOYERS MUST: • 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

9. TRAINING REQUIREMENTS THE EMPLOYER MUST PROVIDE TRAINING: • 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.

10. RETRAINING REQUIREMENTS • 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.

11. Reduce injury and illness rates. Acceptance of high-turnover jobs. Workers feel better about their work. Reduce workers’ compensation costs. Elevate OSHA compliance to a higher level. TRAINING IS IMPORTANT A GOOD PROGRAM WILL HELP:

12. DEDICATION PERSONAL INTEREST MANAGEMENT COMMITMENT PROGRAM IMPLEMENTATION IMPLEMENTATION OF A COMPRESSED GAS SAFETY PROGRAM REQUIRES: NOTE: UNDERSTANDING AND SUPPORT FROM THE WORK FORCE IS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!

13. Establish responsibility. Conduct employee training. Periodically review the program. 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. DANGER COMPRESSED GAS STORAGE AREA PROGRAM IMPLEMENTATION Continued DEVELOPMENT SEQUENCE:

14. RECOGNITION IMPLEMENTATION STRATEGY • EVALUATION • IMPLEMENTATION • CONTROL

15. 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. IMPLEMENTATION STRATEGY Continued • RECOGNITION

16. RECOGNITION IMPLEMENTATION STRATEGY Continued • EVALUATION • IMPLEMENTATION • CONTROL

17. EVALUATION 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. IMPLEMENTATION STRATEGY Continued

18. RECOGNITION IMPLEMENTATION STRATEGY Continued • EVALUATION • IMPLEMENTATION • CONTROL

19. IMPLEMENTATION Written program. Training program. Employee involvement. Supervisor involvement. Corrective action program. Job hazard analysis program. Safety in purchasing (new gases, substitutes etc.) IMPLEMENTATION STRATEGY Continued

20. RECOGNITION IMPLEMENTATION STRATEGY Continued • EVALUATION • IMPLEMENTATION • CONTROL

21. CONTROL 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. IMPLEMENTATION STRATEGY Continued

22. CONTROL MEASURES CONSIDERATIONS: 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. IMPLEMENTATION STRATEGY Continued

23. PRIORITIZATION CONSIDERATIONS: 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. IMPLEMENTATION STRATEGY Continued

24. CONSIDER THE FOLLOWING: THE SUPERVISOR’S ROLE • 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.

25. PRINCIPAL HAZARDS: COMPRESSED GAS HAZARDS • Extremely High Pressure. • Toxicity. • Reactivity. • Instability. • Flammability. • Extreme Low Temperature. • Asphyxiation. • Radioactivity.

26. WHEN THINGS GO WRONG: COMPRESSED GAS HAZARDS Continued • 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.

27. THE TYPICAL COMPRESSED GAS CYLINDER: COMPRESSED GAS HAZARDS Continued • 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.

28. BASIC SAFETY RULES I’LL GET THE RUST OFF OF THIS THING ONE WAY OR ANOTHER! KIDS DON’T TRY THIS AT HOME!

29. THE BIG THREE: BASIC SAFETY RULES 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.

30. FILLING OF CYLINDERS: BASIC SAFETY RULES 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.

31. CONTENT IDENTIFICATION: BASIC SAFETY RULES 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. • Nonlegible/missing labels must be reported.

32. CONTENT IDENTIFICATION: BASIC SAFETY RULES Continued 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.

33. PAINTING CONTAINERS: BASIC SAFETY RULES 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.

34. LEAKING AND DEFECTIVE CYLINDERS: BASIC SAFETY RULES 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.

35. CYLINDER USAGE REQUIREMENTS: BASIC SAFETY RULES 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.

36. MOVEMENT OF COMPRESSED GAS CYLINDERS: BASIC SAFETY RULES 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.

37. STORAGE REQUIREMENTS (GENERAL): BASIC SAFETY RULES 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.

38. STORAGE ROOMS (GENERAL): BASIC SAFETY RULES Continued • 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.

39. STORAGE ROOMS (GENERAL): BASIC SAFETY RULES Continued • Cylinders • - Must not impede emergency egress. • - Cannot be located near exits. • - Cannot be located near stairs. • Must be secured to prevent toppling.

40. OUTDOOR STORAGE (GENERAL): BASIC SAFETY RULES 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.

41. ACETYLENE DANGER NO SMOKING NO FUMAR 4 3 1 GAS INSPECTION CHECKLIST BASIC SAFETY RULES Continued • NAME • PRECAUTIONS • RESTRAINED ABOVE • MIDPOINT • EMERGENCY & USE • PROCEDURES • AWAY FROM • COMBUSTIBLES

42. GENERAL INSPECTION CRITERIA: BASIC SAFETY RULES Continued INSPECT FOR: POSSIBLE RESULT: Dents Weakening of cylinder wall Crevice Corrosion Weakening of cylinder wall Bulges Weakening of cylinder wall ARC/ Torch Burns Weakening of cylinder wall Cuts, Gouges or Digs Decrease in wall thickness Corrosion Decrease in wall thickness Pitting Decrease in wall thickness Neck Defects Leak or cylinder explosion Valve Ease-Of-Movement Corrosion leading to leak Valve Thread Serviceability Leak during operation

43. PRE-OPERATION SAFETY RULES: BASIC SAFETY RULES Continued • 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.

44. POST-OPERATION SAFETY RULES: BASIC SAFETY RULES Continued • 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.

45. 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. STORAGE RULES

46. USE OLDEST STOCK FIRST! DANGER FULL CYLINDERS NO SMOKING! ACETYLENE DANGER GAS STORAGE CHECKLIST COMPRESSED GAS STORAGE AREA 4 3 1 STORAGE RULES Continued

47. FULL CYLINDER STORAGE RULES: 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.

48. FULL CYLINDER STORAGE RULES: STORAGE RULES Continued 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.

49. EMPTY CYLINDER STORAGE RULES: 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.

50. EMPTY CYLINDER STORAGE RULES: STORAGE RULES Continued 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.