HAZARDOUS MATERIALS TRAINING FOR HIGH PRESSURE CYLINDERS

1. HAZARDOUS MATERIALS TRAINING FOR HIGH PRESSURE CYLINDERS Handling Filling Compressor Operation

2. Goal of This Training • To increase your safety and the safety of those around you by familiarizing you with the policies and proper procedures for handling and filling cylinders containing high pressure gas,

3. 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

4. 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, CTC, OR ICC MUST APPEAR ON THE CYLINDER. • STEEL - DOT 3AA 2250 12345B PST 7C 89 +

5. ALUMINUM CYLINDERCODE • DOT 3AL 3000 • P123456 LUXFER 06 A 00 S80

6. THE US DEPT. OF LABOR, OCCUPATIONAL SAFETY HEALTH ADMINISTRATION (OSHA) REGULATES SAFETY IN THE WORK PLACE

7. 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

8. EACH YEAR, SEVERAL DIVING CYLINDERS EXPLODE RESULTING IN INJURIES AND DEATHS. • Often the circumstances are hidden or the incident is exploded on the internet.

9. 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.

10. 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

11. SAFE HANDLING PROCEDURES. • Simple, but important actions

12. DO NOT DROP CYLINDERS. • Treat with respect

13. SECURE CYLINDERS DURING STORAGE AND TRANSPORT. • Do not let them roll around in the back of your vehicle or boat.

14. CYLINDERS ARE HEAVY AND AWKWARD, USE PROPER LIFTING TECHNIQUES. • Wear shoes • Have a clear path

15. 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.

16. CYLINDERS SHOULD BE STORED IN TEMPERATURES NOT EXCEEDING 130 F. • The cylinder burst disks may open due to increased pressure.

17. 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.

18. 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.

19. 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

20. ALL DIVING CYLINDERS SHOULD RECEIVE VISUALL 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.

21. 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.

22. DO NOT USE ANY DIVING CYLINDER:THAT IS AL & HAS A ROUNDED BOTTOMWITH THE CODES: SP6576, SP6688, SP890, CYLINDERS WITH LARGE DENTS, BULGES, LINE CORROSIONWITH VALVES THAT DO NOT HAVE PRESSURE RELIEF DEVICES.

23. DO NOT USE CYLINDERS THAT HAVE THE FOLLOWING CODES UNLESS THEY ARE ALSO STAMPED WITH 3AL CODE: SP6498, E6498, SP7042, E7042 • These were special alloys that were given the 3AL rating at a later date.

24. 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.

25. FILL STATION AND COMPRESSOR OPERATORS • The Fill Station Operator has the responsibility to reject cylinders that do not meet standards.

26. INSPECTION OF A 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.

27. 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.

28. REJECTINGA CYLINDER THATWAS RECALLED REJECT THE FOLLOWING CYLINDERS • SP6576 • SP6688, SP890 • SP6498, E6498, SP7042, E7042 • All round bottom aluminum cylinders • Steel, non-galvanized, vinyl coated.

29. 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

30. 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.

31. SETTING UP FOR FILLING • Open cylinder valve to blow out dust/water • Attach the fill whip to the valve • Close the whip bleed valve • Open cylinder valve and check the pressure in the cylinder • Open the fill whip valve • Open supply valve (cascade system)

32. VALVE TYPES • Metering Valve, provides for slow and controlled pressure adjustments • Ball Valve, rapid turn on and turn off (Use Caution when opening)

33. 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

34. 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

35. 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.

36. CYLINDER STORAGE • Vertically and secured to a wall with a chain • Below 130 F • Away from flammable materials

37. CASCADE OR BANK STORAGE CYLINDERS • Large, storage units with a valve on the top • Filled to 4,500 psig • Interconnected with stainless steel plumbing • Secured in a metal frame

38. CASCADE FILLING PROCEDURES • Cascade filling is the most economical use of banked gas. • To fill from a bank, the pressure in the bank must be higher than the cylinder being filled. • Start filling from the bank containing the lowest pressure in excess of the pressure in the cylinder being filled. • After the pressure equalizes, close the bank and open the next highest bank in the chain. Continue in this mode until the cylinder working pressure is reached.

39. SUMMARY • Handle HP Cylinders with care • Perform an inspection of all cylinders before filling • Do not overfill cylinders • Inspect fill station and compressor prior to use

40. Safety Strategy WORK SMART BE CAREFUL SAFETY FIRST