Health, Safety and Environmental Policy s7

June Origination Date: October 7, 2011 Revision Date: 2012 Release Authorized by: Danny Trahan, Safety Director Manual Rev 4

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 Whip Check...... 2 2.0 PRESSURIZED/COMPRESSED AIR EQUIPMENT...... 3 2.1 Inspections...... 3 2.2 Cleaning...... 3 3.0 Compressed gas cylinders...... 4 3.1 Procurement Specifications and Limits...... 4 3.2 Transporting and Moving Cylinders...... 4 3.3 Placing Cylinders...... 5 3.4 Storing Cylinders...... 5 3.5 Using Cylinders...... 6 3.6 Refilling Gas Cylinders...... 8 4.0 MANIFOLDS...... 8 5.0 REFERENCES...... 9

Copyright © 2012, P2S. All Rights Reserved. P2S Health, Safety & Environmental Page 1 June Origination Date: October 7, 2011 Revision Date: 2012 Release Authorized by: Danny Trahan, Safety Director Manual Rev 4

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

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-/pressure- relief 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.

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.

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.

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.

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.

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.

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