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Handling and Storage of Gas Cylinders Guide

All guides are intended to give further details to information contained in a particular piece of legislation, policy, code, agreement or procedure and must therefore be read in conjunction with them.

INTRODUCTION

To meet the requirements of the NT Workplace Health & Safety (National Uniform Legislation) Act 2011 and Regulations and the CDU Work Health & Safety (WHS) Policy, CDU has produced this Handling and Storage of Gas Cylinders Guide.

PURPOSE

This document is an advisory text which sets out a general guide for the safe handling and storage of gas cylinders. Gas cylinders are used in many University work areas and the following recommended methods of handling, storage and transport will ensure the safety of workers, students and visitors.

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 1 of 9 Abbreviations AS/NZS Australian/New Zealand Standard CDU Charles Darwin University LPG Liquefied Petroleum Gas NUL National Uniform Legislation PCBU Persons Conducting a Business or Undertaking PPE Personal Protective Equipment SDS Safety Data Sheet WHS Work Health and Safety

Relevant Definitions

In the context of this document:

Chemical is defined as any element, chemical compound or mixture of elements and/or compounds where chemical(s) are distributed. Chemicals may be in solid, liquid, gas or plasma.

Competent person means a person who has acquired through training, qualification or experience the knowledge and skills to carry out the task.

Flashback Arrester is a safety device designed to stop a flashback (flame re-entering the mixing chamber) and is for use on equipment where fuel gas and oxygen/compressed air are being used in combination.

Hazard means a situation or thing that has the potential to harm a person. Hazards at work may include: noisy machinery, a moving forklift, chemicals, electricity, working at heights, a repetitive job, bullying and violence at the workplace.

Plant relates to and includes any machinery, equipment, appliance, container, implement or tool, including any component or anything fitted or connected to any of those items. Plant includes items as diverse as hoists, cranes, computers, machinery, vehicles, power tools, etc. (as per Code of Practice – Managing risks of plant in the workplace).

Risk is the possibility that death, injury or illness might occur when exposed to a hazard.

Safety Data Sheet (SDS) is a document prepared by the vendor (manufacturer/importer/supplier) of a chemical which describes uses, chemical and physical properties, hazard information, precautions for use, safe handling and emergency information. It is a legislative requirement for the vendor to supply a copy of the SDS for each chemical to the end user.

Student is a person enrolled at Charles Darwin University in a course of study or instruction.

Worker means any person who carries out work in any capacity for the University, including but not limited to, University’s staff members, contractors, subcontractors and their employees, apprentices or trainees, students gaining work experience, and volunteers;

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 2 of 9 Workplace means any area or place, including vehicle or vessel, where a worker goes or is expected to be, while performing a business or undertaking for the University.

Health and Safety Responsibilities

3.1 How to manage work health and safety risks

It is the responsibility of all workers to identify any hazards and ensure they are reported to supervisors or management so that effective controls can be implemented. Employees are encouraged to attend WHS Risk Management Training and to read the CDU Risk Management Policy. http://www.cdu.edu.au/governance/policies/pol-036.pdf

This document will provide information relating to:

 Duty of Care  Duty to identify hazards  Managing risks to health and safety  Hierarchy of control measures  Maintenance of control measures  Review of control measures

3.2 Duty of Care

Primary duty of care – Persons conducting a business or undertaking (PCBU) must ensure, so far as reasonably practicable the health and safety of all persons engaged or influenced by the persons activities, by eliminating or minimising the exposure to hazards and risks.

Workers and others – While at work, a worker must take reasonable care for their own health and safety whilst also taking all reasonable measures to ensure that their acts or omissions do not adversely affect the health and safety of other persons. The worker must comply and cooperate with any reasonable policy or procedure relating to health or safety at the workplace.

Work Health and Safety Policy http://www.cdu.edu.au/governance/policies/pol-044.pdf

Risk management is about exercising responsibility to ensure workers and the public are properly protected. The Risk Assessment Form allows you to identify the hazard, then identify and control the associated risk. Risk Assessment Form

Gas Cylinders Guide

4.1 General

Compressed, dissolved and liquefiable gases contained within gas cylinders are under very high pressures, and new developments in cylinder technology over the past decade have enabled cylinder pressures to be significantly increased.

There are many commonly used industrial gases stored and used throughout the University. It is for this reason is it important that workers are familiar with the types of gases available, and the hazards associated with their use.

4.2 Know your gases

Since gases are invisible their presence is not readily identifiable and they have the potential to asphyxiate, burn or harm users. To avoid potential incidents and in the interest of

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 3 of 9 personal safety, users must be able to identify gases by their hazard classification and be familiar with the precautions required when handling cylinders.

The label is the primary means of identification of the cylinder contents. As per example below:

If labels are illegible or missing from cylinders, DO NOT use the cylinder. Return the cylinder to the supplier for a satisfactory replacement.

Cylinder colour is the secondary means of identification of the nature of the cylinder contents and the hazards associated with the gas contained within the cylinder. Examples of the more commonly used gases around the University are below:

Gas Carbon T Air Nitroge Oxygen Argon Dioxi Acetylen LPG Refrigeran y n de e t p e

Galvanise Galvanised Bod Pewter Pewter Black Peacock Green Claret or or y Blue Grey silver white grey Ban Blac Aqua d k

Further examples of cylinder colour identification can be obtained from manufacturers or suppliers.

Never repaint a cylinder.

4.3 Classification of gases

Classification is a process used to determine if a chemical can cause harm to human health and safety. It involves the identification and evaluation of the physical properties of a chemical, along with the health effects. It is the classification of a hazardous chemical that determines what information is communicated on the label and SDS. An important part of the label is the class diamond, which represents the characteristic of the gas.

Until the 31st December 2016, chemical classification is in a transitional stage where it is moving from the Hazardous Substances and Dangerous Goods classification to a new Globally Harmonised System (GHS) introduced by Work Health and Safety (WHS) Regulations. During this period you may encounter pictograms from either of the classification systems. Further information on this is available in Section 13 of the CDU Chemical Management Guide.

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 4 of 9 http://www.cdu.edu.au/ohrs/policies/health-safety.html

Examples of pictograms from both the Australian Dangerous Goods (ADG) and the Globally Harmonised System have been provided.

ADG Class Diamonds - gases

GHS classification pictograms - gases

4.4 Cylinder design and construction

Gas cylinders are designed and construction to comply with AS 2469 – 2005 Steel cylinders for compressed gases – Welded two-piece construction – 0.1 kg to 150 kg. There is a wide range of single high pressure cylinders suitable for small volumes of gas, which are available in various sizes and pressures. Sizes are denoted by a letter code which is permanently marked on the cylinder.

Cylinders are usually used individually, but collectively grouped cylinders interconnected by a manifold (Manifolded Cylinder Packs (Pack or Bundle) are available for purposes where larger quantities of gas is required.

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 5 of 9 4.5 Valves, valve guards and protection caps

Cylinders containing gas under pressure are fitted with a cylinder valve which must not be tampered with at any time, as this will compromise the safety of the cylinder. Each valve is specially threaded to receive commercially available pressure regulators. For safety reasons, the cylinder valve outlets for flammable gases (left hand thread/counter-clockwise) and non-flammable (right hand thread/clockwise) are threaded opposite direction to prevent connection of the incorrect regulators.

Some cylinders are fitted with valve guards or protection caps to prevent the valves from being damaged.

 DO NOT damage the threaded portions by connecting an incorrect regulator.  DO NOT over – tighten or use excessive force to connect equipment.  DO NOT remove valve guards.  DO NOT lubricate valves or fittings  DO refit the protection caps whenever the cylinder is not secure or not in use.

4.6 Regulators

Regulators are used to control the pressure from the cylinder to the required piece of equipment at the end of the hose or manifold. The regulator has two pressure gauges, one indicating cylinder pressure, and the other indicating hose pressure. Most regulators have two stages:

 First stage is a fixed-pressure regulator with the function of releasing the gas from the cylinder at a constant intermediate pressure, despite the pressure within the cylinder falling as the amount of gas within the cylinder is used.  The adjustable second stage of the regulator controls the pressure reduction from intermediate pressure to the lower pressure required at the outlet.

4.7 Flashback Arresters

It is important for the manufacturer, testing facilities and the user of the safety devices to appreciate that the devices are only effective for their designed purpose if they continue to perform within their design specifications.

Flashback arresters to be connected to regulators, welding hose and blowpipes shall have end connections in accordance with AS 4267 and AS 1335 to prevent interchangeability.

Testing on flashback arresters in service shall be carried out at a minimum interval of 12 months by an independent third party to determine the suitability for continued use of the safety device.

4.8 Maintenance and servicing Most cylinders are owned by gas companies and it is the responsibility of the supplier to ensure that cylinders are properly maintained, serviced and tested. It is suggested by WHS that annual checks of cylinders be conducted, to ensure that the cylinders in storage are still in good order and within the due test date.  Keep cylinder valves clean.  Never attempt to repair a cylinder.  Never disguise damage to cylinders.  Never mix gases.  Never transfer gas to another cylinder.  Never scrap a cylinder. Have it returned to or picked up by the supplier to condemn and dispose of. Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 6 of 9  Ensure annual inspections of manifold systems are performed.

Handling and use of gas cylinders

Musculoskeletal or crush injuries are just a couple of examples of risks associated with the moving and handling of gas cylinders. Therefore, for general personal safety it is recommended that:

 Mechanical aids (trolleys, forklifts, etc.) should be used wherever possible to move cylinders (especially cylinders >12kg).  Disconnect any attached equipment prior to moving a cylinder.  Ensure that cylinders are safely secured to the lifting device prior to moving.  Observe safe lifting techniques where manually handling of cylinders is required.  Use suitable personal protective equipment (PPE).  In case of a leak or suspected leak, close the cylinder valve tightly before attempting to find a leak or to replace components.  DO NOT roll cylinders other than on their bottom edge.  NEVER lift cylinders by the valves.

Storage of gas cylinders Storage of gas cylinders must be in accordance with AS 4332:2004 – The storage and handling of gases in cylinders. Where one of the below gases is kept or stored, the appropriate standard listed applies in lieu of AS 4332:2004.  AS/NZS 2022:2003 Anhydrous ammonia – storage and handling  AS 1894:1997 The storage and handling of non-flammable cryogenic and refrigerated liquids  AS/NZS 2927:2001The storage and handling of liquefied chlorine gas  AS 3961:2005 The storage and handling of liquefied natural gas  AS/NZS 1596:2014 The storage and handling of liquefied petroleum gas (LPG)

Whilst minimal quantities of gas may be stored indoors, it is preferred that indoor storage of gas cylinders shall be avoided wherever possible.

Cylinder storage facilities shall:

 Be located on the ground floor and not less than 1 meter from any door, window, air vent or duct.  Have a level base constructed of non-combustible materials.  Have adequate drainage.  Be well ventilated.  Have substantial racks or other rigid supports where cylinders can be securely attached to prevent them from falling  Storage arrangements should allow for easy accessibility and rotation (turnover) of stock.  Be free from artificial sources of heat and clear of combustible materials.  Be secure to prevent unauthorised access.

All cylinders should be considered as full and handled with corresponding care. When empty, the valves should be closed and the cylinders marked as empty.

Full cylinders must be stored separately from empty cylinders. Cylinders of different gases, whether full or empty, must be segregated from each other. Example: where oxidising gases and flammable gases are being stored within the same storage area, they must be stored at least 3m apart or separated by a firewall.

Transporting of gas cylinders

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 7 of 9 This section gives information to the requirements associated with transporting gas cylinders safely. It is highly recommended that wherever possible,

 Avoid having to transport gas cylinders in cars and vans.  Arrange to have gas cylinders transported to and from the work site by the supplier.

If no other options are available other than using a van, utility or car, the following is recommended:

 The vehicle must be suitable for the size and type of load.  Use open vehicles or trailers in preference to enclosed vehicles or trailers.  The load must be correctly positioned and secured on the vehicle to maintain its stability.  Acetylene and LPG cylinders must always be in an upright position.  Cylinder storage area of the vehicle is well ventilated.  Remove regulators or attachments prior to transporting.  Ensure cylinder valves are closed.

Signage and placarding

Storage areas must clearly show signage in accordance with State Work Health and Safety and Dangerous Goods regulations.

This includes:

 Class Diamonds and pictograms  Hazchem  No smoking and naked flame warning signs  Authorised access only

Essential Supporting Information

CDU Policies, Procedures and Guides

Work Health and Safety Policy Emergency Management Plan Risk Assessment Form Risk Management Policy Procurement of Goods and Services Procedures Personal Protective Equipment (PPE) Guide Safety Signage Guide Workshop Safety Guide Chemical Management Guide

Acts & Regulations

Work Health and Safety (National Uniform Legislation) Act 2011 Work Health and Safety (National Uniform Legislation) Regulations

Codes of Practice

How to Manage Work Health and Safety Risks Managing the Work Environment and Facilities Managing the Risks of Plant in the Workplace

Australian and New Zealand Standards

Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 8 of 9 AS/NZS 1319:1994 – Safety signs for the occupational environment AS/NZS 31000:2009 – Risk management – Principals and guidelines AS/NZS 1596:2008 – The storage and handling of LP gas AS 2030.1:2009 – Gas cylinders – General Requirements AS 4267:1995 – Pressure regulators for use with industrial compressed gas cylinders AS 4289:1995 – Oxygen and acetylene gas reticulation systems AS4326:2008 – The storage and handling of oxidizing agents AS 4332:2004 – The storage and handling of gases in cylinders AS4484:2004 – Gas cylinders for industrial, scientific, medical and refrigerant use – Labelling and colour coding AS4603:1999 – Flashback arresters – Safety devices for use with fuel gases and oxygen or compressed air AS 4839:2001 – The safe use of portable and mobile oxy-fuel gas systems for welding, cutting, heating and allied processes AS 5034:2005 – Installation and use of inert gases for beverage dispensing

Document History and Version Control

Version Date Approved Approved by Brief Description

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Handling and Storage of Gas Cylinders Guide Version 2 Contact Officer: WHS Page 9 of 9