cg - 1 nwacc business & industry workforce development institute welcome osha 29 cfr 1910.101...

CG - 1 NWACC Business & Industry Workforce Development Institute

WELCOME

OSHA 29 CFR 1910.101

COMPRESSED GAS SAFETY

CORPORATE SAFETY TRAINING


YOUR INSTRUCTOR


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.

COURSE OBJECTIVES


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


Gas Users

Safety Committees

Purchasing Agents

Department Managers

First Line Supervisors

Maintenance Managers

Shipping and Receiving Employees

Accident Investigation Team Members

COURSE ATTENDEES


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


REGULATORY STANDARDTHE GENERAL DUTY CLAUSE

FEDERAL - 29 CFR 1903.1

EMPLOYERS MUST: Furnish a place of employment free of recognized hazards that are causing or are likely to cause death or serious physical harm to employees. Employers must comply with occupational safety and health standards promulgated under the Williams-Steiger Occupational Safety and Health Act of 1970.

OSHA ACT OF 1970


29CFR - SAFETY AND HEALTH STANDARDS

1910 - INDUSTRIAL SAFETY

101 - COMPRESSED GASES (GENERAL)

APPLICABLE REGULATIONS

DANGER

COMPRESSEDGAS

STORAGE AREA


COMPRESSED GAS ASSOCIATION

CGA P-1 - SAFE HANDLING OF COMPRESSED GASES - Over 100 Other CGA Safety Manuals

CONSENSUS STANDARDS

DANGER

COMPRESSEDGAS

STORAGE AREA


OSHA CIVIL PENALTIES POLICY

BEFORE MARCH 1, 1991:

VIOLATION NARRATIVE: TEN (10) EMPLOYEES WERE NOTED NOT WEARING EYE PROTECTION IN AREAS WHERE A REASONABLE PROBABILITY OF EYE INJURY COULD OCCUR.

PENALTY: $500



AS OF MARCH 1, 1991:

CHANGES IN PENALTY COMPUTATION:

1. PENALTIES BROKEN OUT INDIVIDUALLY.

2. PENALTIES INCREASED SEVEN FOLD.

(Continued)



AS OF MARCH 1, 1991:

VIOLATION NARRATIVE: TEN (10) EMPLOYEES WERENOTED NOT WEARING EYE PROTECTION IN AREAS WHERE A REASONABLE PROBABILITY OF EYE INJURY COULD OCCUR.

$ 10 VIOLATIONS TIMES $500 = $5000$ 5000 TIMES SEVEN = $35,000

PENALTY: $35000 BEFORE MARCH, 1991: $500 AS OF MARCH, 1991: $35,000

(Continued)


GENERAL PROGRAM REQUIREMENTS

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

ALL EMPLOYERS MUST:GASSAFETYPROGRAM


TRAINING REQUIREMENTS

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.

THE EMPLOYER MUST PROVIDE TRAINING:


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.

RETRAINING REQUIREMENTS

GASSAFETYPROGRAM


TRAINING IS IMPORTANT

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.

A GOOD PROGRAM WILL HELP:

SAFETYSTATISTICS


PROGRAM IMPLEMENTATION

DEDICATION PERSONAL INTEREST MANAGEMENT COMMITMENT

IMPLEMENTATION OF A COMPRESSED GAS SAFETY PROGRAM REQUIRES:

NOTE:

UNDERSTANDING AND SUPPORT FROM THE WORK FORCEIS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!


PROGRAM IMPLEMENTATION

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.

DEVELOPMENT SEQUENCE:

Continued

DANGER

COMPRESSEDGAS

STORAGE AREA


IMPLEMENTATION STRATEGY

RECOGNITION

CONTROL

IMPLEMENTATION

EVALUATION



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.

RECOGNITION

Continued


RECOGNITION

CONTROL

IMPLEMENTATION

EVALUATION

IMPLEMENTATION STRATEGYContinued



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.

SAFETYPROGRAM

Continued


RECOGNITION

CONTROL

IMPLEMENTATION

EVALUATION



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



RECOGNITION

CONTROL

IMPLEMENTATION

EVALUATION




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.

SAFETYPROGRAM

Continued



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.

Continued



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.

Continued


THE SUPERVISOR’S ROLE

CONSIDER THE FOLLOWING:

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.


COMPRESSED GAS HAZARDS

Extremely High Pressure. Toxicity. Reactivity. Instability. Flammability. Extreme Low Temperature. Asphyxiation. Radioactivity.

PRINCIPAL HAZARDS:



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.

WHEN THINGS GO WRONG:

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.

THE TYPICAL COMPRESSED GAS CYLINDER:

Continued


BASIC SAFETY RULES

I’LL GET THE RUST OFF

OF THIS THING ONE WAY

OR ANOTHER!

KIDS DON’T TRY THIS AT HOME!


BASIC SAFETY RULES

THE BIG THREE:

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.


BASIC SAFETY RULES

FILLING OF CYLINDERS:

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.


BASIC SAFETY RULES

CONTENT IDENTIFICATION:

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.


BASIC SAFETY RULES

CONTENT IDENTIFICATION:

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.

Continued


BASIC SAFETY RULES

PAINTING CONTAINERS:

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.


BASIC SAFETY RULES

LEAKING AND DEFECTIVE CYLINDERS:

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.


BASIC SAFETY RULES

CYLINDER USAGE REQUIREMENTS:

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.


BASIC SAFETY RULES

MOVEMENT OF COMPRESSED GAS CYLINDERS:

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.


BASIC SAFETY RULES

STORAGE REQUIREMENTS (GENERAL):

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.


BASIC SAFETY RULES

STORAGE ROOMS (GENERAL):

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.


BASIC SAFETY RULES

STORAGE ROOMS (GENERAL):

Continued

Cylinders

- Must not impede emergency egress.

- Cannot be located near exits.

- Cannot be located near stairs.

Must be secured to prevent toppling.


BASIC SAFETY RULES

OUTDOOR STORAGE (GENERAL):

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.


NAME

PRECAUTIONS

RESTRAINED ABOVE MIDPOINT

EMERGENCY & USE PROCEDURES

AWAY FROM COMBUSTIBLES

BASIC SAFETY RULESContinued

DANGER

NO SMOKINGNO FUMAR 4

31

ACETYLENE

GASINSPECTIONCHECKLIST


BASIC SAFETY RULES

GENERAL INSPECTION CRITERIA:

Continued

INSPECT FOR: POSSIBLE RESULT:

Dents Weakening of cylinder wallCrevice Corrosion Weakening of cylinder wallBulges Weakening of cylinder wallARC/ Torch Burns Weakening of cylinder wallCuts, Gouges or Digs Decrease in wall thicknessCorrosion Decrease in wall thicknessPitting Decrease in wall thicknessNeck Defects Leak or cylinder explosionValve Ease-Of-Movement Corrosion leading to leakValve Thread Serviceability Leak during operation


BASIC SAFETY RULES

PRE-OPERATION 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.


BASIC SAFETY RULES

POST-OPERATION SAFETY RULES:

Continued


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.


STORAGE RULES

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.


Continued

USE OLDEST STOCK FIRST!

ACETYLENE DANGER

COMPRESSEDGAS

STORAGE AREA

DANGER

FULLCYLINDERS

NOSMOKING!

431

GASSTORAGE

CHECKLIST

STORAGE RULES


STORAGE RULES

FULL CYLINDER STORAGE RULES:

Continued



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.


FULL CYLINDER STORAGE RULES:

Continued

Ensure all labels are readable.

Ensure valve assembly is tightly capped.


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.


Continued

STORAGE RULES


EMPTY CYLINDER STORAGE RULES:

Continued



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.

STORAGE RULES


EMPTY CYLINDER STORAGE RULES:

Continued

Ensure all labels are readable.


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.


Continued

STORAGE RULES


THERE ARE HUNDREDS OF GASES USED IN INDUSTRY.

HERE ARE A FEW EXAMPLES OF COMMONLY USED GASES. ASK YOUR SUPPLIER TO HELP YOU

WITH YOUR SPECIFIC TYPES OF GASES.

SPECIFIC TYPES OF GASES


OXYGEN (INCLUDING OXIDIZING GASES):

Continued

Oxygen and oxidizers can be deadly. Cleanliness is absolutely essential!!! Explosion results upon contact with hydrocarbons. Keep oil, grease, and other hydrocarbons away! Ensure process or system is compatible with oxygen. Assess compatibility of equipment and materials. Separate from combustible materials. Oxygen can “fuel enrich” permeable materials. Oxygen enriched materials burn tremendously.



ContinuedSPECIFIC TYPES OF GASES

THE pH of ACIDS AND BASES

pH IS THE NUMERICAL MEASURE OF ITS RELATIVEACIDITY OR ALKALINITY. THE RANGE IS FROM 0 - 14WITH A NEUTRAL LEVEL EXPRESSED AS A pH OF 7.0.

pH ABOVE 7.0 - MORE ALKALINE OR BASIC.

pH BELOW 7.0 - MORE ACIDIC.



CHECK FOR COMPATIBILITY!

HIGH pHBASEACIDLOW pH


ACID & ALKALINE GASES:

Continued

Avoid contact with all bodily routes of entry. Wear goggles and suitable skin protection. Consider effects on the respiratory tract. Long sleeves and trousers are mandatory. Open toed shoes or sneakers are prohibited. Gas masks/SCBA must be immediately available. SCBA must be used when the concentration could

exceed the rating of the gas mask canister or if the gas could displace oxygen to below 19 percent.



ACID & ALKALINE GASES:

Continued

Emergency showers/eyewashes must be available. Quantities on-site must be limited. Ventilation must be adequate in the work area. Common corrosive and toxic gases include:


Continued

- Boron Trichloride - Bromine Trifluoride- Chlorine Trifluoride - Hydrogen Fluoride- Iodine Pentafluoride - Silicon Tetrafluoride- Sulfur Tetrafluoride - Tungsten Hexafluoride


BHOPAL, INDIA:

Continued

Over 2000 people died. Methyl isocyanate released. Occurred in December 1984. SARA Title III initially proposed as a result. The Union Carbide Facility was not unique. The accident could have occurred anywhere. Most were inhabitants in the area of the plant.



HIGHLY TOXIC GASES:

Continued

Remember Bhopal India! Training is critical. The specific hazards must be understood. Threshold Limit Values must be determined. Storage is critical and must be assessed. Ventilation is critical and must be assessed. Gas discharges must be scrubbed. Discharges must be neutralized. On-site quantities must be limited.



HIGHLY TOXIC GASES:


Medical services should be pre-planned. Suppliers/manufacturers should be consulted. Emergency responders should consulted. Common highly toxic gases include:

- Arsine - Boron Trichloride- Bromine Trifluoride - Bromine Pentafluoride- Chlorine - Fluorine- Germane - Hydrogen Cyanide- Hydrogen Selenide - Hydrogen Sulfide- Nitric Oxide - Phosgene

Continued


CRYOGENIC LIQUEFIED GASES:


In liquid form at relatively low pressures. Extremely low temperatures. Usually below - 238F (- 150C). Handled in heavily insulated containers. Insulated containers minimize evaporation. Proper operation of venting systems is essential. High expansion rate on vaporization. Can cause extreme bodily damage on contact. Full body protection must be utilized.




Continued

OxygenRate of Expansion

- 238F

875 ft3

+65F1ft3



Continued

LOX

Use only hardware designed for cryogenics. Pain is not immediate. Tissue solidifies over time. Blood circulation is arrested. Serious skin burns may result. Blood clots are highly probable. Skin highly vulnerable to infection. Flush with tepid water.




Can displace oxygen leading to asphyxiation. SCBA or airline systems must be used. Oxygen content below 19 percent is dangerous. Common highly inert gases include:

INERT GASES:

- Argon - Carbon Dioxide- Helium - Neon- Nitrogen - Xenon


GENERAL SAFETY CONSIDERATIONS


Don’t be afraid to ask people to wait! Limit conversation while using gases. Know that you could be seriously injured. Know that no one ever expected to get injured. Know that none of us is immune to injury. Know the safe procedures before starting work. Know the location of first aid kits. Avoid horseplay - don’t tolerate it from others. Think about going home in the same shape. Know your gas!


Develop a detailed inspection policy. Document each inspection. Inspect all gases before issue or use. Tag as unusable, damaged cylinders. Inspect cylinders before each use (without exception). Separate damaged cylinders from serviceable cylinders. Consider the effects on gases stored for long periods. Remove damaged cylinders from service immediately.

INSPECTION CONSIDERATIONS:

INSPECTION AND CARE OF GASES

INSPECTIONCHECKLIST

cg - 1 nwacc business & industry workforce development institute welcome osha 29 cfr 1910.101...

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