safety rev. 5 · storage and handling-may 2019 page 1 of 14 ... lpg station, pd-lgn-sop-00-0001,...

SAFETY HSE-SAF-STD-00-0028

Rev. 5.1

COMPRESSED GAS CYLINDERS STORAGE AND HANDLING

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HSE-SAF-STD-00-0028 Page 1 of 14

TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................... 2

2. SCOPE & PURPOSE ................................................................................................... 2

3. DEFINITIONS ............................................................................................................... 2

4. STANDARD ................................................................................................................. 2

5. RESPONSIBILITIES .................................................................................................... 6

6. REFERENCES ............................................................................................................. 6

7. ATTACHMENTS .......................................................................................................... 6

8. APPENDICES .............................................................................................................. 7

9. REVISION HISTORY .................................................................................................. 12

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

5.1 16-May-19 • Added associated training doc. as attachment (sec.7)

Rajesh Dhanavelu

Arantelo D Abreu

Arantelo D Abreu

Next Scheduled Periodic Review: August/2020


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1. INTRODUCTION

Cylinders that store gases in compressed and or liquefied state are used for various activities in the plant. These cylinders have a potential to cause injury and property damage if the hazards are not recognized and proper storage/handling requirements are not followed. This Standard provides information on proper storage and handling of cylinders that contain gases in compressed and or liquefied state in line with the following regulations.

i. 29 CFR 1910.101(b) Compressed Gas Association Pamphlet P1-1965, which is incorporated by reference as

specified in 1910.6. ii. NFPA 55-2005

2. SCOPE & PURPOSE

This Standard is applicable to all compressed gas cylinders that are stored and handled at Q-Chem Plant premises by employees and contractors. This Standard covers all compressed gas cylinders that have dimensions in excess of 15 inches in length and 5 inches in diameter. This Standard does not cover aspects for storage and handling of emergency response equipment cylinders such as FM-200, portable fire extinguishers, and compressed air equipment used in process areas.

3. DEFINITIONS

Compressed Gas Cylinder: It is any portable cylinder with a maximum water volume of approximately 454 litres or less that holds gases in compressed or liquefied state at a pressure more than 1 kg/cm2g.

Handling: It is the moving, connecting or disconnecting a compressed or liquefied gas container under normal conditions or use.

LPG: Liquefied Petroleum Gas OEM: Original Equipment Manufacturers PPE: Personal Protective Equipment Storage: This involves maintaining portable compressed gas cylinders positioned for

current or future usage in an adequately safe condition and location. SCBA: Self Contained Breathing Apparatus

4. STANDARD

4.1. General

i. Compressed gas cylinders shall have labels that as a minimum shall contain the following: a) Identity of the chemical b) Hazards of the chemical c) Precautions and PPE requirement d) Gas manufacturers name and contact details

ii. Vendor labels shall never be removed or defaced.


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4.2. Storage

i. Compressed gas cylinder storage areas shall be clearly marked with the hazard information pertaining to the gases contained in the cylinders.

ii. Compressed gas cylinders storage area shall meet all of the following conditions: a) Dry location b) Flat surface c) Adequate ventilation

iii. Compressed gas cylinder shall not be stored or mounted for use directly on the soil/sand as this will aid corrosion at the cylinder bottom.

iv. Compressed gas cylinders shall always be stored in upright position with the valve end at the top. Following are the exceptions for the section 4.2.(iv) of this Standard:

a) SCBA cylinders stored horizontally in the appropriate racks in the fire station. b) Breathing air cylinders secured in the appropriate carts. c) LPG Cylinders for forklifts.

v. Compressed gas cylinders, valve protection caps (where the cylinder is designed to accept a cap) shall always be in place, hand tight, except when cylinders are in use.

vi. Laboratory calibration gas cylinders, valve protection caps (where the cylinder is designed to accept a cap) shall always be in place, hand tight, except when cylinders are in use or is connected for use.

vii. Compressed gas cylinders shall be properly secured with restraints (chains or slings) to prevent them from falling. See Appendices A and B for example pictures of good and bad practices.

viii. Compressed gas cylinders shall not be stored near heat sources (like radiators). ix. Compressed gas cylinders shall not be stored near corrosive materials. x. Compressed gas cylinders shall not be stored near flammable and combustible liquids.

xi. Compressed gas cylinders shall be kept far enough away during storage from welding or cutting operation so that sparks, hot slag or flames will not reach the cylinder.

xii. Compressed gas cylinders shall not be stored where they are vulnerable to hazards caused by impact (e.g. near vehicle traffic).

xiii. Compressed gas cylinders shall not be stored in the exit routes xiv. Store full compressed gas cylinders separately from empty ones. Empty cylinders shall

bear tags or labels indicating that they are empty. Valves on the empty cylinders shall be kept closed.

xv. Gases with the same hazard class shall be stored in the same area. Incompatible gases (e.g. flammables and oxidizers) shall be kept at least 20 ft. from each other, unless separated by a non-combustible wall at least 5 ft. in height and with a fire resistance rating of at least 30 minutes.

xvi. End user/DSR will verify the calibration gas contents and hydro test date either from the cylinder or from the certificate of analysis (COA).


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xvii. Materials Department/DSR to ensure date of hydro test of compressed gas cylinder shall not be overdue with reference to the manufacturer`s recommendation.

xviii. There is no general requirement for a user to return gas cylinder for inspection if the contents have not been used even if the inspection/test interval might have lapsed. However, the user shall be responsible to ensure that inspection and testing of the gas cylinders are arranged after the contents have been discharged.

4.3. Transportation

i. Regulators and fittings from the cylinder shall be disconnected before moving or transporting them and valve protection caps (where the cylinder is designed to accept a cap) shall always be in place, hand tight while moving or transporting

ii. Regulators and fittings on Laboratory calibration gas cylinders shall be disconnected before moving or transporting them and valve protection caps (where the cylinder is designed to accept a cap) shall always be in place, hand tight while moving or transporting; unless the cylinder is “connected for use”; and the portable hand trolley (special truck) fully protects the regulators and fittings from accidental damage.

iii. Compressed gas cylinder shall never be rolled or dragged; use hand trucks that are appropriate for the size of the compressed gas cylinders being moved.

iv. Compressed gas cylinders shall be secured on a cradle appropriate for the size of the cylinder if transported using a forklift truck.

a) If a cradle is not available, adequate precautions shall be taken to prevent the cylinder from falling by using suitable slings, chains.

v. Compressed gas cylinders shall be secured in a cradle when lifted to higher elevations using hoist or crane.

vi. Compressed gas cylinder valves, shrouds, or caps shall not be used for lifting cylinders unless they have been designed for lifting purpose.

vii. Compressed gas cylinder shall not protrude from the sides of the vehicle during transport.

4.4. Handling and Use

i. Compressed gas cylinders shall be inspected prior to each use. Any defective or damaged cylinder shall immediately be taken out of service, tagged, and taken for repair or replacement.

ii. Compressed gas cylinder containing ‘Liquefied Petroleum Gas’ (LPG) – refer to Logistics unit standard operating procedure, LPG Station, PD-LGN-SOP-00-0001, for refilling activities.

iii. Compressed gas cylinders shall be secured in vertical position (up right with valve end up) unless specifically designed to be used otherwise.

iv. Personal Protective Equipment (PPE) that is appropriate for the contents of the compressed gas cylinders shall be worn before connecting regulators.

v. Regulators, fittings, and other piping/tubing materials shall be inspected for defects and rating for the intended application before connecting them to the cylinder.

vi. Labels shall be maintained on the compressed gas cylinder identifying the cylinder contents and specifying precautions. If the label is not legible or is missing, the cylinder shall not be taken in service; return the cylinder to the vendor.


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vii. Regulators shall be charged slowly and personnel shall stay clear from valve outlets and other pressure release points.

viii. Regulators, fittings, and other piping/tubing materials shall be disconnected from the cylinder only after depressurizing the system.

ix. Contents of a cylinder shall never be used to clean or blow off dust or debris from the valve nozzles.

x. If the valve on the cylinder is corroded, no attempt shall be made for opening it; the cylinder must be quarantined and sent for repair.

xi. Valve wrench shall be left in place while the cylinder is in use where ever applicable. xii. Compressed gas cylinders shall be kept far enough away during use from welding or

cutting operation so that sparks, hot slag or flames will not reach the cylinder. If this not possible, a fire resistant shield shall be provided.

xiii. Compressed gas cylinders shall be positioned away from areas where vehicle traffic is allowed during handling. If the cylinders are to be positioned in the vehicle traffic area due to operational reasons then vehicle entry shall be prohibited until such time the cylinder is in use.

xiv. Compressed gas cylinder valves shall be closed, regulators disconnected and valve protection caps placed when the work is complete or interrupted. Work interruptions include end of work shift, lunch-break etc.

4.5. Repairs and Maintenance

i. Q-Chem does not carry out repairs on compressed gas cylinders or valves on cylinders from outside suppliers. Damaged or defective cylinders shall be sent to vendor for repair or replacement.

4.6. Leaks and Accidental Releases

i. In-case of a minor leak, the cylinder shall be moved to an isolated, well ventilated area, barricade the area and post appropriate warning signs. PPE recommended for the gas shall be worn by the personnel moving the cylinder.

ii. In-case of a major leak, evacuate the area, sound the alarm and initiate ‘Emergency Response Team’s (ERT) response.

iii. A compressed gas cylinder that is involved in fire has very high potential for failure. If involved in any fire compressed gas cylinders shall be taken out of service and returned to the vendor.

4.7. Acetylene Cylinders

i. Following are the additional precautions for storing and handling acetylene cylinders: a) Acetylene cylinders can explode as a result of decomposition caused by mechanical

shock to the container. b) Acetylene is contained in the gas cylinders by dissolving the acetylene gas in acetone

on a porous medium inside the cylinder to reduce the rate of decomposition. So, acetylene cylinders are never empty.

c) If involved in fire acetylene cylinders should be cooled for a minimum of 24hrs (it is recommended to lay them in portable water dams).


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5. RESPONSIBILITIES

5.1. Materials Department

i. Responsible for ensuring that all compressed gas cylinders delivered at site meet the requirements stated in this Standard.

ii. Responsible for storing the compressed gas cylinders at designated storage area until it is delivered to the user departments.

iii. Responsible for ensuring proper labels as stated in the section 4.1 of this Standard are affixed to all compressed gas cylinders that are stored in the Materials Warehouse.

iv. Ensure date of hydro test of compressed gas cylinder shall not be overdue with reference to the manufacturer`s recommendation.

5.2. Safety Department

i. Safety Specialist, once notified of issue, shall enter long term action items identified during audits, into the Action Tracker system.

5.3. User Department /DSR

i. Ensures that compressed gas cylinders are managed, transported, stored and used as per the requirements stated in this Standard.

ii. Verify the validity of calibration and gas contents Hydro test due date and discard the expired cylinders.

5.4. Area Owner

i.Conduct and document quarterly audits of compressed gas cylinders stored and used in their areas utilizing The Compressed Gas Cylinder Quarterly Audit Form (HSE-SAF-SFM-00-0146).

ii. Submit completed audit forms to departmental Administrative Assistants for record keeping. iii.Develop action plans for any audit issues that require more than a week to complete. iv.Notify Safety Department of any long term action items which were identified during audits,

and require entry into the Action Tracker system.

6. REFERENCES

6.1. Logistics Procedure, LPG Station, PD-LGN-SOP-00-0001 6.2. OSHA 29 CFR 1910.101, Compressed Gases (General Requirements) 6.3. OSHA 29 CFR 1926.350, Gas Welding and Cutting 6.4. NFPA 55-2005, "Standard for the Storage, Use, and Handling of Compressed Gases and

Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks". 6.5. QP Regulation For Gas Cylinders - Appendix IV - Inspection And Test Frequencies For Gas

7. ATTACHMENTS

7.1. Compressed Gas Cylinder Quarterly Audit Form - HSE-SAF-SFM-00-0146

http://qedms/NetFYI/cgi/NetFYIIsapi.DLL?Method=AddLogin+RetrieveDoc&L=L&DSN=FYI&UserID=RO&PASSWORD=RO&C=Plant%20Information--RO&F=2927&D=734007





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7.2. Compressed Gas Cylinders Storage and Handling – Refresher Course - HSE-SAF-CBT-00-0010

8. APPENDICES

8.1. Appendix A - Compressed Gas Cylinders Storage and Use: Examples of good practices 8.2. Appendix B - Compressed Gas Cylinders Storage and Use: Examples of bad practices

http://qecmpcnm.q-chem.local:9080/navigator/bookmark.jsp?desktop=QCHEM&repositoryId=RecordsManagerRepository&vsId=%7B8073125C-0100-C89D-8211-99CB4FA3D5DD%7D

http://qecmpcnm.q-chem.local:9080/navigator/bookmark.jsp?desktop=QCHEM&repositoryId=RecordsManagerRepository&vsId=%7B8073125C-0100-C89D-8211-99CB4FA3D5DD%7D


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Appendix A Compressed Gas Cylinders Storage and Use: Examples of Good Practices


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I. Appendix B Compressed Gas Cylinders Storage and Use: Examples of Bad Practices

• Cylinders are not secured

• Cylinders are improperly secured; the rope that runs across the cylinders will not prevent any of them from falling

• Cylinders are stored on non-flat surface


• Cylinders are rolled on the ground

• Cylinders are improperly secured; the rope that runs across the cylinders will not prevent any of them from falling


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• Cylinders are improperly secured. Group of cylinders are tied together and tethered to another cylinder that is in use


• Cylinders are improperly secured. Group of cylinders are tied to a trolley that is free standing


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• Cylinder valve is used as a storage hook

• Cylinder is not secured

• Bad house keeping

• Regulators are not removed from the cylinder that is not in use; it is stationed at an area that is not intended for cylinder storage

• Cylinder is stationed at an area that is not intended for cylinder storage without disconnecting regulators and oxy acetylene torch


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• Valve protection cap is not placed

• Housekeeping – cylinders are placed midst paint cans and other readily combustible materials

• Lifting lug on the cylinder is damaged

9. REVISION HISTORY

Rev. Issue Date Amendment Description Prepared By Reviewed By Approved By

5 29-Mar-18

• Business Revision – Type -2 • Next scheduled periodic revision

year changed from 2018 to 2020 to be in line with the 5 year frequency change requirement

Muhammad F Khan

Arantelo D Abreu Ryan L Price

4 30-Oct-16

• Business Revision – Type 1 category

• Added the requirement on verification of the calibration and

Ranjeet K Maity

Arantelo D Abreu/ Haresh

Patel/ Liju K Paulson/

Ryan L Price/ Roehl

Bartolome/Dirk/ Abdulla S Al-


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hydro test by the End User/DSR – section 4.2 (xvi) to (xviii)

Denish Lama/ Gopal

Radhakrishnan/ Abdul Wasim

Sheikh/ Mohammed

Qahtani

Khulaifi/ Akmal Rana/ Manuel

Abiad/ Abdulaziz Y Al-

Motawa/ Abdulla S Al-Zoubi/Jamal

3 24-Aug-15

• Change category: Type 1 • ‘LPG cylinder for forklifts’ is included

as an exception item from the compressed gas cylinders to be stored in upright position. (4.2.(iv).(c))

• A requirement added: Q-Chem does not carry out repairs on valves on cylinders from outside suppliers. (4.5.(i))

• Added the responsibilities for Area Owner. (5.4)

• A new form HSE-SAF-SFM-00-0146 added. (7.1)

Carl Benson

Carl Benson, Gopalakrishnan Radhakrishnan,

Mattathil Philipose

Akmal Rana Ali Al-Marri

Suhael Quraishi Anthony Dugat Kevin Kabell, Carl Poldrack

Roehl Bartolome,

2 30-Jun-14

Periodic Revision Change Category: Type-1

Added 4.2.(vi) Laboratory calibration gas cylinders, valve protection caps (where the cylinder is designed to accept a cap) shall always be in place, hand tight, except when cylinders are in use or is connected for use.

Added 4.3.(ii) Regulators and fittings on Laboratory calibration gas cylinders shall be disconnected before moving or transporting them and valve protection caps (where the cylinder is designed to accept a cap) shall always be in place, hand tight while moving or transporting; unless the cylinder is “connected for use”; and the portable hand trolley (special truck) fully protects the regulators and fittings from accidental damage.

Updated 4.4.(ii) to changing document reference to LPG Station, PD-LGN-SOP-00-0001.

Updated References for SOP and OSHA.

Carl Benson

Ponnambath A Latheef;

Gopalakrishnan Radhakrishnan; Mohammad U

Khalid; Mattathil Philipose

Carl Poldrack Abdulla S Al-

Khulaifi Kevin C Kabell Akmal Rana Jamal I Khalil

1 05-Dec-11

Standard Review with Change Review Team

• Added both Storage and Handling to Definitions section

• Further defined Scope to include the following:

This standard does not cover aspects for storage and handling of emergency response equipment cylinders such as FM-200 and portable fire extinguishers or compressed air equipment used in process areas. (See Emergency

Kimbal Harty


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Section)

0.0 05-Feb-07 First Release Roehl

Bartolome

S. Jeyaseelan

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