vwa1171 air receivers

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A handbookor workplaces

Working saelywith air receivers

October 2008Edition No. 1


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Contents

WorkSae Victoria is a trading nameo the Victorian WorkCover Authority.

The inormation presented in Workingsafely with air receivers is intended orgeneral use only. It should not be viewedas a defnitive guide to the law, andshould be read in conjunction with theOccupational Health and Safety Act 2004and theOccupational Health and SaetyRegulations 2007.

This publication is protected by copyright.WorkSae encourages the ree transer,

copying and printing o this publicationi such activities support the purposesand intent or which the publicationwas developed.

Introduction 1

How to use this handbook 2

1. Equipment 3

Air receivers 3

2. Environment 12

Plant layout 12

Workplace traffic 13

Noise 14

Housekeeping 14

3. Work procedures 15

Information, instruction, training and supervision 15

Operating air receivers and auxiliary systems 16

Maintaining air receivers 18

4. Information and guidance 20

Appendices 21

Appendix A: Common air receiver andauxiliary systems safety issues checklist 21

Appendix B: Inspection and maintenance records 23

Appendix C: Types of pressure equipment and other definitions 26

Appendix D: An introduction to guidance material 27


3/32WorkSae Victoria Handbook / Working saely with air receivers 1

Introduction

Pressure vessels are potentially very dangerous and can ail catastrophically

causing multiple atalities, serious injuries and property damage. The Longordgas explosion in Victoria in 1998 was the result o pressure vessel ailure.

Two people were killed in an air receiver explosion at a roadhouse in Karachi, Pakistan.The body o one o the people killed was ound at a distance o 1 kilometre romthe place where the explosion occurred.

These two separate incidents (pictured let) occurred in Victoria. It was ortunate thatno-one was in the vicinity when the explosions took place.

This handbook covers a type o pressure vessel called an air receiver. An air receiverthat has a hazard level o A, B or C must be plant registered. Reer to AustralianStandard AS 4343-2005, Pressure equipment Hazard levels.

To calculate the hazard level o your air receiver(s), reer to Comcares Unredpressure vessel calculatorat worksae.vic.gov.au. Where the calculator reersto licence, this should be interpreted as meaning registration under Victorianrequirements. This calculator only calculates hazard levels A, B and C.

While the ocus o this handbook is air receivers, there is also some inormationon other elements o compressed air systems. This handbook does not coverthe specifcs o compressed air or the supply o respiratory air.

Air receivers are used in many workplaces across Victoria, and can be ound inmanuacturing, mechanical shops, panel shops, tyre shops, dry cleaners, hospitals,TAFEs, universities, construction sites and in the mining industry.

It is expected that employers, health and saety representatives (HSRs), health andsaety committees, employees and WorkSae inspectors will use this handbook to

assess health and saety risk controls under the test o reasonably practicable(see Appendix D or a defnition o reasonably practicable).

This handbook is not a substitute or training or expert advice. It does not cover thespecifcs that operators need to know to perorm their job competently and saely.

A general overview o guidance material can be ound in Appendix D.

Occupational health and saety legislation in all states requires employers to:

ensurerisksassociatedwithplantandtheiroperationsareeliminatedorreducedso ar as is reasonably practicable

ensuresupervisorsandemployees,includingindependentcontractors,aretrainedand provided with inormation on:

the nature o hazards associated with the plant

the sae operation o plant.


4/322 Handbook / Working saely with air receivers WorkSae Victoria

Introduction

How to use this handbook

This handbook provides a range o inormation that can be used to decide the mosteective risk control solutions or air receiver saety.

Many o the tasks outlined in the ollowing pages are presented in two columns.

Work practices undertaken with air receivers that are deemed to be unacceptableunder occupational health and saety (OHS) legislation are highlighted in the redcolumn. To avoid exposing employees and contractors to risk o injury or illness,the practices described in these columns must not be allowed to happen.

Common risk control solutions to prevent exposing employees or contractors tounacceptable work practices are highlighted in the green column. These solutions

are regarded as reasonably practicable or most workplaces where air receiversare located and thereore would be expected to be implemented when required. Thatsaid, the risk controls listed in the green column are not the only way to control risks.I an alternative way to control risks is used, it should at a minimum achieve thesame standard as set out here.

Unacceptable Work Practice Risk Control Solutions

Work practices and systems in thered column must not be used inworkplaces where air receivers arelocated. An employer who allows these

work practices to be used is likely tobe in breach o OHS legislation.

The solutions in the green column arethe most eective at reducing risk andshould be the aim o all workplaces.



1. Equipment

A pressure vessel is a container that holds either gasses or liquids and is subject

to internal or external pressure. It includes interconnecting parts and components,valves, gauges and other fttings up to the frst point o connection to the connectingpiping. See Appendix C Types o pressure equipment and defnitions.

Pressure vessels, including air receivers, have hazard levels assigned to them. Thosewith a hazard level o A, B or C have specifc requirements, including the requirementto be plant registered.

Air receivers

An air receiver is a type o pressure vessel. It is a tank that stores compressed airor large demands in excess o compressor capacity.

Vertical air receiver

A vertical air receiver tends to be larger and almost always has a hazard level oA, B or C.

Horizontal air receiver

A horizontal air receiver tends to be smaller. As a general rule, i it is over a metrein length then it will have a hazard level o C as a minimum.

Registration

An air receiver must be registered in Victoria according to the hazard level, as ollows:

Airreceiverplant registration is required where an air receiver has a hazardlevel o A, B or C

Airreceiverdesign registration is required where an air receiver has a hazard

level o A, B, C or D.To register your air receiver, download the Application or registration o item o plantorm rom WorkSaes website, www.worksae.vic.gov.au

Vertical receiver.

Horizontal receiver.



Hazard levels

Pressure vessels can be rated rom A through to E, with A being the most hazardousand E being the least hazardous. There are a number o actors that contribute to apressure vessels hazard level, which include:

size

pressure

temperature

sourceofpower

location

usage

hazardouscontents contentstype.

Air receivers are classed as having non-hazardous gas content. With many o therisk actors consistent or air receivers, what determines their hazard level is thesize o the vessel and the maximum design pressure.

To calculate the hazard level o your air receiver(s), reer to Comcares Unredpressure vessel calculatorat worksae.vic.gov.au. Please note that where thecalculator reers to licence, this should be interpreted as meaning registrationunder Victorian requirements. This calculator only calculates hazard levels A, B and C.

Lockouts

To operate an air receiver saely, it is crucial that it can be locked out and tagged out.The ollowing are examples o when an air receiver may need to be locked out andtagged out:

whennotinuse(topreventunauthoriseduse)

whenbeingworkedon(toensuresafetyofmaintenancestafforoperators)

whendeemeduntforuse(eitherfollowinganincident,duringaninspectionor beore commissioning).

1. Equipment

This on/o switch or the air compressoris capable o being locked out.



1. Equipment

Incorrect:The nozzle or the pressurerelie valve has been plugged.

Correct:The pressure relie valve islocated behind the gauge.

Incorrect:This blowdown valvedischarges oil and water onto thewall and foor creating hazards.

Correct:This blowdown valvedischarges into a container sothat the oil and water is captured.

Saety devices

An air receiver must have a number o devices to ensure its sae use. Like all otherplant, these devices require constant inspection, surveillance, monitoring,maintenance and repair. They include:

pressure relief valves designed to prevent pressure building up beyond thedesign pressure o the air receiver.

blowdown valves used to drain contaminants rom the air receiver. There areautomated systems available. These need to be tested to ensure that they areworking on a regular basis.



pressure gauges used to monitor the pressure within the air receiver.

1. Equipment

Correct:The shut o valve allows thisair line to have the air supply stoppedin case o rupture.

Incorrect:This pressure gauge isbroken and the needle is stuck againstthe rest. This gauge has no red lineand is not within the calibration rangeor the air receiver.

Correct:This pressure gauge has thered line and is within the calibrationrange or the air receiver.

shut off valves used to shut the air o rom the air line or hose. They need tobe accessible easily rom locations along the line in case o rupture or otherissues when immediate access is required.

isolation point should be located so that the air compressor can be shut downsaely in an emergency. The isolation point will not discharge the energy orcompressed air rom the system.



Selecting an air receiver

Beore purchasing an air receiver, the employer should consult with key sta,including health and saety representatives (HSRs). This consultation should bedocumented and include operational requirements and any hazards that need to beconsidered, or example:

theintendeduse

operationalparameters

frequencyofuse(eg24hoursadaycontinuouslyorsporadically)

physicalconstraintsoftheworkplace

requireddistancesfromotherplant

requireddistancesfromammableliquids requireddistancesfrompeople

impactcausedbytheweather.

Consultation should also consider saety within the workplace ater the air receiveris purchased, or example:

whatnewriskswillbeintroducedtotheworkplace

whatengineeringcontrolswillneedtobeintroduced(egpipingthatispressurerated)

whatnewsafesystemsofworkwillneedtobedeveloped

whatspecicinformation,instruction,trainingandsupervisionwillberequiredor the new plant?

A ormalised sae work method statement and a risk assessment should alsobe completed.

All o these should orm the basis o discussions with the supplier o the air receiver.

The manuacturers recommendations are also critical in selecting the appropriate airreceiver, or example:

somecompressorandairreceiversetsarenotdesignedtosupplyrespiratoryair

whichsetofcomponentsofacompressedairsystemshouldbematchedtomeetrequirements and maximise health and saety.

1. Equipment

This piping is rated or the requiredpressure as per the appropriatestandard.



Installing an air receiver

An air receiver shall be installed and anchored on proper oundations to prevent tippingover. The supports shall be protected against corrosion. The air receiver shall be levelwith the blowdown valve at the lowest point on the vessel. The blowdown valve needsto be accessible or perorming the regular blowdown and maintenance activities.

Commissioning an air receiver

Beore using an air receiver or the frst time or beore restarting ater maintenance or

repair, it must be commissioned to specifc perormance parameters. An air receiver witha hazard level o A, B or C has specifc checklists and must meet recording requirements.

A competent person should be appointed to perorm the commissioning.

Alterations to an air receiver

Proposed alterations to an air receiver should be assessed by a competent personbeore the alterations are made. They should be consistent with the designers andmanuacturers recommendations. For an air receiver with a hazard level o A, B, C orD and where alterations create new hazards, a design registration must be submitted.A Registration o Plant Design orm can be obtained rom worksae.vic.gov.au.

1. Equipment

This air receiver is not anchored in place. This air receiver is anchored in place bya bolt.



Inspection

Inspections should be carried out by competent person(s) at intervals to keep theair receiver in a sae condition.

Commissioning or recommissioning inspection this must be done beorethe air receiver is used or the frst time and ollowing repairs, changes to use,relocation and when returning to service ater period o non-use.

Pre-operational and operational surveillance and monitoring regularsurveillance is an essential part o the operation o all air receivers. This mustinclude checking and monitoring all saety devices, visual observation, as wellas monitoring or abnormalities, including odours and temperature extremes.

Periodic in-service inspection assures the sae operation o an air receiver untilthe next scheduled inspection. The major elements o periodic inspections are:

external inspections include fttings, saety devices, protective coatings,anchoring, supports and identifcation markings. These inspections are usedto detect anomalies or deects, such as corrosion, leaks, bulging, signs oexcessive temperatures or signs o cracking

internal inspections are used to detect anomalies or deects to internalsuraces. There is a variety o non-destructive testing techniques or thesetests. Care must be taken to ensure that the testing is truly representativeo the air receivers condition

pressure relie valve is tested at the same time as the internal inspectionto ensure that it is in a sae working condition.

See Maintaining air receivers, page 18.

Inspection intervals

Pressure equipment Commissioninginspection required

First yearly inspectionrequired

Typical inspectioninterval (years)

Typical interval oroverhaul and benchtest (years)

Externalinspection

Internalinspection

Air receiver

pV 100MPa.L No No

pV > 100MPa.L Yes No 2 years 4 years

Pressure relie valve Yes Yes 4 years

WorkSae Victoria recommends the above inspection intervals as a minimum, subject to the condition o the plant.

1. Equipment



Repair

The task o repair is a technical area that requires liaising with various people.This may include the manuacturer, the supplier, an in-service inspector or othercompetent people. The ollowing are points to consider:

duetocostofrepairversuscostofreplacement,adamagedairreceiveris oten scrapped

thecausesofalldefectsmustbeaddressedbeforeanyrepairs,alterationsor modifcations

thestored energy needs to be saely discharged and the system locked outbeore any repairs, alterations or modifcations that require opening thecompressed air system

proposalsforrepairs,alterationsandmodicationsmustbereviewedbya competent person

repairs,alterations,andmodicationsmustbe:

competently designed

carried out by a competent person

tested to ensure that they meet the design standard

recorded in the register o pressure equipment(SeeAlterations to an air receiver, page 8)

repairmustbecarriedoutundersupervisionofacompetentperson

anairreceiverthathassafety-relateddefectsmustbeimmediatelywithdrawnrom service

whenacompetentpersonsreportrecommendstheairreceiverbe scrapped, it must be locked out and tagged out to prevent urtheruse beore decommissioning

anyairreceiverthatcannotberepairedorisnotgoingtoberepairedmustbe decommissioned.

A dent in an air receiver is serious and must be treated in the same wayas a reduction o thickness or a crack in the wall/shell, which may leadto a recommendation to scrap the air receiver.

Equipment1.



Equipment1.

Records

Both a register o pressure equipment and an inormation fle must be kept or allpressure equipment rated as a A, B or C hazard level. It is recommended that allpressure vessels, including those with hazard levels o D and E, be included in theregister.

There is a variety o inormation required to be kept in the register o pressureequipment and the inormation fle. The competent person who perorms theinspection, surveillance, monitoring, maintenance and repair tasks should be ableto advise you on what is required to keep your records to the appropriate standard.

The records kept in relation to inspection and maintenance should contain theollowing inormation as a minimum:

1. What is looked at?

2. What is looked or?

3. What are the rejection/acceptance criteria?

4. How is it looked or?

5. What is ound?

6. What recommendations are made, eg uture inspections, repairs or changesto current operating procedures and parameters?

7. Actions taken based on those recommendations.

SeeAppendix B Inspection and maintenance records.



2. Environment

Plant layout

The layout o plant should always be considered rom a health and saety perspective,as well as a production perspective. Poor location o an air receiver can aect theongoing health and saety o operators, maintenance personnel and people in thesurrounding area, as well as the integrity o the pressure vessel.

The ollowing matters should always be considered:

locatingthecompressorandairreceiveroutsidetominimisetheeffectsofheatand noise, and where:

it cannot be struck by mobile plant

it can be ully accessed or inspection and maintenance (eg work platorms)

saety devices can be monitored

other plant does not aect its operation (eg drawing in exhaust umes romcombustion engines)

thedirectionthatablowdown/pressurereliefvalvedischarges

avoidingburnsthroughcontactwithhotpiping

thelocationofshut-offvalvesandisolationpoints

thelocationofdangerousgoods(inrelationtotheairreceivertoavoidthepossibility o fre).

The air receiver shall be anchored according to the requirements stipulatedin Australian Standard AS 1210, Pressure Vessels.



Workplace trafc

A documented trafc management plan is crucial or resolving many hazards andrisks. An air receiver is high risk plant and so the trafc management plan shouldtake into account the potential or impact by mobile plant. Trafc hazards that shouldbe addressed include:

designatedtrafczones

sitelayout

exhaustfumes(whichcanaffecttheairqualityoftheairreceiver)

workstationsaroundtheairreceiver

barriersandsignage

trappingspaces

blindspots.

The trafc management plan should also include incident reporting andinvestigation procedures.

The trafc management plan should be regularly reviewed and updated whenworkplace changes or equipment upgrades occur.

Reer to the WorkSae Victoria guide Forklit Saety Reducing the Risk.

2. Environment

This air receiver is protected rom tracby a properly installed trac barrier.



2. Environment

Noise

Compressors and leaking air systems can produce a harmul level o noise. Whenselecting an air compressor, one o the actors that must be taken into account is thenoise emission o the plant. The positioning o the air compressor and air receiver canhelp minimise risks associated with noise. Maintenance will also minimise risk byhaving the plant running at its optimum efciency and eliminating air leaks.

Work practices are another way to minimise risks; or example, avoid the dumping oair without the appropriate hearing protection or when other people are in the vicinity.

I employees in your workplace are exposed to noise that exceeds the exposurestandard o 85 dB(A) averaged over an eight-hour period or that has a peak noise

level o 140 dB(C), your workplace is too noisy and controls must be implementedto ensure noise exposure does not exceed the standard.

Furthermore, i any o the ollowing occurs, noise controls are likely to be required:

employeeshavetoraisetheirvoicestocommunicateatadistanceofonemetre

employeeshaveatemporaryreductioninhearingorringingintheirearsafterleaving work or the day.

The Occupational Health and Saety Regulations 2007 set out a hierarchy o controlsto be applied when fxing noise hazards, and include:

1. eliminating noise sources

2. substituting quieter plant or processes, or implementing engineering measures

3. administrative measures

4. hearing protectors.

When hearing protection is required, hearing tests must be provided or employees.This is to ensure the hearing protection is working eectively.

It is worth noting that i there are changes to the workplace, such as new oradditional machinery, it may be necessary to redo noise level tests.

Reer to the Occupational Health and Saety Regulations 2007 or more inormation.

Housekeeping

By implementing a good housekeeping plan, workplaces can be kept clean and reeo waste. You can reduce the risk o injuries occurring due to slips, trips and alls, as

well as injuries resulting rom hitting stationary objects. A tidy, well laid out workplacecan also increase work efciency. Space around the air receiver needs to be keptclean and ree o combustibles so as to prevent the likelihood o fre.

An air receiver has a discharge valve to remove contaminants. This discharge valveneeds to be located where it will not create slip hazards by discharging directly ontotheoor.

Programs that ocus on organisation, cleanliness and standardisation can beintroduced to the workplace. Cleanliness can be maintained in a clean as you gomanner. Good housekeeping creates a tidy workplace that helps identiy hazards andrisks more eectively.



3. Work procedures

Inormation, instruction, training and supervision

Providing inormation, instruction and training is an important means o controlling risk. To be eective, training must be taskspecifc and competency based.


The air receiver

Nooperatorsmanualisavailableonsite.

Employeesdonothaveaccesstoanoperatorsmanual.

Employerhasnotensuredoperatorsaretrainedonthespecifc plant in use at the workplace (eg an employeewho was employed because they have experience ooperating plant at a previous workplace has not beentrained on the specifc plant due to that experience).

The air receiver

Employerprovidesanoperatorsmanualthatincludesthe manuacturers recommendations.

Employerensurestheemployeeunderstandstheinstructions given in the operators manual.

Employerensuresemployeesaretrainedonthespecicplant in use at the workplace, including:

lockouts and tag outs

saety devices

isolation points

operation

inspection and maintenance requirements.


The workplace Therearenosafeworkmethodstatementsinplace.

The workplace Safeworkmethodstatementsareinplace.

Operatorshavebeeninductedandarefamiliarwiththearea they will be working in.

Supervisorensuresthatoperatorsarefamiliarwithanyoperating procedures and other site rules, including:

emergency and evacuation procedures

procedures or reporting aults, hazards and risks.



Operating air receivers and auxiliary systems

Regular operational surveillance is an essential part o the sae operation o all pressure equipment.

The air receiver is only one element o a compressed air system. The health and saety o personnel and the operation o theair receiver will be aected by all elements o the system.

The maximum allowable working pressures o air receivers should never be exceeded. Only hydrostatically tested and approvedtanks shall be used as air receivers.


All plant within the compressed air system

Operatorsarenottrainedandcompetent.

Safetysupervisionisnotadequateforthetasksbeingperormed, the potential hazards and the skills othe operators.

All plant within the compressed air system

Operatorsaretrainedandcompetent.

Appropriatesafetysupervisionisprovidedforcompressed air work.

Allmalfunctionsandhazardsarerecordedinthelogbook and repaired.

Unsafeplantisappropriatelydisabled,taggedout,electrically isolated, energy discharged and not operated.

Plantisoperatedwithinitslimits.

Air receivers

Pre-operationalchecksarenotconductedpriortouse. Safetydevicesarenotmonitored.

Airreceiversarenotdrained.

Air receivers

Pre-operationalchecksareconductedpriortouse. Safetydevicesareconstantlymonitoredwhilethe

air receiver is in operation.

Accessplatformsareprovidedwhererequired.

Airreceiversaredrainedfrequentlytopreventbuild-upo contaminants.

3. Work procedures



3. Work procedures


Air distribution lines and hoses

Airlinesandhosesarenotinspectedfrequently.

Defectiveairlinesand/orhosesareused.

Airlinesandhosesareusedtodischargecompressedair.

Airlinesandhosesareusedtoblowdustoff

employees clothing.

Airhosesareleftontheoorwhennotinuse.

Air distribution lines and hoses

Airlinesandhosesarefrequentlyinspectedfordefects.

Defectiveairlinesandhosesarenotusedandarerepaired or replaced immediately.

Airlinesandhosesarecheckedtomakesuretheyareproperly connected to pipe outlets beore use.

Airhoseshavesafetycouplingswhichshutofftheairowwhennotcoupledtoatting.

Safeworkmethodstatementsareclearlydisplayedto

prevent employees rom using compressed air to cleandust rom clothing.

Airhosesarenotbentorkinked.

Airhosesareplacedintheappropriatestoragesystemswhen not in use.

Saety devices

Safetydevicesarenotmonitored.

Safetydevicesarenotinspectedandtested.

Malfunctions,faultsandunusualeventsarenotreported.

Saety devices

Safetydevicesaremonitoredregularly.

Safetydevicesareinspectedandtestedregularly.

Malfunctions,faultsandunusualeventsarereported immediately.

Air compressor operation

Aircompressorsareusedwithoutregardtothemanuacturers recommendations.

Air compressor operation

Aircompressorplantisonlyoperatedbyauthorisedand trained personnel.

Aircompressorsareusedonlyaccordingtothemanuacturers recommendations.

These couplings shut oair supply when no ttingis attached.



3. Work procedures

Maintaining air receivers

Most causes o ailures o air receivers and associated hazards can be eliminated through proper maintenance regimes.This is a critical area, and planning these tasks goes a long way to reducing the associated risks. Supervision is anotherarea that is critical to achieving saety in relation to maintenance tasks.


Reporting aults

Faultyplantisnotreported,recordedortagged.

Faultyplantcontinuestobeused.

Reporting aults

Defectiveplantisnotedinthelogbookandreportedto the supervisor or an authorised person.

Defectiveplantislockedout,taggedout,clearlymarked as aulty and rendered unusable pendinga decision on how serious the ault is and whetherthe plant is repairable.

Onlycompetentpeoplerepairfaults.

General maintenance

Therearenoproceduresformaintenance.

Maintenanceproceduresarenotfollowed.

Lockout/tagoutproceduresarenotavailableorarenot used.

Workersarenotabletolockoutplantwiththeirownlock.

Anypersoncanremoveanotherpersonslock.

General maintenance

Thereisamaintenanceprocedurethattakesintoaccount the recommendations o the manuacturer.

Onlycompetentpeoplecarryoutmaintenancetasks.

Allcompetentperson(s)carryingoutmaintenance

on the compressed air system ollow the maintenanceprocedure.

Thecompressedairsystemisswitchedoff,dischargedo energy and locked in position beore maintenance.

Eachpersoninvolvedinthemaintenanceworkattachestheir own lockto the appropriate switch.

No person is able to remove another persons lock.

Accessplatformsareprovidedforservicingairreceiverswhere required:

checking pressure relie valve

testing pressure relie valve

checking or external corrosion.

Access platorm or servicing

the air receiver.



3. Work procedures


Preventative maintenance

Thereisnopreventativemaintenanceprocedureinplace.

Preventativemaintenanceproceduresarenotfollowed.

Preventative maintenance

Preventativemaintenanceiscarriedoutregularlyasdetermined by the usage requency in line with designeror manuacturer recommendations.

Preventativemaintenanceisconductedbyacompetentperson according to the maintenance procedure.

Recommissioning

Therearenoformalisedstart-upproceduresinplace.

Start-upproceduresarenotfollowed.

Recommissioning

Thereisarecommissioningandtestingprocedurethat has been undertaken prior to re-using an air receiverthat has been decommissioned.

Start-upproceduresarefollowed.

Visualinspectionsaredonetoensurethatnoothermaintenance people are on or near the air receiver.

Alltagsareremovedonceitissafetodoso.



Inormationand guidance

General Employeescancontacttheirunion Employerscancontacttheirindustryassociation VisitWorkSafeVictoriaatworksae.vic.gov.au

WorkSafeVictoriapublicationscanbeobtainedbyphoningWorkSae toll ree 1800 136 089 or emailing [email protected]

Legislation Occupational Health and Saety Act 2004 Dangerous Goods Act 1985

OccupationalHealthandSafetyRegulations2007

Other publications WorkSafe Consultation on health and saety: A handbook or Workplaces WorkSafe Employee Representation, 2006

WorkSafe Your health and saety guide to consultation WorkSafe Metal Fabrication Industry a guide to saety

WorkSafe Wood products manuacturing industry a guide to saety

WorkSafe Machinery and Equipment Saety An Introduction, 2007

WorkSafe Your health and saety guide to Managing young workers

WorkSafe Saety Tips or Young Workers

AS1210-1997,Pressure Vessels

AS/NZS3788-2006,Pressure equipment In-service inspection

AS4343-2005,Pressure equipment Hazard levels

AS3873-2001,Pressure equipment Operation and maintenance

AS3892-2001,Pressure equipment Installation AS1271-2003,Saety valves, other valves, liquid level gauges, and other

ttings or boilers and unred pressure vessels

AS1657-1992,Fixed platorms, walkways, stairways and ladders Design, construction and installation

4.



Appendices

Appendix A Common air receiver and auxiliary systemssaety issues checklist

WorkSae Victoria has noticed some common health and saety issues in relationto air receivers. Applying the inormation contained in this handbook and usingthis checklist will help minimise risks.

Installation:

Airreceiverissecurelyanchoredtotheoor

The supports are designed or anchoring the air receiver(eg the piping is not designed to be used or anchoring)

Air receivers position means there is no build up o contaminantat the opposite end o the air receiver to the blowdown valve

Therearenoammableliquidsinthevicinityoforneartheairreceiver

Air receiver is located away rom trafc areas

Compressor:

The compressor is using the correct lubricant

The compressor has adequate guarding to prevent contact with the pulleysor belts

The compressor has adequate insulation/guarding to prevent contact withthe hot piping

Operator:

The operator is sufciently competent to perorm tasks adequately and saely



Appendices

Air receiver:

There is no internal corrosion that could aect the wall/shell thickness

There is no internal build-up o contaminants

Pressure relie valve:

The pressure relie valve is the correct type and size

The pressure relie valve is set at the correct pressure

The pressure relie valve is located at a sae level

The pressure relie valve is vertical

The nozzle or the pressure relie valve has not been plugged

There is a pressure relie valve

Blowdown valve:

Thelocationoftheblowdownvalveisanadequatedistancefromtheoorto avoid splash back

Thelocationoftheblowdownvalverelativetotheoorisadequate

The location o the blowdown valve is located at the lowest point on theair receiver

The blowdown valve is working efciently

The automated blowdown valve is regularly tested to ensure that itis unctioning

Pressure gauge:

The pressure gauge is o good quality

The pressure gauge has a red line marking

The pressure gauge is within the calibration range required or theair receiver



Appendices

Appendix B Inspection and maintenance records

What is a solution to the problem?

Inspection and maintenance records should:

bekeptforthelifeofeachitemofplant

beinaformatthatallowsathirdpartytoreadilyaccessthem

provideaclearunderstandingoftheoperation,inspectionandmaintenanceactivities relating to the particular item o plant.

It is critical that inspection and maintenance records be kept whether the taskis undertaken in-house or by contract.

The ollowing seven steps need to be documented:



3. What is the rejection/acceptance criteria?


5. What is ound?

6. What recommendations are made?

7. What actions are taken based on those recommendations?



Appendices

Example o internal inspection:

Please note this is only a brie example and does not cover the complete inspectioncriteria o an internal inspection.

Inspection type:

Internal Inspection

Date:

9 October 2008

Inspected by:

Henry Green of KBs Repairs Pty Ltd


I checked the wall thickness of the air receiver via an internal inspection.


I looked to see if there was thinning of the wall thickness due to pitting or corrosion.


I measured against AS/NZS 3788 & AS 1210.


I did this: via non-destructive testing.

5. What is ound?

I found that there was no thinning of the wall thickness.


I recommend that the air receiver was suitable for continued use until thenext inspection.


The recommendations were acted on and the next inspection was booked into the register of

pressure equipment for action at the appropriate time.



Example o pressure relie valve inspection:

Please note this is only a brie example and does not cover the complete inspectioncriteria o the pressure relie valve.

Inspection type:

Relief valve Inspection

Date:

9 October 2008

Inspected by:

Henry Green of KBs Repairs Pty Ltd


I checked the pressure relief valve.


I checked that the correct device was installed and that there was no external mechanicaldamage.


I measured against AS/NZS 3788 & AS 1210.


I did this: via an on-line external visual inspection.

5. What is ound?

I found that the correct device was installed, there was external mechanical damage.


I recommend that the pressure relief valve be replaced with a new one set at thedesign pressure.


The recommendations were acted on and completed 9 October 2008.

Appendices



Appendix C Types o pressure equipment andother defnitions

What is pressure equipment?

Pressure equipment includes pressure vessels and boilers.

What is a pressure vessel?

A pressure vessel is a container that holds either gasses or liquids and is subject toeither internal or external pressure. It includes interconnecting parts and components,valves, gauges and other fttings up to the frst point o connection to connectingpiping. Pressure piping has a dierent meaning to connecting pipingand is explainedbelow. Some types o pressure vessels are described below.

Air receiver a tank that serves to store compressed air or large demands inexcess o compressor capacity.

Autoclave a vessel in which high heat and pressure (generated by convertingwater to steam) is used to sterilise and cure objects.

Caloriferadevicethatheatsuidsbycirculatingthemoverheatingcoils.

Chilleraself-containedmachinewitharefrigerationcircuitthatcoolsauidcircuit.

De-aerator a device or air removal used to remove dissolved gases rom boilereedwater to make it non-corrosive.

Heat exchanger a device built or efcient heat transer rom one mediumto another.

Pressure piping component examples include separators and strainers.

Reactor a device used to orce a controlled reaction with a given substance.

Steam type digester a high-pressure cooker.

What is a boiler?

Aboilerisaclosedvesselinwhichwaterorotheruidisheatedorsteamorothervapour is generated at a pressure above that o the atmosphere. The heated orvaporiseduidexitstheboilerforuseinvariousprocessesorheatingapplications.

What is a Competent person?

A person who has acquired the knowledge and skills, through training, qualifcation,

experience or a combination o these, to enable them to correctly perorm therequired task.

What is an In-service inspector?

A person able to inspect pressure equipment, including air receivers, or the purposeofestablishingconformitywiththespeciedrequirementsinAS/NZS3788-2006.

What is an Inspector?

Any person involved with an inspection unction in accordance with AS 3873-2001

What is an Inspection?

Conormity evaluation by observation and judgement as appropriate by measurement,testing or gauging.

What is a Surveillance?

Activities that observe the general condition o plant.

Appendices



Appendix D An introduction to guidance material

The legal ramework

There is a legislative ramework that sets minimum requirements or controllingrisk and or consultation in the workplace. This handbook provides ways to complyin Victoria with the Occupational Health and Saety Act 2004 and relevant sectionso the Occupational Health and Saety Regulations 2007. The rest o this Appendixprovides a brie introduction to matters which are regulated by the Act.

Consultation

All employers are required to consult with their employees. This includes consultationwith an independent contractor and any employees o the independent contractor.Employers must consult health and saety representatives (HSRs), where they exist.Consultation must cover hazard identifcation, risk assessment and risk control, aswell as any proposed changes in the workplace, plant, substances or work processesthat could impact on the health, saety or welare o workers.

It is recognised that employee input and participation through consultation improvesdecision-making on health and saety. Apart rom being a legal requirement,consultation between employers and employees is an essential part o eectivelymanaging health and saety at work, and a valuable means o improving health andsaety and productivity outcomes.

There are many positive outcomes rom consultation. Employers become moreaware o hazards and occupational health and saety (OHS) issues experienced by

employees. Employees can provide input and suggestions about how to solve OHShazards and risks, and contribute to determining how work can be done more saelyand efciently. Eective consultation can oten lead to employees taking moreownership o risk controls. This in turn leads to better adherence o control measures.

See Section 4, Inormation and guidance or reerences on consultation.

Representation

Employees are entitled to, and should be encouraged to, be represented in relationto occupational health and saety.

Elected HSRs have been an important eature o occupational health and saety inVictoria since 1985. It is widely acknowledged that HSRs can make a real dierencein occupational health and saety. There is oten a better saety culture with hazards

and risks being raised, and better health and saety outcomes oten achieved.

Appendices



Issue resolution

When a health, saety and/or welare issue arises in relation to compressed airsystems, the employer and employees aected must attempt to resolve it. Theemployees are entitled to be represented by their health and saety representativein this process.

Section 73 o the Occupational Health and Saety Act 2004 details how healthand saety issues are to be resolved at the workplace. The employer or theirrepresentative manager, supervisor and employees aected by an issue must tryto resolve the issue by using the agreed workplace procedure. I there is no agreedprocedure, then the prescribed one must be used (see Occupational Health andSaety Regulations 2007 Chapter 2, Part 2.2). The employer or representative

attempting to resolve the issue must be sufciently senior and competent to actand make decisions. I the issue cant be resolved, a WorkSae Victoria inspectorcan be called in to assist in this process.

For more inormation on the duty to consult, reer to the WorkSae publication,Consultation on health and saety: A handbook or workplaces, 2007.

Contractors

An employers legal duty to provide and maintain a sae work environment appliesto employees, contractors and labour hire workers

Young workers

Young Victorian workers aged between 15 and 24 years are more likely to

be injured at work than any other age group. Young workers must be properlytrained, supervised and provided with sufcient inormation to work saely.Supervision especially needs to be tailored or young peoples needs.See worksae.vic.gov.au/youngworkers.

Reasonably practicable

When determining reasonably practicable controls, Section 20 o the OccupationalHealth and Saety Act 2004 outlines what you must take into account. Specifcally,the actors to be considered are:

thelikelihoodofhazardorriskeventuating

thedegreeofharmthatwouldresultifthehazardorriskeventuated

whatthepersonconcernedknows,oroughtreasonablytoknow,aboutthe

hazard or risk and any ways o eliminating or reducing it theavailabilityandsuitabilityofwaystoeliminateorreducethehazardorrisk

thecostofeliminatingorreducingthehazardorrisk.

It is important to understand that all the actors listed above must be taken intoaccount when deciding i something is reasonably practicable.

For more inormation, reer to the WorkSae Position How WorkSae applies thelaw in relation to Reasonably Practicable.

Appendices


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