Hazmat Training for Cylinder Safety

Familiarization with Federal RegulationsGeneral awareness/familiarization with

cylinders Proper handling/Preventive procedures Safety issues and training Reporting observed concerns

Federal Regulations

Department of Transportation (DOT) enforce the Code of Federal Regulations Title 49 172.00 which mandates all persons who “handle, transport or are likely to be affected" by the hazards of high pressure cylinders must receive "function specific" training to the HAZMAT within 90 days of employment and retraining every 3 years afterward. AoP requires this training to be completed within one week of hire

DOT regulates the transport and handling of high-pressure cylinders

Title 29 CFR 1910.101(a) Requires employers to take ultimate responsibility for the safe condition of compressed gas cylinders under his control

Federal Regulations The U.S. government regulates matters affecting the safety and health

of employees (only) in all industries, including compressed gas, through the Department of Labor, Occupational Safety and Health Act (OSHA).

Employees/volunteers must receive appropriate hazmat training whenever assigned new duties

The ICC was an older version of the DOT and cylinders stamped with ICC may be used if they met all other standards

In every state, all dive store employees and anyone handling cylinders on a regular basis must comply with rules equal to OSHA 29 CFR 1910.

To change cylinder gas type (i.e. air to Nitrox or reverse), the original content must be removed and labeling corrected. Changes shall be made in accordance with CGA Pamphlet C-10

Scuba Cylinders Made of steel or aluminum Range in capacity from a few cubic feet (50 L) to

120 cubic feet (3428 L) Common pressures range from 1,800 psi (124

bar), to 2,250 psi (155 bar), to 3,000 psi (207 bar) to 3,500 psi (238 bar)

Steel cylinders with a “+” sign can be overfilled by 10%

All SCUBA cylinders are required to have current Hydrostatic test date and EOI (VIP) Sticker regardless of size

Cylinder Codes

Always look at a list or reject codes before using or filling an unfamiliar cylinder examples of alloys to recheck are below (not a complete list) Reject SP6576, SP6688, SP890, SP6498,

E6498, SP7042, E7042 NOT overstamped with 3AL

Reject all round bottom aluminum cylinders

Cylinder Care and Maintenance Handling with care. Best to transport well secured vertically.

When transporting horizontally block in place and orient sideways.

Fill slowly (300 – 600 psi per minute) Rinse after use Storage pressurized (minimum of 100 psi) secured vertically

is best. Visual inspection needs to be conducted yearly or sooner if

tank is drained Hydrostatic test every 5 years REPORT CYLINDER THAT APPEARS DAMAGED OR

CONTAINS LESS THAT 100 PSI OF AIR TO THE DSO FOR INSPECTION.

Cylinder Care and Maintenance SAFETY CONCERNS

Tanks are best carried by the valve with the opening away from skin. Air embolism can occur through contact with skin and can occur readily in people other than divers.

Escaping air may be loud and can cause particles to become airborne. Use eye and ear protection.

Cylinders are heavy use proper lifting techniques to prevent injury.

Dropped cylinders may injure feet or toes or shear off valve. Never place a pressurized cylinder in an environment greater

than 130º F* (car trunk on a hot day). Any cylinder exposed to fire should be removed from service

•130º F is the maximum operating temperature for a cylinder

•130º C is the maximum exposure temperature for a cylinder

The kinetic energy stored within a full80 ft3 tank exceeds one million foot pounds,sufficient energy to disintegrate concrete blockwalls, propel fill station operators through walls,destroy fire trucks, and jet cylinders great distances.

AT LEAST ONE CYLINDER EXPLODES ANNUALLY!!

90% OF CYLINDER EXPLOSIONS OCCUR DURING THE FILLING PROCESS

Disguised damage

Boots often hide corrosion including self draining boots. They should always be removed when inspecting a cylinder.

Stickers or paint may be placed over damage Auto repair putty used to cover defects Vinyl coated cylinders should not be used or

filled under any circumstancesREPORT ANY SUSPECT CYLINDERS

IMMEDIATELY TO DIVE SAFETY OFFICER

General cylinder handling

Never move any cylinder by rolling it along the ground

Never leave any tank standing up (including flat bottomed AL tanks)

Any unfamiliar stamp should be checked to see if it is a cylinder that should be rejected (e.g. SP 6576 identifies a bevel bottom aluminum tank that should be rejected.)

Cylinders rejected during a Visual Inspection can be returned to service after reconditioning by qualified technician is completed and additional inspection is passed

Condemned cylinders (failed Hydrostatic test) with obliterated codes may never be returned to service and should be destroyed

Cylinder BasicPre-fill Inspection

Look over the exterior of the cylinder for any evidence of damage (bulges, cracks, etc.)

Check most recent hydrostatic test stamp (should be within 5 years of current date)

Check for a current VIP/EOI sticker (should be within one year of current date). If sticker is suspect for any reason, obtain written inspection record.

Look over valve for any damage and ensure valve has pressure release mechanism (burst disc)

The FSO has the absolute authority to require an internal cylinder inspection prior to filling

AoP Fill Station OperationsOpening Procedures

1. Ensure fill valves on panel are closed (DO NOT over-tighten)

2. SLOWLY open storage bank isolation valve, located inside the dive office above the work bench, all the way

3. Check “Inlet Pressure” gauge on fill panel (it should read the same as the bank pressure gauges outside behind the compressors)

4. Check “Fill Pressure” gauge on fill panel (it should be 3400 psi: notify dive officer immediately if fill pressure is incorrect, DSO must authorize any changes to this regulator setting)

5. Inspect fill station area: look for any cracked or broken hoses or gauges, bent or broken stainless tubing, or malfunctioning door

6. Be sure all proper PPE is located at fill station (safety glasses, back belt, ear protection)

AoP Fill Station Filling Procedures

1. Place cylinder in fill station carefully with the valve handle facing the 12 o’clock position.

2. Gently blow moisture from cylinder valve by opening the valve slightly for a few seconds

3. Remove dust cap from fill yoke4. Attach fill yoke to cylinder valve

(DO NOT over tighten), close bleeder valve. Once snug, tilt yoke away from valve handle

5. Slowly open cylinder valve all the way and read cylinder pressure on corresponding gauge. Notify DSO if pressure is below 100 psi

6. Close fill station door

7. Slowly open corresponding fill panel valve, carefully observe fill rate. AoP fill rate is 300-500 psi per minute

8. When cylinder pressure reaches the desired psi, close fill panel valve (DO NOT overfill to allow for cool down)

9. Close cylinder valve10. Open bleeder valve until line

pressure is zero11. Remove fill yoke, replace dust cap,

and close bleeder valve12. Close fill station door13. DO NOT open fill station while

Behind The Scenes guests are in dive locker

AoP Fill StationStorage Bank Procedures

When storage bank pressure reaches 3,500 psi:

Ensure storage bank isolation valve, located inside the dive office above the work bench, is open

Depending which compressor is in use… Compressor A: Press and hold the “On” button until the

compressor is running Compressor B: Flip “On/Off” switch to “On”

It is permissible to leave compressor area when banks are filling

Compressor will shut off automatically when storage bank pressure reaches 5,000 psi

If using compressor B, turn “On/Off” switch to “Off” position when banks are full

AoP Fill Station

End of Day Fill Station Shut Down

Check “Inlet Pressure” gauge on fill station If “Inlet Pressure” is below 3500 psi, turn on

compressor If “Inlet Pressure” is above 3500 psi, do not run

compressor Ensure the compressor B “On/Off” switch is in the “Off”

position before leaving Close storage isolation valve all the way (DO NOT use

excessive force) Keep fill station door OPEN overnight

AoP Fill Station The air quality of the AoP compressor is tested at least every

six months

The air quality of the AoP compressor meets CGA Grade E

Always use available employee safety equipment when filling

The top shelf of the tank storage rack can only have one row of tanks

DO NOT operate fill station if you are wet

AoP Fill Station

REMEMBERSAFETY

IS YOUR

RESPONSIBILITY