Gas Cylinder Safety Consciousness Session

Gas Cylinder Safety Consciousness Session (Question on acetylene cylinder)

Regulator

The regulator is the next most important safety device to be fitted to a gas cylinder before operation/use. It allows for the high pressure of the cylinder contents to be brought down to a usable working pressure. 

Regulators come as a single stage for short term applications and two stages for long term applications. Regulators are also constructed from different materials, mainly brass or stainless steel.

The application will define the required regulator. If you are unsure of which kind of regulator to use, consult your gas supplier.

Regulators are designed to be fitted directly to the cylinder valve. No other fittings, connections or lubricants shall be used to connect a regulator to a gas cylinder valve.

Regulators for flammable gasses are left hand threaded and have a notch cut out of faces on the securing nut to distinguish them from non-flammable gas regulators. 

Most cylinders have one or more safety relief devices. These devices can prevent rupture of the cylinder if internal pressure builds up to levels exceeding design limits. Pressure can become dangerously high if a cylinder is exposed to fire or heat, including high storage temperatures.

There are three types of safety-relief devices. Each relieves excessive gas pressures in a different way:

Safety- or Pressure-Relief Valves: These valves are usually a part of the cylinder. They are normally held closed by a spring. The force holding the valve closed is set according to the type of gas in the cylinder. The valve opens if the cylinder pressure exceeds the set safety limit. Gas is released until the cylinder pressure drops back to the safety limit. The valve then closes and retains the remaining gas in the cylinder.

Rupture Discs (also known as frangible or bursting discs): These discs are usually made from metal. They burst or rupture at a certain pressure, releasing the gas in the cylinder. The bursting pressure is designed so that the disc ruptures before the cylinder test pressure is reached. These devices cannot be reclosed, so the entire contents of the cylinder are released.

Fusible Plugs (also called fuse or melt plugs): Temperature, not pressure, activates fusible plugs. These safety devices are used where heat could initiate an explosive chemical reaction. A pressure-relief valve or rupture disc acts too slowly and too late to prevent rupture of the cylinder if an explosive reaction has already begun. The fusible plug releases the gas before the hazardous reaction can begin. Fusible plugs are made of metals that melt at low temperatures. For example, acetylene cylinders have a fusible plug which melts at about 100°C (212°F). This temperature is safely below the temperature at which hazardous polymerization may occur.

Not all compressed gas cylinders have safety devices. Some gasses are so toxic that their release through a safety device would be hazardous. Cylinders for these gasses are built to withstand higher pressures than normal cylinders. When these "toxic gas" cylinders are involved in a fire, the area must be evacuated.

IS Standards CHAPTER V

DISSOLVED ACETYLENE GAS CYLINDERS

37. Additional requirements for dissolved acetylene gas cylinders— Dissolved acetylene gas cylinder shall comply with following additional provisions, namely: -

(i) The porous substance shall fill as completely as possible the cylinder into which the acetylene is compressed.

(ii) The porosity of the substance shall not exceed 92 percent and in no case shall be less than 75 percent.

(iii) Any solvent used shall not be capable of chemical reaction with the acetylene gas or with the porous substance or with the metal of the cylinder.

(iv) If acetone is used as a solvent it shall comply with the requirements of IS:170, the quantity of acetone including the gas in solution shall be such that the cylinder meets the requirements of additional tests specified in IS:7312.

(v) The valves of the cylinders shall not contain more than 70 percent copper in their composition.

(vi) The pressure in the cylinder shall not exceed 16 kgf/cm2 at a temperature of 15 °C.

(vii) Every cylinder shall before being filled with porous mass be tested by hydrostatic pressure to a pressure of not less than 60 kgf/cm2. This pressure may be reduced to 53 kgf/cm2 if the cylinder is fitted with fusible plug. No cylinder which shows a permanent stretch in excess of 7½ per cent of the total stretch suffered during hydrostatic stretch test shall be allowed. 

(viii) The safety relief devices if fitted, shall operate at a pressure of 53 kgf/cm2 or at a temperature of 100 °C + 40 °C/–2 °C.

(ix) Every cylinder shall have permanently and conspicuously marked upon it or upon a brass plate soldered to it the name of the manufacturer and the words “Acetylene properly compressed into porous substance” and shall bear the following markings, namely: -

(a) Serial number and identification of manufacturer;

(b) Number of the standard;

(c) Test pressure;

(d) The date of hydrostatic stretch test with code mark of the place where the test was carried out;

(e) Date of filling of porous mass;

(f) Water capacity’;

(g) A symbol to indicate the nature of heat treatment;

(h) Identification of porous mass and porosity percentage;

(i) Tare weight (inclusive of valve);

(j) Inspector’s official mark;

(k) Maximum gas capacity.

“dissolved acetylene cylinder” means a cylinder having a valve and with or without safety devices, containing a porous mass, a solvent for the storage of dissolved acetylene and at least sufficient acetylene to saturate the solvent at atmospheric pressure and at a temperature of +15°C; Explanation. -Acetone or any other solvent used shall not be capable of chemical reaction with the acetylene gas or with the porous mass or with the metal of the cylinder or valve; 

- “dissolved gas” means a gas which under pressure is dissolved in a fluid solvent appropriate to the particular gas as for example, acetylene in acetone or ammonia in water;

- “tare weight” in relation to - (1) acetylene cylinder means the weight of the cylinder together with any fittings, permanently attached and includes the weight of valve any safety device, porous mass, requisite quantity of solvent for dissolving acetylene, and the weight of acetylene gas saturating the solvent at atmospheric pressure and temperature of 15°C;

- Particulars of MATERIAL SAFETY DATA SHEET to be referred before handling any compressed gas cylinder. 

Note: All Consciousness Sessions are customized to suite site, client and level of candidates, these customizations are required to specifically address knowledge sessions, make the right connect to the people attending. 

Properly researched training / Consciousness session can give correct and effective information with an enhanced knowledge sharing session. 

For Quarries please do write to us on support@hse-rm.com

On completion of this training programme you will:

-          Understand the importance of safety and safety awareness.

-          Understand accident and causes of accident.

-          Understand various types of workplace hazards.

-          Understand various control measures that can be used to minimize the risk.

-          Understand how you can contribute to enhance your workplace safety.

Rigging Safety & Permit to Work Training Services by HSE-RM Solutions

Consciousness Session on Rigging Safety & Work Permit

HSE-RM Solutions [http://www.hse-rm.com/training-hse-consciousness/]

Changing conventional means of training to stakeholders Consciousness Session on Rigging Safety & Work Permit, Specially designed program to bring out, true meaning of learning. Focused on current practices, best practices and providing resourcing solution in safe handling procedures. 

Objective of Consciousness Session

·        To enhance awareness

·        In the proper selection, use, and maintenance of slings

·        In the recognition of hazards associated with rigging.

·        In adopting the safe rigging practices  

·        This training is designed to assist you in understanding and complying with OSHA's standards for sling use in General Industry, Maritime, and Construction.

·        To prevent any ACCIDENT related to RIGGING

Elements of Consciousness Session

ü  Safe Rigging Practices

ü  What standards apply?

ü  Factories Act Section 28 Hoist and lifts  and  Gujarat Factory Rules – 58 & 59

ü  FORM NO. 9 (Prescribed under Rule 58) Report of examination of hoists and lifts

ü  Factories Act Section 29 Lifting Machines, Chains, Ropes and Lifting Tackles and Gujarat Factory Rules – 60, & 60 A

ü  FORM NO. 10 (Prescribed under Rule 60) Prescribed for the report of Examination of the lifting machines, ropes, and lifting tackles.

ü  Rigging Hazards (Recognition, identification & Control) Basics; Rigging Safety - Signaling 

Å      Safe Rigging Practices

ü  Check the slings and ensure that the rigging angle is correct.

ü  Make sure the load is properly secured and inform the Crane Operator of the weight of the load.

ü  Make sure the lifting gears such as slings and shackles are well-maintained and in good working condition.

ü  Make sure the load is stable, secured and balanced before any lifting operation.

ü  Make sure any loose items are placed in a proper receptacle or container to prevent the load from falling during the lifting operation.

ü  Immediately report any defective or faulty lifting gear to the Lifting Supervisor.

ü  Place adequate paddings on the edges of the load to prevent the sling from damage.

Å      Good Practices

ü  Correct use of choker hitches

ü  Correct way to balance a shackle load

ü  Correct hook-up methods

ü  Correct rigging method

ü  Hook up unused slings

ü  Correct loading method

ü  Use paddings during lifting

ü  Correct methods of joining sling eyes.

ü  Use original screw pin

ü  Use tag line to control movement of the load

ü  Correct method of unloading

ü  Check hook for any defects and make sure it is in good working condition

ü  Check shackle for any defects and make sure it is in good working condition

ü  Check wire ropes for any defects and make sure they are in good working condition

ü  Understand and practice correct hand signals

Job Hazard Analysis

(Pre-Task Planning and Lifting Plans)

The Pre-Task Planning or Lifting Plan (Job Hazard Analysis) shall recognize all elements of foreseeable risk inherent in an operation and satisfactorily address them thus ensuring that safety is not compromised. This shall include the following, but is not limited to:

ü  Ground conditions and crane support

ü  Crane and rigging suitability.

ü  Structural capability of the load.

ü  Direction of an operation and control of the load.

ü  Discussion about load supports, support, and stability of cribbing, horizontal rotation requirements, where horizontal requirements are to take place (these should only take place at a minimally elevated position and any cribbing fully supported).

ü  Personnel not being subjected to location/working below a suspended load.

ü  Interface with other contractors.

ü  Access to/from lifting attachments.

ü  Interface with the Manufacturing personnel (where required).

ü  Safety procedures.

ü  Exclusion zone.; PPE

ü  Hazards of horizontal rotations if required.

Risk Assessment

Qualitative Risk Assessment

How Risk Is Appraised?

In the estimation of risks, qualitative risk assessment is beneficial for any organization or institution as it delivers real-time benefits by prevention through a third eye, in simple few steps awareness and proactive thinking can reduce risks, employers can prevent incident break out.

 Every organization has an existing framework of conducting the risk assessment of the project and reviewing of the safety plan, is this plan continuously updating? are its adequacy and efficiency checks done on regular basis? you need to redo the assessment to ensure your provisions are in line with the new legislation & continuously evolving process plant. In addition, every time your business changes in terms of premises, business activity or process even staff, you should undertake a revision of the assessment.

Approach Summary

Our friendly advisory support & safety experts will help you to understand and comply with all the legal requirements, along with all other relevant national and international latest emerging legislation. Qualitative risk assessment is all about simplifying understanding of risk and hazard to ensure continuous engagement of stakeholders for efficient and establishing evolving sustainable work practice.

Risk assessment requires you to examine both your premises and your work practice to assess the risk they pose, it is an opportunity to examine how your business could be improved as in the important exercise of reducing or eliminating risk. Risk assessment gives an insight, that you may discover underused parts of your premises or work practice that can be reviewed, not only to ensure the safety of your staff but also potentially improve productivity too.

Why Risk Assessment?

A detailed risk assessment for both your premises and business practice is required to draw up safety policies and procedures best suited. It’s important to explore modern means of protection system in the industry making our processes, premises, operations, and workforce safer. Is detection system adequate, does the detection system positioned correctly, some very basic system sometimes give more proactive protection, each facility quantity and quantum of risk differ?

Like any risk assessment, the qualitative assessment begins with obtaining information on risk factors, followed by risk classification in terms like "acceptable" or "unacceptable" or classifications such as "low", "medium", "high". Once seen as a risk for assets with a high risk will take mitigation measures. These measures are based on a hierarchy of business activities and their associated risks.

The qualitative assessment does not require determining the likelihood of data, only estimates of potential losses. Some related items are discussed in this approach.

• Threats - what can go wrong or attack the system such as fires or fraud. They are present in any system.
• Vulnerabilities - make the system more prone to attacks or the attacks may have more success and greater impact. For example, if fire, the presence of flammable materials is a vulnerability.
• Controls - are counter-measures vulnerabilities and their effects may be manifested in the following forms:
• Preventive controls protect against vulnerabilities and attacks can cause failure or reduce their impact;
• Corrective controls reduce the effect of attacks;
• Detective controls discover attacks and trigger preventative or corrective controls. 

After identification, the risks can be grouped by importance and likely to occur and represented in a matrix.

Organizing Risk in Two Criterial

1. Level of Risk
2. Degree of Probability

Risk assessment involves: 

• Looking for the hazards;
• Deciding who might be harmed and how;
• Evaluating the risks and deciding whether the existing precautions are adequate or whether more should be done;
• Recording your findings and telling your employees about them; and
• Reviewing your assessment and revising it if necessary, for example:
• If the work changes significantly;
• If there is an accident; or
• When someone returns to work after sickness or injury, or suffers a change in their health, that could affect or be affected by their work.

(HSE-RM Solution Service Index for Risk Assessment)

Informal Risk Assessment Techniques & Tools 

• Stop-Look-Analyze-Manage (SLAM)
• Job Safety Analysis (JSA)
• Workplace Risk Assessment and Control (WRAC)
• Preliminary Hazard Analysis (PHA)
• Failure modes and effects analysis (FMEA) and failure modes and effects and criticality analysis (FMECA)
• Fault / Logic Tree Analysis (FTA/LTA) and Event / Decision Tree Analysis (ETA/DTA)
• Hazard and Operability Studies (HAZOP)
• Bow Tie Analysis (BTA)
• Structured “What-if” Technique (SWIFT)
• Business impact analysis (BIA)
• Root cause analysis (RCA)
• Cause-consequence analysis
• Cause-and-effect analysis
• Layers of protection analysis (LOPA)
• Safety integrity level (SIL)
• Decision tree analysis
• Reliability centered maintenance,
• Sneak analysis (SA) and sneak circuit analysis (SCI),
• Markov analysis,
• (HIRA) Hazard Identification and Risk Assessment
• Hazardous Area Classification (HAC)

Regular update and perception analysis of collective data can enhance protection, response, institutional real time assessment, monitoring, and adaptation. Our Advisory Team & Associate partners have developed a digital system of OSH Management to assist the organization in achieving such goals.

OSH Management System Implementation

HSE-RM Solution

Can Help Digitalize your HSE Management System…

Fire Risk Assessment

Qualitative Fire Risk Assessment & Impact Assessment

By HSE-RM Solutions (www.hse-rm.com)

Every organization has an existing fire risk assessment done at the time of project and fire safety plan, is this plan continuously updating, is it adequacy and efficiency checks done on regular basis, you need to redo the assessment to ensure your provisions are in line with the new legislation & continuously evolving process plant. In addition, every time your business changes in terms of premises, business activity or even staff, you should undertake a revision of the assessment.

Fire risk assessment requires you to examine both your premises and your work practices to assess the fire risk they pose, it is an opportunity to examine how your business could be improved as in important exercise of reducing or eliminating risk. Fire risk assessment and impact assessment gives insight, you may discover under used parts of your premises, or work practices that can be reviewed, not only to ensure the safety of your staff, but also potentially improve productivity too.

Fire Safety Requirements

The Fire Safety Standards requires you, the business manager, to provide and manage:

·         Means of Escape

·         Signs and Notices

·         Emergency Lighting

·         Fire Alarm

·         Fire Extinguishers

·         Fire Doors and Compartments

Fire Risk Assessment

A detailed fire risk assessment for both your premises and business practices is required to draw up fire safety policies and procedures best suited. It’s important to explore modern means of protection system in the industry making our processes, premise, operations, and work force safer. Is detection system adequate, does the detection system positioned correctly, some very basic system sometime give more proactive protection, each facility quantity and quantum of risk differ.

With correctly evaluated economical blend of technology and science, protection level can be achieved, response time evaluation, reach path, evacuation path, access path, exit path are some commonly miscalculated measures of a safety plan.

Regular update and perception analysis of collective data can enhance protection, response, institutional real time assessment, monitoring and adaptation is possible HSE-RM Solution & Associate partners have developed digital system of OSH Management to assist organization in achieving such goals.

Fire Training

As the responsible person, you are also required to implement and keep records of:

·         Fire Procedures, including evacuation

·         Staff Training

·         Fire Drills

Simplify Selection & Practical Guide

Guidelines for how many? A person should not have to:

·         Travel more than 25 metres to get to a fire extinguisher.

·         Reach out more than two doors to get to an extinguisher.

·         Reach to different floor level to find an extinguisher.

How many is not always easy to gauge but, as a general rule, you will need one water-based extinguisher such as water, water additive (the best option for most) or foam (3 litre or bigger) for every 2000 square foot or 200 square metres of floor space. This is per floor.

Once you have a water-based one, you are likely to have electrical risks such as computers, retail lighting, fridges, machinery, servers, electric forklifts, etc. This will need a CO2 extinguisher and it makes sense to have a pairing of CO2 and water-based for every fire point. The 2kg is by far the more popular but the 5kg CO2 size would be better for server rooms, machinery, industrial, etc.  It is best not to have too many different types on the same premises if possible as this adds to confusion in a panic.

With upgrading technology and resource availability may it be management or protection level integration, system implementation organization like yours can be supported on both the fronts by our customized, tailored, and unique project capabilities.

Please feel free to communicate us for your further requirements at support@hse-rm.com; 

Fire Safety By HSE-RM Solution