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HAZMAT CYLINDER HANDLER COURSE
In-House Pressure Related HAZMAT Training Title 49CFR172.700
Written by:
William L. High & Edward A. Kasten
PowerPoint developed by Don Kinney
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Code of Federal Regulations (CFR) Title 49-172.700
All Persons who handle, transport or are likely to be affected by the hazards of compressed gas cylinders and their contents shall receive appropriate safety training.
Hazmat Training within the dive and fire protection industries should provide specific safety awareness for all applicable groups such as employees, service technicians, air fill station operators (FSO), Nitrox gas blenders as well as volunteer helpers, and even customers
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Regulatory Agencies
Department of Transportation (DOT) regulates the transport and handling of high pressure cylinders
Occupational Safety and Health Administration (OSHA)- regulates the safety of employees.These regulations only apply to employees.
It would not apply to a sole proprietor with no employees.
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Required Employee Knowledge
Know how to safely handle and fill cylinders
Identify illegal or damaged cylinders
Understand the hazards of high pressure air and, where Nitrox service is provided, mixing and gas transfer procedures.
Training in Hazmat makes the workplace safer.
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Training Requirements Documented training
should be provided to all employees before they encounter the real and potential hazards of compressed gas
Within 90 days of hire Refresher training every
3 years By a certified instructor.
PSI trained in inspections.
A SCUBA instructor would not qualify.
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Training shall include:Hazmat training should be provided
whenever an employee is assigned new duties.
General awareness/familiarization training
Function-specific trainingSafety Training to include:
Emergency ResponseEmployee ProtectionAccident AvoidmentSafe handling Procedures
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Required Documentation
A written record of the training for each Hazmat employee shall be maintained.
A copy of the training material shall be maintained
Documentation that the hazmat employee has been trained and tested.
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Record Keeping
Records are essential evidence in any civil or criminal action
Retain training and inspection records for at least 5 years
The record should include:Participant signatureDate and location of trainingDescription of material Name and number of PSI instructor
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Consequences of Improper handling, Filling and inspection
Several SCUBA or storage cylinders explode each year causing death, injury and property damage.
The Kinetic energy stored within a full 80 cubic foot cylinder exceeds one million foot pounds:Enough to disintegrate walls and destroy vehicles
About 90 percent of cylinder explosions occur during the filling process.
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Handling DangersWhen you carry the
cylinder by the valve - keep opening away from your hand.Air embolism may occur
through the skin if Secure cylinders to prevent movement
Maximum operating temperature 130 deg. F
Personal injury or cylinder damage may occur from dropped cylinder
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Service Pressure Service pressure must be
clearly displayed on all cylinders
The service pressure is established by a calibrated gauge at a constant 70 deg. F
A fill station operator will have no defense against civil or criminal charges if the cylinder later fails explosively due to over -pressurization of the cylinder
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Filling Policies
Fill at 300 – 600 psig per minute to service pressure
DO NOT over - pressurize cylindersProvide protection for FSO’sReject (set aside for professional inspection)
un-galvanized, steel coated cylindersRequire all persons to remain away from
fill station
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Cursory Inspection
What to look for:
Inspect exterior for damage caused by corrosion or exposure to heat
Perform hammer test on Steel Cylinders (listen for bell-like tone)
Look for EOI Sticker and proper hydrostatic test date Verify specification codes are proper In the U.S. only fill-ICC, DOT, CTC/DOT and TC/DOT
Cylinders Check cylinder residual air for odor Inspect cylinder having zero pressure Be Alert for improper valves I.e. metric in national gas
straight threaded cylinder
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Reject on Cursory Inspection Set aside for professional inspection the following cylinders:
Bevel bottom aluminum cylinders (SP6576) Any aluminum cylinder marked with SP6688 Any cylinder marked with SP890 COMPOSITE SCBA older than 15 years Hoop wrap SCBA E7235 4500 NOT retrofitted SP6498, E6498, SP7042 and E7042 NOT Over-stamped with 3AL All round bottom aluminum cylinders Valves w/o pressure relief devices or with fusible plugs or known or
suspected double discs Cylinders with known or suspected history of overfilling Cylinders with dents, bulges, line corrosion or pits Un-galvanized, vinyl-coated steel cylinders
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Disguised Damage
Boots often hide corrosion damageStickers may be placed over damageAuto Repair putty used to cover defectsOwner attempt to apply interior coating
of paint, zinc or epoxyPhysically altered cylinder – cut and
threaded to transport contraband
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Filling Cylinders
Conduct a cursory inspection of all cylinders before filling.Most explosions could have been avoided by a
simple cursory inspectionThe fill station operator may question the
validity of the stickerIncomplete inspectionInvalid inspectionNo sticker at all
During fill, be cautious of a cylinder falling
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Condemned Cylinder
Any cylinder marked condemned or having obliterated codes may NEVER be returned to serviceDO NOT FILL IT!
A trained PSI cylinder inspector may condemn a cylinder
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Fire vs. Cylinders
The Maximum sustained exposure temp. for 3AL cylinders is 265 degrees F
Between 265 and 350 degrees the cylinder must be hydro-ed before being placed in service
Reject the cylinder if exposed to over 350 deg. F and refer to a trained PSI inspector If any plastic has melted the
cylinder has been exposed to temperatures in excess of 350 degrees. The tank must be condemned
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Visual Inspection
If you have not been trained in Cylinders inspections – DO NOT DO IT!
Title 20CFR1910.101(a) – Each Employer shall determine that compressed gas cylinders under his control are in a safe condition to the extent that this can be determined by visual inspection. Visual and other inspections shall be conducted as prescribed in the HAZMAT Regulations of DOT(49CFR, Parts 171-179 and 14CFR part 103). Where those regulations are not applicable, visual and other inspections shall be conducted in accordance with CGA pamphlet C-6.
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Visual Cursory InspectionVs.
Internal Inspection
Anytime you fill/use a cylinder you should perform a cursory visual inspection.
An internal inspection should be conducted at least annually by a trained PSI Inspector.If necessary - depending on circumstances –
the cylinder may be inspected more often.
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Transporting Cylinders Secure the cylinders
vertically If they can not be
transported vertically, secure them horizontally facing sideways
Valves placed forward or to the rear may shear in a crash causing catastrophic damage
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Transporting Cylinders
According to DOT:When transporting cylinders for commerce,
it is necessary to place placards on all four corners of your vehicle when the load of cylinders meets or exceeds 1000 pounds.
Approximately 29 cylinders (aluminum)
The placard must state: NON-FLAMMABLE GAS - AIR
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Cylinder Storage
Store vertically, when possible, and secured tightly
Store below 130 deg. F in a dry environment
Protect from casual passersby O2 cylinders must be stored at
least 20’ from flammable gas containers or combustible materials.
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Cascade or Bank System
DOT storage cylinders are large (9” diameter by 51” long)
Store in cool dry areaValve caps should remain on inactive tanksSecure cylinders with chain to prevent fallingYou should not roll a cylinder to move it. Use a
proper dolly or other device. 10 year star service does not apply to cascade
or banked cylinders when they are attached to a compressor.
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ASME Cylinders
American Society of Mechanical Engineers (ASME)
These cylinders are intended for permanent installations and do not require hydro retest.ASME cylinders should still be visually inspected at
least annually ASME cylinders are usually plugged at each
rounded endSidewall plug allows the cylinder to be mounted
horizontally and frequently drained.
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SCBA(Self-Contained Breathing Apparatus)OSHA 1910.134
Written standard operating proceduresUser must be instructed/trained in
proper use of respiratorsRespirator must be cleaned and
disinfected after each useRespirators for emergency use shall be
thoroughly inspected at least once a month or after each use.
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SCBAComposite SCBA’s are generally manufactured
starting with a thin aluminum shell. The shell is then reinforced with fiberglass or a carbon material. Manufacturing the cylinder this way makes it
lighter for the user, but does NOT make it less susceptible to damage.
SCBAs are NOT designed for SCUBA useSCBA cylinder SP12479 has been tested for scuba
use but there are concerns about its continued use in underwater environment
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SCBA InformationCylinder Types (2000 psig-4500psig):
SteelAluminumComposite – hoop or full wrap
Steel and Aluminum solid wall have an unlimited service life 5 year hydro retest interval
ALL Composite cylinders are limited to a 15 year service life Fiberglass and Kevlar - 3 year hydro retest interval Carbon - 5 year hydro retest interval
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SCBA Operating Procedures
SCBA’s manufactured by MSA ( Mine Safety Appliance) and Interspiro have been designed for emergency fill rates as high as 6,000 PSIG/MIN
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SCBA Limitations
Although protected to some degree by the protective overwrap, the SCBA aluminum liner should not reach a sustained temperature exceeding 250 deg. F.
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SCBA Use
Warn users against storage restraints that may cause cylinder abrasions.
Composite cylinders are not designed for underwater use and should NOT be filled in a water bath.
Examine exterior at least every 30 days.Look for: distortion, dents, cuts & abrasionsSCBA’s require visual inspectionsDamage limits for composites are listed in the
CGA manual C-6.2.
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SCBA Damage Levels
Three Levels of Damage recognitionLevel 1 - Acceptable
Normal wear and tear and Minor damageLevel 2 - Rejected or Repaired
Depth of damage is greater than .005” but less than the value appearing in CGA C6.2
Tank should be re-hydro tested after repairLevel 3 - Condemn
Damage or abrasions greater than CGA C6.2 value
Frayed or delaminated fibers from the cylinder may be reason for condemning it. (Refer cylinder to trained PSI inspector for inspection)
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Resource Materials
Inspecting Cylinders –By William (Bill) High
Guide to SCUBA Cylinder Inspections –By Luxferesd5 Cylinder Manufacturing
Luxfer SCBA Guide