Using Propane Safely e-learning reference material

Guide Book Series

Propane

Using Propane Safely Your essential user manual

Everything you need to know to work safely with propane cylinders

Key safety practices for users of LPG cylinders

A concise, accessible, reference workbook

Fully illustrated, easy to follow

Guide Book Series

Copyright

Copyright

Contents

Gas Safe Consultants Ltd (Gas Safe) owns all copyright on its products. You may not totally or partially reproduce these materials without written permission from Gas Safe. This includes unlicenced and unauthorised copying in public and private organisations. This means you may not:-

Copyright Contents

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Essential steps: Fundamentals: Flammable gases: Propane

Working safely with industrial gases The environment we work in The dangers of fire and explosions LPG - Liquefied petroleum gas Design, construction and operation Product labels and colour codes Essential gas control equipment The weakest link in the system Preparation for use with a blowtorch Key safety issues Key safety issues Getting gas to the workplace Location, design and construction Basic safety requirements Actions to be taken

{ { photocopy the whole of, or a substantial portion of these materials

{ { copy them to include with your written materials

10 12 14 16 18 20 22 24 26 28 30 32

Cylinders and valves: Identifying cylinders: Pressure regulators: Hoses: Using cylinders safely:

reformat them

{ {

{ { publish, scan or upload them to retrieval systems, digital media or file sharing internet sites

Disclaimer Information contained in this resource is drawn from sources believed to be reliable. Gas Safe, its employees, associates and contractors do not warrant the correctness of the sources used and accept no responsibility to any person(s) or organisation(s) for any errors or omissions or for any loss or damage howsoever caused from the use of this resource.

Fork lift trucks: Bitumen boilers

Moving cylinders safely: Storing cylinders safely: Transporting cylinders:

Reason Release date Details Unit released September 2018 UPS V1.0 release

Cylinders in fires: Ten steps to safety

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Guide Book Series

Gas Safe Essentials

Essential Steps Working Safely with Propane

Each work area and situation must be risk assessed before work commences and the information detailed must be supplemented with: • Caution • Common sense • A few simple rules

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Ensure you are using the correct equipment that is undamaged, regularly inspected and within its expiry date. Oxy-fuel gas equipment should be inspected at least annually and written records kept.

Users should always refer to the manufacturer’s operating instructions for the equipment being used. Ensure standard operating procedures are in place for all gas operations.

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Users should always refer to the Safety Data Sheet for the gas(es) being used.

Ensure you have the right gas for the job. Check you have a full complete product label on a properly painted cylinder.

Always set the correct gas pressure.

Cylinder gas systems should be leak tested each time before use. Always leak test with an approved solution or spray.

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Ensure cylinders are handled and moved safely by trained operators using the correct mechanical aids. Always undertake a risk assessment prior to any new manual handling operation that includes gas cylinders.

Cylinders should be safely secured in a safe, well ventilated environment.

All gas cylinder operations must only be undertaken by trained employees.

Always follow industry standards and guidelines as issued by the British Compressed Gases Association and UKLPG.

Important

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Guide Book Series

The Working Environment

Fundamentals The environment we work in

Gas density relative to air One of the most important properties of a gas is its density relative to air. The density of air is 1. So if the density of a gas is lower than air (i.e. 0.6) the gas will rise, if it’s higher (i.e. 1.5) it will fall.

Gas

Density relative to air

You are surrounded by a gas called air that has three main components; nitrogen, oxygen and argon.

Hydrogen

0.07 0.14

Helium

Acetylene Nitrogen

0.9

Lighter than air

0.97

Air

1

Argon

1.38

Propane

1.5 1.5

Heavier than air

Propylene

The density dictates whether a gas will rise or fall if it leaks into, or is released into the working environment. All gases that are lighter than air will tend to move to the highest point in any enclosed space and will collect there unless there is ventilation at high levels. Gases that are heavier than air such as propane and butane will collect in low lying areas and should not be stored or used near to drains, ducts, trenches or inspection pits.

20.93%

0.93%

0.11%

78.03%

Nitrogen

Oxygen

Argon

Carbon Dioxide Neon Helium Krypton Hydrogen Xenon

Operators may work with a variety of different gases. Each gas has its own characteristics which affect:

{ { The way the human body reacts to a gas

{ { The gas’s behaviour in the working environment

When handling and using gases operators should always have access to the corresponding Safety Data Sheet (SDS) for each of the gases being stored, handled, transported or used. The SDS provides essential information on the properties, hazards associated with the gas, first aid, fire fighting measures, handling and storage as well as other facts. Safety Data Sheets are freely available from your gas supplier. You can also download them from the web.

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Guide Book Series

Flammable Gases

Flammable Gases The dangers of fire and explosions

Propane LPG - Liquefied petroleum gas

These gases all have an associated asphyxiation hazard but also present the more important hazards of fire and explosion. These gases when mixed with air or oxygen and provided with an ignition source will burn. These gases may also be referred to as ‘fuel gases’.

LPG describes a group of hydrocarbon gases which exist as vapour under ambient conditions of temperature and pressure, but which can be liquefied by the application of moderate pressure.

Air content vol %

Gas content vol %

Propane (C 3 H 8 ) is colourless and odourless in its natural state. For safety reasons a stenching agent (a sweetish fish like smell) is added during production to aid detection by smell at very low levels.

0%

100%

Acetylene 2.2 - 85.0

Propane is stored inside the cylinder as a liquid under vapour pressure. One volume of liquid propane will produce approximately 270 volumes of vapour (gas). Propane is lighter than water and it therefore floats on top of it in a similar way to oil and petrol. For this reason propane cylinders must not be stored or used near to grids, drains and gullies. Propane gas is one and a half times heavier than air so any escape will find its way to the lowest level where it can remain and form a flammable mixture with the air.

Hydrogen 4.0 - 75.0

Propane 2.2 - 9.5

Propylene 2.0 - 10.5 The above chart shows the flammability concentration limits for an atmosphere of air. The red band shows the percentage range of fuel gas that presents a particular danger of fire or explosion. As the percentage of the fuel gas increases the risk of fire or explosion becomes greater. After the concentration has exceeded the upper value the air becomes saturated with the gas and an ignition becomes less likely. As the lower concentration limits are a very small percentage it is important that all fuel gas systems are leak tested prior to use and all working environments have sufficient ventilation. Methane 5.3 - 15.0 Butane 1.4 - 9.3 Carbon Monoxide 10.9 - 74.2

LPG is non-toxic but at very high concentrations in air the vapour is an anaesthetic and subsequently an asphxiate by diluting or decreasing the available oxygen in the air. Propane should always be stored and used in well ventilated areas.

If you discover a colleague collapsed in a working environment, raise the alarm, stop people from entering the area and implement the emergency rescue procedure.

Reference UKLPG CP24 Pt6 The use of Propane in cylinders at Commercial and Industrial Premises HSE INDG 227 Working safely with flammable substances

Reference UKLPG Technical Fundamentals

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Guide Book Series

Cylinders and Valves

Cylinders and Valves Design, construction and operation

Propane cylinders are pressure vesels and should be treated with care: Never repaint, change markings or remove product labels Never interfere with cylinder valve threads Never remove a valve guard or modify a cylinder Never mix gases in a cylinder Never transfer gas from one cylinder to another Never apply PTFE to cylinder valves or regulators Never scrap a cylinder you do not own Never allow cylinders to become too hot Never use a cylinder as a container for other substances Just as a small volume of boiling water will produce a lot of steam, 1 volume of liquid propane will produce approximately 270 volumes of gas when vaporised. For this reason propane cylinders are fitted with a pressure relief valve which operates at approximately 26 bar. Should the take-off rate from the cylinder become excessive the boiling liquid needs more heat. This comes from the surrounding atmosphere trying to heat the cylinder. Condensation of the moisture from the relatively warmer atmosphere in contact with the cold cylinder surface results in frost appearing on the cylinder. If this is allowed to develop the boiling rate slows and the pressure within the cylinder may fall. If the operator requires a high flow rate of propane gas then it may be necessary to manifold two or more cylinders together to supply the required pressure. In normal use, as the gas is used the liquid “boils off”, reducing the cylinder liquid content. When the cylinder valve is closed the pressure in the cylinder builds and the liquid stops boiling. In other words the pressure in the cylinder will always be approximately 7.5 bar despite the fact that the gas is being used.

The first gas cylinders were manufactured in 1874. Since then manufacturers have been constantly improving their methods of production and ultimately the capacities and capabilities of gas cylinders. Today there is a wide variety of cylinder types that meet the needs of all applications. Permanent gases such as oxygen, nitrogen, argon, hydrogen and helium are filled into gas cylinders that have been manufactured from a single cylindrical block of steel called a billet. This type of cylinder is a hollow tube with a closed concave base that permits it to stand upright. The opposite end is tapered to a small opening that is threaded to accommodate the installation of a valve. This type of cylinder contains gas molecules and may be operated either with a spindle key or a handwheel

Propane cylinders look different and are different to other gas cylinders. The pressure at which propane forms liquid is much lower than other gases, this means that the cylinders are lighter, have thinner walls and are of a welded construction. Propane is stored as a liquid under approximately 7.5 bar (100 psi) pressure.

The boiling point of propane is -42.1°C. Since the cylinder is not insulated sufficient heat can be absorbed through the cylinder wall to generate the heat needed for the liquid to boil thus giving off a vapour, i.e. gas. When the cylinder control valve is opened to release the pressure the liquid will boil in the same way that water boils. As the liquid boils it uses ‘available’ heat from the cylinder wall. Over time the amount of usable heat will fall and the cylinder shell will cool.

Gas cylinders are fitted with a cylinder valve which must not be removed or tampered with. Valves fitted to non-flammable gas cylinders have conventional right-hand threads whilst valves fitted to flammable gas cylinders mostly have left-hand threads. An exception is ppropane cylinders used on forklift trucks which are fitted with right- hand connections

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Guide Book Series

Identifying Cylinders

Identifying Cylinders Product labels and colour codes

Operators need to know what gas is inside a cylinder. The primary means of identification is the product label. The hazard of the gas may be confirmed by the colour of the cylinder shoulder.

An important part of the label is the hazard diamond(s) which represent the characteristic of the gas. A label with multiple diamonds indicates multiple associated hazards. The colour coding of gas cylinders changed in 2001. The colour coding now applies solely to the shoulder or curved part at the top of the cylinder. This means that the shoulder colour for all gas cylinders supplied by all the gas suppliers in the UK are standardised. With respect to labelling and colour coding propane cylinders have an ‘exemption’ in that suppliers are able to stencil the gas name onto the side of the cylinder instead of attaching a label to the cylinder. Also, propane cylinders can be supplied in a variety of colours. It is essential that operators ensure that the cylinder contents are either labelled or stencilled onto to the cylinder.

A propane cylinder without either a full, complete, legible product label or the gas name stencilled onto the side of the cylinder must not be used and must be immediately returned to the gas supplier.

Product name

Safety information

Supplier’s name

Cylinder size

Emergency contact number

A selection of propane and butane cylinder colours and sizes.

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Dangerous goods identity number

Cylinder weight

Guide Book Series

Regulators

Pressure Regulators Essential gas control equipment

Pressure regulators for use with oxygen and inert gases have different threads to that of fuel gases. All oxygen and inert gas fittings have normal right hand threads. All fuel gas fittings have left hand threads (identified by notches on the connecting nut). Regulators should only be used by trained operators in-line with an approved standard operating procedure. Reference should be made to the manufacturer’s operating instructions.

The pressure at which cylinders are filled is far greater than that required for most applications and therefore it needs to be reduced by a pressure regulator to a safe working level. Propane regulators can be divided into two types:- { { They may be supplied with a pressure adjusting screw that can be a screwed in or out to adjust the pressure of gas being supplied to the process being used. { { They may be supplied without a pressure adjusting screw. This type of regulator supplies a fixed flow or pressure to the process being used

Never use left hand to right hand adaptors, their use could cause serious injury.

High pressure propane regulators (up to 4 bar working pressure) are manufactured to BS EN 16129. This new standard replaced BS EN 13785 in 2013.

If the pressure regulator is fitted with pressure gauges, these should never be removed, exchanged or tampered with in any way.

Regulators should receive a visual inspection each time prior to use. They should be formally inspected at least annually and written records should be kept.

The maximum inlet and outlet pressures will be specified on the regulator. This dictates how much pressure the regulator can withstand before failing and must be at least as high as the cylinder pressure. Always cross reference the product and pressure information on the regulator with the product and pressure information on the cylinder product label or stencil on the side of the cylinder. Operators should always use the correct sized spanner to connect the regulator to the cylinder valve. Adjustable spanners should not be used as they can ‘round-off’ the hexagon nut.

Regulators should be replaced five years after their date of manufacture or in-line with the manufacturer’s guidelines.

Damaged regulators must not be used. Out of date regulators must not be used.

Each gas has specific chemical and corrosive properties; the internal mechanism of the regulator is designed with these in mind.

Always use a regulator that is designed for use with the specific gas being used.

Never use any form of jointing compound or thread tape such as PTFE between the regulator threads and the cylinder valve and outlet connections.

Never make modifications to a regulator.

Never interchange regulators between different gases.

Whether they are in storage or in use, inlet and outlet connections must be kept free of dust or other debris, any form of oil, grease or solvents. Contaminated units must not be used and must be removed from service.

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Guide Book Series

Hoses

Hoses The weakest link in the system

Operators must not make up their own hose assemblies. Also….operators must not repair worn hoses by cutting away the damaged section of the hose and then replacing the connections with worm drive screws.

Hoses are constructed to carry pressurised gas from the regulator to the point of use and are probably the item that purchasers of gas control equipment consider least. Often they are the item that will receive the most abuse and wear. There can be no question that hoses are the “weakest link” in most systems, and often receive the least attention. All hoses used to carry pressurised gas require strength and rigidity in order to prevent damage, which could result in leaks. Each type of hose has a maximum working pressure which must never be exceeded.

If hoses are repaired they must be tested to the relevant European Standard.

If you discover a hose fitted with one or more worm drive screws, remove it from the regulator and replace it with a new hose that is manufactured to the correct European standard. Unlike regulators here is no specific life or exchange interval for hoses. They should be visually inspected each time prior to use and replaced when they are damaged, contaminated or show signs of deterioration. The connectors on high pressure propane hose should be secured with swaged or crimped clips. Operators should always select a hose that is the correct length for the job in hand. A hose that is too long is not only a trip hazard but will also reduce the pressure of gas being fed into thapplication.

High pressure hoses for use with propane are orange and are manufactured to BS 3212-2 or BS EN 1256 which is the standard for welding and allied processes. Hoses are designed and manufactured to be used with specific gases. Always use the correct colour of hose…..never interchange them.

Operators should always use the correct sized spanner to connect the hose to the regulator or flashback arrestor.

It should be noted that butane or low pressure LPG hose is coloured black. This hose is rated for a maximum working pressure of only 50 millibars. Don’t use low pressure LPG hose for high pressure propane applications.

Operators need to protect hoses from heat, mechanical damage, sparks, oil or grease.

Many operators make up their own hose assemblies by cutting a length of hose from a hose reel and then attaching assemblies with worm drive screws. This is bad practice and should not be undertaken.

Reusable worm-drive clamps must not be used.

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Guide Book Series

Using Cylinders

Using Cylinders Safely Preparation for use with a blowtorch

Check the regulator thread for damage and/or contamination and if it is in good condition attach it to the cylinder valve outlet using the correct size spanner and only reasonable force to tighten.

Damaged or contaminated regulators must not be used.

This information is for guidance only. Operators should always follow the equipment manufacturer’s instructions as well as an authorised standard operating procedure for the job being undertaken.

Visually check the hose is the correct colour and standard and is undamaged, then attach it to the regulator outlet.

Hose assemblies manufactured to BS EN 1256 will have a non return valve (NRV) fitted to one end of the hose. The end with with NRV must not be fitted to the regulator outlet.

Before undertaking any activity with propane cylinders operators should ensure that they are wearing the correct personal protective equipment.

Attach the end of the hose with the non return valve to an undamaged blowtorch torch that is suitable for the job being undertaken, in this example, shrink wrapping.

Safety glasses are essential when working with high pressure gas cylinders.

The cylinders should be located in a safe, well-ventilated area and secured to stop them from toppling over. Ensure you have the correct gases by referring to the product label or stencilling on the cylinders. New cylinders are fitted with either a valve cap and/or shrink wrapping to protect the valve from contamination. Most valve caps are removed by peeling away the plastic tab and flipping the lid open. Wearing eye protection, look inside the valve outlets and check for any foreign material such as particles of dirt or water. Any material detected must be removed. This can be carried out by wiping the inside of the valve outlet with a clean, dry, lint-free, oil and grease free cotton cloth.

Slowly open the cylinder valve, half a turn on the handwheel is usually sufficient.

If the regulator is fitted with a pressure adjusting screw, slowly screw it in and set the correct working pressure on the outlet gauge of the regulator.

The regulator in this example is fitted with a red ‘flow’ button that should be depressed, allowing gas to flow from the regulator, through the hose towards the blowtorch.

Before lighting the torch an approved leak test solution should be applied to all joints and any potential leakage points.

If there is frothing the system should be immediately de-pressurised and the leak corrected.

Visually check that the regulator is undamaged and is the correct regulator for the gas contained inside the cylinder. Ensure the regulator has the inlet capacity to cope with the pressure inside the propane cylinder and has the correct outlet pressure rating for the job to be undertaken. Never open and quickly close the cylinder valve to blow any debris out of the valve outlet. This old industry practice called ‘snifting’ has resulted in some serious injuries.

Never use jointing compounds or thread tapes to try and rectify a gas leak.

Once the system is leak free the operator can press the trigger on the torch which automatically lights the gas

At the end of the work period close the cylinder valves and, depending on the type of system being used, safely de-pressurise the system in a well ventilated area.

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Guide Book Series

Fork lift trucks

Fork Lift Trucks Key safety issues

A full fork lift truck cylinder weighs approximately 36kgs. The manual handling aspect of the cylinder changeover must be risk assessed and it is advisable that two trained operators are available to undertake the removal of the ‘empty’ cylinder and the lifting and securing of the new ‘full’ cylinder into the cradle on the rear of the vehicle. The cylinder must be loaded so that the arrow on the base of the cylinder is pointing downwards (towards 6 o’clock). This ensures that the dip tube inside the cylinder points downwards and will work effectively. The cylinder must be restrained with a strap that is in good condition. The operator should check that there is an ‘O’ ring washer inside the hose connector and that it is in good condition. The hose may be screwed onto the cylinder valve outlet. This connection is usually secured ‘hand-tight’. The cylinder valve may then be slowly opened to avoid a sudden rush of liquid into the hose. The valve may be opened fully and then turned back half a turn. After the valve has been opened the operator should now leak test the connection between the valve outlet and the hose with an approved leak test soluion or spray. If any bubbles are visible the valve should be closed and the leak corrected.

This information is for guidance only. Operators should always follow the vehicle manufacturer’s instructions as well as an authorised standard operating procedure for the cylinder change-over. The cylinder changeover must only be undertaken in a safe, well ventilated area by trained operators who are wearing the correct personal protective equipment. Safety glasses are essential when working with pressurised propane cylinders that contain very cold liquid

Propane cylinders for use on fork lift trucks are designed to be used horizontally. The gas pressure above the liquid forces the liquid through a dip tube, down the hose and into the engine. Unlike ‘standard’ propane cylinders which have left hand connections, the majority of the cylinders that are designed for fork lift trucks have right hand connections. When the ‘in-use’ cylinder has ‘run-out’ operators should ensure that they have a tight hold on the hose when they unscrew the connection with the cylinder as there may be some residual gas inside the hose. Before changing the cylinder operators must ensure that they have a full cylinder that not only contains the correct gas (reference must be made to the cylinder label or stencilling on the side of the cylinder) but is also designed for use on a fork lift truck. After removing the valve protector, the operator should visually inspect the valve for damage and/or contamination. If either is found the cylinder must not be used. If niether is found then the cylinder can be loaded onto the cylinder cradle.

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Guide Book Series

Bitumen boilers

Bitumen Boilers Key safety issues

When the cylinder and boiler have been secured in a safe area, and the regulator and armoured hose have been connected to the cylinder, the operator can now visually inspect the burner and attach it to the armoured hose using the correct spanner. Before lighting the burner it is essential that the operator checks that it will easily fit inside the boiler prior to lighting the system. If there’s a blockage inside the boiler it’s easier to sort out the problem before the burner is lit. Once the operator is sure the burner will fit into the boiler they can turn on the propane cylinder by slowly opening the cylinder valve. The valve may be opened fully and then turned back half a turn. The burner can now be lit using the correct type of spark lighter. Once the burner is lit is can then be safely inserted into the boiler. Now the burner is inside the boiler the operator can safely leak test the connections downstream of the cylinder. Firstly the operator should leak test the connection between the regulator and the cylinder valve. Then they should check the connection between the armoured hose and the regulator. If a leak is found the system should be safely shut down and the leak rectified. Finally they should carefully leak check the connection between the armoured hose and the

This information is for guidance only. Operators should always follow the boiler manufacturer’s operating instructions as well as an authorised standard operating procedure for correctly setting up the system. The cylinder set-up and boiler lighting must only be undertaken in a safe, well ventilated area by trained operators who are wearing the correct personal protective equipment.

The operator should visually inspect the boiler for damage prior to starting the job. Damaged boilers should not be used. Operators should also check that the vents are clear of excess tar. Next the operator should check that the gas cylinder is correctly labelled or stencilled as propane. The cylinder should be secured on a flat, level surface and must be at least 3m away the boiler. The cylinder must also be upwind of the boiler and should be sited so that a spillage of bitumen could not reach it. The operator can now remove the valve protector/plug and visually inspect the valve for damage and/or contamination. If either is found then the cylinder should not be used. The propane regulator should be visually inspected to ensure that it isn’t damaged, is in-date and will deliver the correct working pressure to the boiler. If the regulator is suitable for service it can be fitted into the cylinder valve outlet and secured with the correct sized spanner, preferably not an adjustable spanner. Some regulators designed for bitumen boilers are supplied with an armoured hose already attached. It is strongly recommended that an armoured hose is used with bitumen boilers and standard rubber hoses could ignite if they came into contact with hot bitumen. Operators should always visually inspect the armoured hose for damage before use. Damaged hoses must not be used. 22

At the end of work it is essential to shut the system down safely. A common practice with many types of equipment is to close the cylinder valve first and then allow the residual gas to burn off at the torch/burner. After the flame burns out the operator can close any valves fitted to the equipment and carefully disassemble it.

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Guide Book Series

Manual Handling

Moving Cylinders Safely Getting gas to the workplace

For small distances it may be necessary for operators to ‘churn’ the cylinder. ‘Churning’ a cylinder means balancing the rim of its base, slightly off the vertical, steadying it there with one hand and propelling it so that it rolls along the rim with the other. Churning a cylinder is permissible:

Propane cylinders are supplied in a variety of sizes. It is important to remember that they are potentially dangerous if not treated and moved with care and respect.

{ { Over flat, level ground

For short distances

{ {

{ { By trained operators, wearing the correct PPE

A risk assessment must be completed prior to any new manual handling operation.

{ { Only by those who have the physical capacity to control the cylinder

The key elements to consider when moving gas cylinders are:

Operators should take care when churning a propane cylinder as:-

Upright

{ {

{ { the cylinder contains liquid which will ‘slosh’ around and move the centre of gravity { { the cylinder is fitted with a handwheel valve. If the operator tries to churn the cylinder whilst holding the handwheel they may inadvertently open the valve and vent a stream of very cold gas.

Secure

{ {

Under direct control

{ {

All operators undertaking manual handling activities must have the individual capability to move the load. They must be trained in manual handling operations and wear appropriate personal protective equipment (PPE):

Never attempt to churn a cylinder with equipment attached. Never roll a cylinder along the ground. Never try to catch a falling cylinder, get out of the way! Never drag a cylinder.

Eye protection

{ {

Gloves

{ {

{ { Safety footwear (toetectors)

When handling cylinders operators should be aware of the hazards posed by uneven, sloping, slippery and vibrating surfaces, as well as loose debris.

The safest way to move a propane cylinder is secured on an appropriately sized cylinder trolley with the valve closed.

If you are in any doubt about moving a large gas cylinder ensure you get some assistance before undertaking the operation.

Cylinder trolleys are ‘work equipment’ and should be maintained in line with the requirements of the Provision and Use of Work Equipment Regulations.

Reference BCGA Guidance Note 3 GN3 Safe cylinder handling and the application of the manual handling operations regulations to gas cylinders

Never use damaged trolleys or trolleys that have unsuitable wheels for the terrain to be moved over. Never use trolleys that have no restraining mechanism.

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Guide Book Series

Storage

Storing Cylinders Location and design considerations

The storage area should be well lit and have suitable signage identifying which gases are inside the store and the hazards posed.

Full cylinders should be stored separately from empty cylinders. The areas relating to full and empty cylinder stores should be labelled appropriately.

Planning a storage facility is an important activity that needs to be undertaken before ordering gas cylinders from a supplier. Propane cylinders should be kept in a purpose-designed storage area following the principles laid out in BCGA Code of Practice 44 and UKLPG Code of Practice 7.

It is advisable to segregate cylinders in the store by their gas type. Less than 50kg of propane may be stored in the same area as other fuel gases. If the store contains more than 50kg of propane then these cylinders must be stored 3 metres away from any other type of gas cylinder.

A risk assessment must be undertaken on any potential storage area with consideration given to site boundaries, parking areas and emergency evacuation procedures.

As propane is heavier than air, propane cylinders must not be stored near to low lying areas such as drains, ducts and basements.

The area should be free from fire risks, including sources of heat and ignition and flammable materials. Propane cylinder gas stores should be sited in a non-smoking zone and be equipped with fire fighting facilities.

Emergency plans should be prepared for all storage areas and there should be accessible escape routes. In larger storage areas it is advisable to have access via outward opening doors and egress via a separate door that is operated by a panic bar.

The store should be secure and well-ventilated. It is advisable to construct the store from wire mesh or use a purpose built cage which will allow the Fire and Rescue Service to play water on the cylinders in an emergency situation.

Emergency procedures should be practiced on a regular basis.

The storage facility should be easily accessible for cylinder movements and access should be restricted to authorised personnel only.

Stock rotation is essential and it is advisable to operate on a F irst I n F irst O ut basis.

The storage area should remain accessible for the emergency services at all times.

It is recommended that the Fire and Rescue Service are made aware of the location of the cylider gas store as well as the number and types of cylinders being stored.

The base of the store should be a smooth, level surface which is well-drained and non-flammable (preferably made of concrete).

Reference BCGA Code of Practice 44 The storage of gas cylinders

The propane cylinders should be stored upright and secured to prevent them from toppling over.

Only compressed gas cylinders should be stored within the area. The area should not be used for general storage and should not contain materials such as fuels, oil, paint or corrosive liquids.

Reference UKLPG Code of Practice 7 Storage of Full and Empty LPG Cylinders and Cartridges

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Guide Book Series

Transportation

Transporting Cylinders Basic safety requirements

It is the driver’s responsibility to ensure that their vehicle is safe, well-maintained and has the capability to carry gas cylinders. The driver must have received appropriate training and knowledge about the gases being carried and be aware of the basic actions required in the event of an emergency.

The driver does not need to carry any special documents to transport small quantities of gas cylinders. However, it is useful to have the right information to assist the emergency services in the event of an incident.

It is safe to carry propane cylinders on vehicles providing operators follow some basic legal and safety requirements. This content highlights the basic rules for transporting small numbers of gas cylinders on vehicles whilst at work. Anyone carrying gas cylinders on a vehicle in the course of their work has to comply with ADR (Road Traffic Regulations) . Full compliance with ADR is required to carry toxic or corrosive gases. There are exemptions for other gases if the number of gas cylinders being carried is under the specified threshold limits laid out in ADR. Ideally gas cylinders should be transported in an open vehicle. If this is not possible, drivers must make sure that they have good ventilation to maintain a healthy environment inside the vehicle. The most effective way to improve ventilation is to open a window.

Drivers are not required to display any hazard warning labels or signs on their vehicles if they are only carrying small quantities of gas cylinders.

Organisations must make sure they have informed their insurance company that they are carrying gas cylinders on their vehicle(s).

If the driver suspects that there is a leak from a gas cylinder, they should take the following immediate actions: If driving, stop and park the vehicle as soon as practical in a safe place, away from naked flames and flammable substances. Turn off the ignition. Do not smoke or allow anybody to smoke in the vicinity of the vehicle. Check the cylinder valve. If it is open, close the cylinder valve immediately (if safe to do so).

Smoking must never be allowed in a vehicle when gas cylinders are being carried. This includes everybody - not just the driver.

It is mandatory to carry a fire extinguisher if gas cylinders are being transported at work. A 2kg dry powder extinguisher is the minimum requirement and the driver must be trained in its use. The ignition of a flammable gas following a leak could be catastrophic, also oxidising gases strongly support combustion.

Increase the ventilation in the vehicle. Open all doors, windows, luggage areas etc. If there is a liquid leak (i.e. LPG) do not touch the liquid as it will result in a cold burn. If the cylinder continues to leak, and it is safe to do so, remove the leaking cylinder from the vehicle and place in a safe, well-ventilated area. Consider notifying the emergency services. Ensure that the vehicle has been adequately ventilated before continuing with the journey. If the leak cannot be stopped, do not return a leaking cylinder onto the vehicle. If additional help is required, contact your gas supplier for advice.

Cylinders must be securely stowed, preferably in the luggage area. If the vehicle is involved in an accident the driver and any passengers could be injured by unsecured items being thrown around inside the vehicle. Gas cylinders should be removed at the end of each journey and it is advisable that they are not left in closed vehicles overnight. If the vehicle is left for short periods, then the cylinders should be kept out of sight as they, and their associated equipment are attractive to opportunist thieves. Drivers should ensure the valves are closed on all cylinders being transported. They should also check there are no leaks (using an approved leak detection solution or spray). If ancillary equipment is attached to the cylinders the system should be fully purged of gas (in a well-ventilated area) before the journey commences.

The emergency services attending an accident or incident should be advised that the vehicle is carrying dangerous goods (gas cylinders). 29

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Guide Book Series

Cylinders in Fires

Cylinders in Fires Actions to be undertaken

Emergency plans Cylinders that are handled and stored and used in a safe manner, should not give rise to an emergency situation. However, it should be recognised that they may occasionally become involved in an incident. Local management should carry out risk assessments to identify potential emergency situations. Emergency plans should then be established, and as necessary advice sought through liaison with the emergency services. The emergency plan should identify:

When a propane cylinder is exposed to excessive heat there is a risk of it bursting as the gas inside the cylinder may expand at a faster rate than the relief valve is able to vent off the excess pressure. If the cylinder bursts pieces of exploded metal may be sent hurtling through the air for distances up to 400m.

{ { Potential emergency situations.

{ { Identification of the gases held, the approximate stock holdings and their hazard categories.

Raise the alarm and evacuate the area. Operate the sprinkler systems, if available. Contact the emergency services. Inform them of the number, type and location of the cylinders, where possible. Do not approach cylinders that are involved in the fire until you have been advised by the emergency services that it is safe to do so. Evacuate all personnel to a safe distance (at least 200m) from the fire area, conduct a roll call to ensure that all persons are accounted for. Due to the fact that exploding gas cylinders may travel up to 400m from the fire area, inform all neighbours of the fire situation and encourage them to evacuate their premises. The emergency services will assist in the evacuation process. Provided that it is safe to do so and without putting anyone at risk, cylinders that are not directly involved in the fire should be removed as quickly as possible to a safe area. Ensure their valves are closed and that they are isolated from other processes. When the emergency services arrive, advise them of the actions you have undertaken and confirm how many cylinders are involved in the fire and what type of gases are contained inside the cylinders. The emergency services will spray copious amounts of water onto the cylinders. They will use fire monitors to allow the fire fighters to withdraw to a safe position. The Fire and Rescue Service has defined procedures for dealing with gas cylinders involved in a fire. You must ensure that all personnel observe the evacuation. Only return to the work/fire area once you have been given the all clear by the emergency services. 30

{ { Location of the gas cylinder stores (and other hazardous goods stores).

{ { The procedures to be followed, for example, site evacuation, accounting of personnel.

{ { The responsibilities of key personnel, including the appointment of an incident controller. This must be a trained person with adequate local site knowledge to take charge of the emergency and assist the emergency services as necessary. { { Access to and availability of emergency equipment and PPE. Further advice on fire-fighting equipment and fire precautions may be obtained from either the the Fire and Rescue Service. Additional information is available in the product Safety Data Sheet. { { Essential contact details. All personnel who are required to handle and store gas cylinders must receive suitable information and instruction regarding the emergency plans. Emergency plans should be reviewed or practiced on the following occasions: { { The involvement of the emergency services.

{ { On a routine basis; at least annually.

{ { Whenever significant changes are made to the site.

{ { When there is a significant change in the quantity of gases held

{ { There is an introduction of a different hazard category of gas, or the removal of a particular hazard category.

{ { When an incident has occurred. Any lessons learnt must be incorporated back into the emergency plan.

In the event of a serious gas leakage

Raise the alarm.

{ {

{ { Evacuate the immediate area.

{ { Instigate the emergency plan.

31

Guide Book Series

Summary

Ten Steps to Safety

1. Ensure risk assessments have been undertaken

2. Ensure all staff/operators are correctly trained

3. Ensure the equipment is inspected

4. Ensure standard operating procedures are being followed

5. Ensure cylinders are upright and secure

6. Ensure the correct PPE is being worn

7. Ensure equipment is not being repaired

8. Ensure all gas systems are leak tested prior to use

9. Set the correct working pressure or flow

10. Ensure systems are correctly shut down and de-pressurised

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