Oxy Aceylene Equipment

8/10/2019 Oxy Aceylene Equipment

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FREQUENTLY ASKED QUESTIONSABOUT

Portable Oxy-Fuel Gas EquipmentVersion 1 March 2007

ThisdocumenthasbeencompiledfromthemostcommonaskedquestionstoWorkSafeonportableoxy-fuelgascuttingandweldingequipment.IthasbeenpublishedtoassistindustrybyclarifyingandexplainingWorkSafespositiononthesecommonquestions.Oxy-fuelgases,includeoxygen,acetyleneandliquefiedpetroleumgas(LPGas).

Typical oxy-fuel gas equipment

Contents

Page

1.TRANSPORTINGGASCYLINDERSINVEHICLES...................................22.STORINGGASCYLINDERSONCONSTRUCTIONSITES.......................33.USE,CAREANDHANDLINGOFGASCYLINDERS..................................64.FLASHBACKARRESTORS........................................................................ 75.FIREPROTECTIONEQUIPMENT..............................................................86.MAINTENANCEOFOXY-FUELGASEQUIPMENT...................................87.PERSONALPROTECTIVEEQUIPMENT.................................................108.ATTACHMENTONE.................................................................................119.FURTHERINFORMATION........................................................................12

Frequently Asked Questions:

Portable Oxy-Fuel Gas Equipment,March 2007 Page 1 of 12


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1. TRANSPORTING GAS CYLINDERS IN VEHICLES

1.1 How should I transport gas cylinders in my work ute, tray truck ortrailer?

Whentransportinggascylindersonutilities,openvehicles,ortrailers:

Removeregulatorsbeforeloadingontovehicleandtransporting.

Ensurecylindervalvesremainclosedandusevalveprotectionguardsorcaps,where

possible.

Securecylindersinanuprightposition,topreventthemtippingorfallingover.

Avoidcarelesshandling,donotdroporallowheavyobjectstofallonthem.

Removeorsecureloosetoolsandmaterialsthatcandamageandrupturecylinders.

Carryfirefightingequipmentonyourvehicle.

Parkvehicleintheshade,wherepossible.

DONOTsmoke,usenakedflameornonflameproofelectricsanywherenearavehiclecarryingfuelgases.

DONOTtransportfuelgascylindersinaseparateenclosedcargocompartment(suchasutilitieswithcanopies),unlessthecompartmentispermanentlyventedtooutside.

DONOTcoverutilities,openvehicles,ortrailerswithatarpaulinwhentransportingfuelgascylinders.

DONOTleavecylindersunattendedinvehicleswheretheyareaccessibletounauthorisedpersons.

1.2 Is it OK to transport gas cylinders in my work van?Yesprovidedadditionalsafetyprecautionsaretaken.Where the cargo compartment is open to the passenger compartment and/or engine

compartment (as in most typesof vans) then youmust house the fuel gas cylinders in aseparate airtight compartment, which must be permanently vented to the outside of thevehicle. The number of cylinders carried will be dependant on the size of the fuel gascompartment.Ensure cylinder valves are closed and checked for leaks, (e.g. with soapy water) beforeloadingintovan.

DO NOTuse cylinderswhilst theyare still in your van. Always remove them to open airbeforeuse.

Note: Wheneverpossible,gascylindersshouldbetransportedonopenvehicles,ortrailers.




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2. STORING GAS CYLINDERS ON CONSTRUCTION SITES

Storagerequirementsvarydependingonthequantityofgasbeingstoredandwhetherthestoreisclassifiedasaminorstorage.Forthisreasonitisessentialtodeterminethequantityofgascylinderson-site,sothatcylindersarestoredinanappropriatemannerandin

accordancewithdangerousgoodslegislation.

Note:Quantitiesofgasinuse,asstand-byorempty,shouldbeminimisedasfaraspossible.

2.1 What quanti ty of gas is classif ied as a minor storage?

Refer to the tables below and the following work example to determine if the quantity of gason-site is classified as a minor storage.

TABLE 2.1

MAXIMUM QUANTITIES OF GASES PERMISSABLE FOR

CLASSIFICATION AS MINOR STORAGE

AS 4332 2004 Section 2.3

Division Class) of Gas Maximum Aggregate Water CapacityDivision(Class)2.1

Flammablegas(LPG,Acetylene)

500litres

Division(Class)2.2Nonflammablegas(Nitrogen,Argon)

2000litres

Division(Class)2.2withClass5.1subsidiaryrisk(Oxygen)

1000litres

MixedGaseswithnoindividualclasstoexceedits

subclassintable2.1

2000litres

AGGREGATE WATER CAPACITY OF CYLINDERS

AS 4332 2004 Appendix C

Type of Gas Cylinder size

G E D

Oxygen 48litres 24litres 10litresAcetylene 48litres 24litres 10litres

Cylinder Size

45 kg 15 kg 9 kgLPG 108litres 44litres 23litres

For an example see Attachment 1 - WORK EXAMPLE: Determining minor quantities.




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2.2 How should gas cylinders be stored?

Cylinderstorageareasshouldbewellventilatedandpreferablyoutdoors.Protectionfromweatherisdesirable,butnotattheexpenseofventilation.Withinthestorageareaoxygencylindersshouldbestoredatleast3metresfromfuelgascylinders,unlessseparatedbyafirewall(minimum4hourfirerating).

STORAGE OF FUEL GASES EXAMPLES

EITHERUseascreenwall(DiagramA)toachievethesegregationdistance,ORMaintain3metresegregation(DiagramB).

Diagram A Diagram B

Allcylindersshouldbetreatedasfull,regardlessoftheircontentandthefollowingsafetyprecautionsobserved:

Securecylindersinanuprightposition,inawellventilatedarea.

Keepcylindersawayfromignitionorartificialheatsources(eg.weldingleads,flames,heatersetc.)andotherflammablematerials.

Storefullandemptycylindersseparately.

Protectionfromdirectsunlightisrecommended.

DisplayDanger:NoSmoking,NoIgnitionSourcesandRestrictedArea,AuthorisedPersonnelOnlysignageinthecylinderstoragearea.

DONOTrepaintcylindersorobscurecylinderlabels,evenifthecylinderisrusty,dirtyordamaged.

DONOTusecylindersthatcannotbeclearlyidentified.

Note:Cylindersshouldnotbeaccessibletounauthorisedpersons.




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2.3 What if the quanti ty of gases in cylinders is greater than those givenfor minor storage?

Cylindersshouldbekeptinapurpose-designedstoreorstoragearea:

Storetobeatgroundlevel,thebaseorfloorshallbelevelandconstructedofnon-

combustiblematerials.

Storetobeconstructedofnoncombustiblematerials.

Storetobeseparatedfromotherbuildingsorhavea4hourratedfirewallandtheroof

ofthestoreshallbe3hourfireratedifanotherbuildingisontop.

Storeandcylinderstobeprotectedfromimpactbyvehicles,forkliftsetc.andfenced

andsecuredagainstunauthorisedaccess.

ElectricalequipmentinflammablegasstoresshallcomplywithAS/NZS3000andthe

storageareashallhaveNOIGNITIONsources.

Cylinderstoredoorsshallopenoutwards.

Storetobeventilatedeitherbymechanicalornaturalmeans.

StoretobefittedwithappropriatefireprotectionsystemrefertoAS4332table7.2.

FurtherinformationonthestorageofgascylindersexceedingthemaximumquantitiesclassifiedasaminorstoragecanbefoundinAS4332,Section4,Table2.1.

2.4 Can I store gas cylinders in unmodif ied shipping (freight)

containers?No.Unmodifiedshippingcontainersshouldnotbeusedasanalternativetoapurposebuiltcylinderstoreorstillage.AS4332-Thestorageandhandlingofgasesincylinders,Section4providesguidanceontheconstruction,locationandventilationofstoresandshouldbereferencedpriortostoringcylindersinmodifiedshippingcontainers.

2.5 What signage (placarding) do I need on a gas cylinder store orstillage?

Gasstoresandstillages(classifiedasaminorstorage)shouldhavethefollowingsignsattached:

Awarningsigntoprohibitsmokingandtoexcludeothersourcesofignition,e.g.

DANGER:NOSMOKING,NOIGNITIONSOURCES.

Awarningsigntorestrictentrye.g.RESTRICTEDAREA,AUTHORISED

PERSONNELONLY.

DangerousgoodsplacardsandHAZCHEMouterwarningplacardsshallbedisplayedatpremisesifthequantityofdangerousgoodsexceedsminorstoragequantities(RefertoTable2.1whendeterminingstoragequantities).Theseplacardswarntheemergencyservicesof

thechemicalhazardspresentandprovidestheinformationnecessaryforthemtodealsafelywithanemergencyatthepremises.




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3. USE, CARE AND HANDLING OF GAS CYLINDERS

3.1 What do I need to consider before manually lift ing and carryingcylinders?Gascylinderscanbeawkwardtomoveduetotheirsize,shapeandweight.Liftingand

carryingofcylindersisahighriskactivity,thereforepropercontrolmeasuresshouldbeputinplacewhenmovingcylinders.Employersneedtoconsidertheuseofappropriateliftingortransportequipmenttominimisemanualhandlingrisksassociatedwithmovingfullandemptycylinders.

Whereitisnotpracticaltousemechanicalliftingaids,andcylindersaremanuallyliftedandcarried,thesmallestsizedcylindersuitableforthejobshouldbeused.Do Not rollcylindersalongthegroundinahorizontalposition,asthiscanopenordamagethecylindervalve.Note: Cylinder valves should not be used as a lifting anchor point at any time.Also, care should be taken whenmanually lifting and carrying cylinders up stairs and between floor levels and should be avoided where possible.

3.2 Can I use gas cylinders that are lying in a horizontal posi tion?

No.Gascylindersshouldonlybeusedwhilsttheyareinanuprightpositionandsecuredagainstfalling.

Thetransportationorstorageofacetylenecylindershorizontallyshouldbeavoided.

Whereacetylenecylindershavebeentransportedorstoredhorizontally,thecylindershould

beallowedtostanduprightforaminimumof12hourspriortouse.Thiswillallowtheacetone

toevenlyre-distributewithinthecylinderandpreventacetonebeingcarriedintotheflame.

Note:An indication that acetone is being carried to the flame can be the discoloration of the flame.

3.3 Can I use oxy fuel gas equipment in poor ly ventilated areas?

Yes.Wherepracticable,forcedventilationshouldbeprovidedtothearea.Cylindersshouldbelocatedoutsidepoorlyventilatedareasandequipmentshouldbeleaktestedatworkingpressurepriortobeingused.

3.3 Can adjustable worm drive clips (jubilee clips) be used to clamp gas

hoses?

No.Theuseofjubileeclipscouldcausegasleaksduetounder-tightened(loosened

connections)orover-tightened(cutinhose)conditions.




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4. FLASHBACK ARRESTORS

4.1 What are some of the common causes of flashback?

Aflashbackistheburning-backoftheflameintotheblowpipeortheignitionofanexplosivemixtureinoneofthegaslines.Frequently,theonlysignofflashbackisacloudofcarbonsmokeissuingfromtheweldingtipwhentheblowpipevalvesareopen.Theleastamountof

damagecausedbyaflashbackistheburningoftheinsideofthehoseliningwhich,ifrepeatedoveraperiodoftimewillresultindisintegrationofthehose.Commoncausesofflashbacksare:

Incorrectoperatingpressures

Blockageintheweldingtip

Faultyequipment,suchaswornormalfunctioningtorchvalves

Backfeeding,whichoccurswhenhigherpressuregasfeedsbackupalowerpressure

gasline

Flowrateofacetyleneexceedswithdrawalrate

o Withdrawalrate,referstotherateatwhichacetylenegasisabletowithdrawfrom

acetoneliquid

o Flowrate,referstotheamountofgaspassingthroughtheregulator

Therefore,theflowrateshouldbelessthanthewithdrawalrate.Whereitexceedsthewithdrawalrate,acetoneliquidwillbewithdrawnwithacetylenegasfromthecylinder.

Acetoneliquidbeingwithdrawnfromthecylinderisoneofthemajorcausesofflashbackwithacetyleneequipmentandischaracterisedbytheflametakingonayelloworgreentinge.

Forfurtherinformationregardingflowratesandwithdrawalrates,contactyourlocalgasequipmentsupplier.

GuidancecanbefoundinAS4267Pressureregulatorsforusewithindustrialcompressedgascylinders.

Note:Acetylene regulators should be designed in such a way that it shall not be possible to adjust them to anoutlet pressure exceeding 150 kPa in the flowing condition.

4.2 Do I need to use flashback arrestors?

Yes.Suppliersofallcommonfuelgassystemsrecommendtheuseofflashbackarresters(compliantwithAS4603)topreventflamestravellingbackintothecylinders.Itisrecommendedthatflashbackarrestorswithadequate(high)flowcapacitiesbeused.

Thefitmentofincorrectflashbackarresterscanresultinreducedflowcapacity,whichmaybebelowtheminimumrequiredbytheheatingorcuttingdevice.Thishasthepotentialtocauseanincreaseinflameinstabilityatwhichpointtheinstalledsafetydevices(flashbackarrestors)mayincreaseratherthandecreasetheriskofflashback.

Forhighflowapplications,especiallyheating,theoperatorneedstoensurehigherflowflashbackarrestorsareused.Consultmanufacturersorsuppliersspecificationsforfurtherinformation.




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4.3 Where should flashback arrestors be fit ted?

Suppliersadviceshouldbefollowedtoensurethecorrectplacementandfittingoftheflashbackarrestors.WorkSaferecommends:

forhoses3metresorless,flashbackarrestorsfittedtoeachgaslineattheregulator

outletissufficient

forhoseslongerthan3metres,twoflashbackarrestorsshouldbefittedtoeachgas

line;oneattheblowpipeconnectionandoneattheregulatoroutlet

Theregulatorendofthegashoseshouldincorporateaflamearrester,nonreturnvalveandatemperatureactuatedcutoffvalve.

Thetorchendofthegashoseshouldincorporateaflamearresterandnon-returnvalve.

5. FIRE PROTECTION EQUIPMENT

5.1 Do I need to have access to a fire extinguisher?

Yes.Anappropriatefireextinguisherneedstobereadilyaccessibleincaseofafire.Typically,asuitablefireextinguisher(DryChemicalorCO2)shouldbeeitherattachedtothe

cylindertrolleyorbeintheimmediateareawherefuelgasesarebeingused.Incertainapplications,firehosereels,gardenhosesandfireblanketscanalsobeusedtoextinguishfires.

Note:The most common incidents to occur are ignitions of leakages of fuel gas from hose connectionsor defective hose. An appropriate emergency plan needs to be in place in case of a fire and/or explosionand should form part of the safe work procedure.

6. MAINTENANCE OF OXY-FUEL GAS EQUIPMENT

6.1 Who should carry out maintenance work on oxy-fuel gasequipment?

Itisexpectedthatmaintenanceworkiscarriedoutbyatechnicallycompetentpersonwhohassoundknowledgeandexperienceofoxy-fuelgasequipmentandunderstandstheimportanceofintegrityandsafetyintheuseofoxy-fuelgasequipment.




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6.2 What inspection and maintenance regime should I have in place formy oxy-fuel gas equipment?Aswithalltypesofplantandequipment,regularinspectionandperiodicmaintenanceshouldbecarriedoutonoxy-fuelgascomponentsincluding:

Regulators(includingtheirintegralprotectivedevices)

Flashbackarrestors

Hoseassemblies

Blowpipes,mixersandattachments

Asuitableinspectionandperiodicmaintenanceregimeincludes:Daily inspection: apre-operationvisualcheckshouldbecarriedoutwhenconnecting

equipmenttocylinders.Damagedequipmentmustbewithdrawnfromservice.

Weekly inspection:visuallyexamineandcheckequipmentforitssuitabilityforcontinueduse.Allthreadsandsealingsurfacestobecheckedfordamage,oil or greasecontaminationandleaktestedwheredeemedappropriate.Six month inspection:equipmenttobefunctiontestedtoensurecorrectoperationofinternalcomponents.Hoseassembliestobecheckedforcracksandothersignsofwearandtear.Refurbishment and replacement program:Faultycomponentsshouldberefurbishedandreplacedinaccordancewiththemanufacturersorsuppliersrecommendations.Allrepaired

componentsshouldbefunctionandleaktestedbeforeuse.Recordsofinspectionandmaintenanceshouldbekeptbythepersonwhoownstheoxy-fuelgasequipment.Onemeansofcompliancemaybetotagorattachstickerstooxyfuelgasequipmentthathasbeeninspectedandtested.Note:If fuel gas and oxygen components are subjected to harsh working conditions or rough treatment, itmay be necessary to inspect them on a more regular basis.

6.3 Who can inspect and test flashback arrestors?

Inspectionandtestingofflashbackarrestorscanbecarriedoutbythemanufacturerorsupplieroftheflashbackarrestorsoratechnicalcompetentperson.Thetestingmustbedoneevery12monthsonmachinerypurposebuiltforthetaskandapprovedbythemanufactureroftheflashbackarrestor.Testingwillincludecheckson:

Throughflow

Non-return

Leaktightness




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7. PERSONAL PROTECTIVE EQUIPMENT

7.1 Why cant I use sunglasses as eye protection when carrying out hot

work processes?

OnlyeyeprotectionthatcomplieswithAS1336shouldbewornwhencarryingouthotworkandusingoxy-fuelgassystems.Ingasweldingorcutting,andresistanceweldingorbrazing,suitableeyeprotectionshallbeprovidedtoguardagainstinvisibleradiationandtoreducethevisibleradiationtoacomfortablelevel.Forsuchprocesses,sufficientprotectionwillusuallybegivenbygogglesandglasseswithfiltersofShadeNumbers3to7,inclusive.

GuidancecanbefoundinAustralianStandardAS1336Recommendedpracticesforoccupationaleyeprotection,Section5,Eyeprotectionagainstultravioletandinfraredradiation.

7.2 What clothing should I wear during hot work?Clothingshouldbewellfitting,yeteasytoremoveandfreefromoilorgreaseandmadefrom

heavycottonorwool.Leatherworkbootsshouldbeworntoprotectthefeetfromsparkshotslagandotherobjects.Leatherglovesshouldbeworntoprotectthehandsandsafetyglassesshouldbewornwhenworkingwithgasunderpressure.Syntheticorotherflammableclothing,includingsometypesofhighvisibilityvestsandnylon,flyingjackets,shouldnotbewornbyworkersinvolvedingascuttingorwelding.GuidancecanbefoundinAustralianStandardAS4839,Thesafeuseofportableandmobileoxy-fuelgassystemsforwelding,cutting,heatingandalliedprocesses,Section10,SafetyInstructions.




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Attachment 1:

WORK EXAMPLE: Determining minor quantities.

Whendeterminingminorstorages,thetotalcapacityallowedforanyparticularsituationshallincludecylindersinuse,sparecylindersnotinuseandcylindersawaitingremoval.Step1-Conductastocktakeofallgascylinderson-siteincludingempties,checkingsizeofcylinderandquantity.Stocktakerevealsthefollowinglistofcylindersison-site;6OxygensizeG,6AcetylenesizeG,4OxygensizeEand4AcetylenesizeE.Step2-Multiplythenumberofcylindersbythewatercapacityofeachcylinder.

6OxygensizeG (6x48L) = 288litres

6AcetylenesizeG (6x48L) = 288litres

4OxygensizeE (4x24L) = 96litres

4AcetylenesizeE (4x24L) = 96litres

= 768litresNote:eachindividualdivision(class)ofgasislessthanthemaximumaggregatewatercapacity;Acetylene384litres(500LMax),Oxygen384litres(1000LMax)andthecombinedmixedgascapacityarelessthan2000litres.ThereforetheabovestoreofgascylindersisclassifiedasaMINORSTORAGE.




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FURTHER INFORMATION

Alerts and G uidance Notes

WorkSafeGuidanceNoteElevatingworkplatformsandtheplacementofgascylindersforcuttingorwelding.

WorkSafe Victoria

GototheWorkSafehomepage,www.worksafe.vic.gov.auchooseanindustryorpublicationcategory

Contacttheadvisoryserviceon1800136089ORemailinfo@worksafe.vic.gov.au

Standards Australia

AS4332:2004Thestorageandhandlingofgasesincylinders

AS4839:2001Thesafeuseofportableandmobileoxy-fuelgassystemsforwelding,cutting,heatingandallied

processes

AS4603:1999-FlashbackarrestersSafetydevicesforusewithfuelgassesandoxygenorcompressedair.

AS1336:1997-Recommendedpracticesforoccupationaleyeprotection.

AS1674.1:1997-Safetyinweldingandalliedprocesses

CopiesofstandardscanbeobtainedbycontactingStandardsAustraliaon1300654646orbyvisitingthewebsiteatwww.standards.com.au

Note:

ThisguidancematerialhasbeenpreparedusingthebestinformationavailabletoWorkSafeVictoria.Anyinformationaboutlegislativeobligationsorresponsibilitiesincludedinthismaterialisonlyapplicabletothecircumstancesdescribedinthematerial.Youshouldalwayscheckthelegislationreferredtointhismaterialandmakeyourownjudgementaboutwhatactionyoumayneedtotaketoensureyouhavecompliedwiththelaw.Accordingly,theVictorianWorkCoverAuthorityextendsnowarrantiesastothesuitabilityoftheinformationfor

yourspecificcircumstances.


http://www.worksafe.vic.gov.au/mailto:[email protected]:[email protected]://www.worksafe.vic.gov.au/

Oxy Aceylene Equipment

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