Slides Gas Cylinder Storage V1.3

Gas Cylinder Storage | NSW&QLD | 2011 Supagas | Training &HR | Page 1

PRE SLIDE INFORMATION

The following set of slides is a snapshot of the Supagas NSW and QLD Gas Cylinder Storage course as at 28/08/2015.

The slides are intended for Induction and Training purposes yet are subject to modification and updates as per business changes.

Please contact Luke Wilson (Training) on [email protected] should you have any questions, feedback, comments and/or changes which you may

have.

mailto:[email protected]

SUPAGAS

Luke Wilson – 28/08/2015

Gas Cylinder Storage V1.3


CONTENTS

Agenda, Objectives, Intro, Tone and Expectations

Gas CylindersStorage Areas

Minor Storage of LPG

Quantities for Storage

Test/Exam

Q&A

FAQ’s

Installation of LPG Cylinders


Agenda and Objectives

Timing

Aim■ Approx. 1-2hrs

■ This session will give participants a basic overview of the requirements in regards to safe gas cylinder storage.

ObjectivesUpon completing this session participants will be able to: ■ Recognise the Supagas and industry standards in regards to Safe Cylinder Storage.■ Describe all the types of gas cylinders that Supagas use and sell and what they do.■ Identify the site requirements for the safe storage of gas cylinders.■ Explain the required separation distances of gas cylinders outdoors.■ Recognise the restrictions that apply to gas storage indoors.■ Describe the signage needed for gas cylinder storage. ■ Explain the importance of safe storage distance for LPG cylinder installations and exchanges.■ Explain the process of In-Situ filling and the safety requirements this requires.■ Describe the regulatory conditions we must follow when storing minor quantities of LPG.■ Describe the regulatory conditions we must follow when storing maximum quantities of LPG.■ Describe the regulatory conditions we must follow when storing maximum quantities of Industrial Gases.


Fire Exits and Emergency Evacuation Procedures

Introductions

Session is Mandatory

Adult Education

Supagas Expectations

Introduction, Tone and Expectations


Supagas – Gas Cylinders

A Cylinder is a pressure vessel used to store gases at above atmospheric pressure.

It is a closed container designed to hold gases or liquids at a pressure substantially different from the ambient pressure (the current pressure of the gas or liquid that surrounds the object).

The pressure differential is dangerous and many fatal accidents have occurred in the history of the cylinder’s development and operation, however, our cylinders today are protected by a Safety Relief Valves SRV.

Design, manufacture, and operation are regulated by the authorities that is backed by legislation and involves parameters such as maximum safe operating pressure and temperature.

Also design codes and Australian standards dictate the choice of steel for the cylinder with no welds for most gas cylinders allowed, whilst they are also given anti-corrosive treatment.

Gas Cylinders

http://www.youtube.com/watch?v=tNhOucuk4Io&feature=related



SRV’s come in various forms Bursting Discs: small metal gaskets engineered to rupture at a pre-determined pressure. Fusible Plugs: backed with a low-melting-point metal, so that the valve must be exposed to

excessive heat before the plug can rupture. Pressure Relief Valves PRV: Spring loaded re-seatable valves that open only after a certain

pressure is reached. Valves will open to relieve pressure and then re-seat once pressure is reduced to a safe level.

PRV - Boiling Liquid Expanding Vapour Explosion BLEVE Control

https://www.youtube.com/watch?v=UM0jtD_OWLU



Transportation of high pressure vessels is regulated by governments throughout the world. In our case various levels of testing and transportation requirements are set out by the Regulations, Codes of practice, Legislation and Australian Standards. Furthermore Supagas has developed a range of Safe Operating Procedures that are to be used by all workplace participants.

There are a variety of tests performed on cylinders, such as hydrostatic pressure , tensile strength, impact tests etc.

During the manufacturing process, vital information is stamped permanently on the cylinder, this includes the type of cylinder, the working or service pressure, the serial number, date of manufacture, the manufacture's registered code and the test pressure. Other information may also be stamped as determined by Australian Standard 2030.

High pressure cylinders are used multiple times and are tested and visually examined at set intervals. In Australia testing for most cylinders is required every ten years. Supagas also performs visual checks on all cylinders at the time of filling.

Gas Cylinders - Projectiles

Click the hyperlink to learn more about Gas Cylinder Safety:

Leaking Flammable Gas

http://www.youtube.com/watch?v=X7hOIsBZTPE


Cylinder Storage Area

Supagas – Cylinder Storage

Supagas aims to fulfill all requirements of AS1596 and AS4332 regarding cylinder storage.

All staff, Reps, Drivers etc. have a “Duty of Care” – an obligation to tell customers if they are storing gas cylinders in a non-compliant manner and to notify Supagas immediately.

In the Duty of Care, we inform customers on how they are NOT complying with the law and we require them to take action to meet compliance.

If they fail to meet compliance, Supagas has the right to stop delivery until compliance by the customer is achieved as we cannot supply to non conforming sites.

This module will assist you to identify what these requirements are and your duty as a Supagas Employee in ensuring all staff and customers know this.

AS/NZS 1596:2014


Supagas Storage - Do you know the Yard?

What are the current storage areas we have for gases? - List and name all

What gases can be stored next to each other and what gases cannot? - List and name all

What needs to be considered when storing gas at our sites?

What needs to be considered when storing gas at our customers sites?

ACTIVITY ONE


In 2 groups work in teams to write down responses that answer the following questions.

Supagas Storage Surveillance – In Office

You have 15 mins to complete the task and the team with the most correct and full answers wins immunity to complete the test.

NOTE: You cannot leave the room or text asking anyone for information. Your facilitator will monitor.

NOTE: The following activity is designed if staff cannot go out into the yard with safety vests.

ACTIVITY ONE


Supagas - Dangerous Goods

Who can tell me what we mean by DG’s?

How many classes of DG’s are there?

What are the main type of DG’s we have on our site?

Dangerous Goods are articles or substances that could pose a significant risk to the health or safety of humans or property when being transported.

Goods that are considered dangerous are assigned to a class according to the most significant risk presented by the goods, as determined by the criteria set down by the United Nations.

Nine

Gases


Class 2 Gas

2.1 FLAMMABLE GAS(Acetylene, LPG (propane), Hydrogen)

Three (3) Divisions:

2.2 NON FLAMMABLE/NON-TOXIC GAS(Carbon Dioxide, Argon, Oxygen, Helium, Nitrogen)

2.3 TOXIC GAS(Chlorine, Carbon Monoxide, Sulphur Dioxide)

Mix of Dangerous Goods/Classes of Gases (2.1 & 2.2)

(Can be a mix of various types of DG’s)


Supagas – Site Requirements

What are the gases? What are the distances allowed between the gases below?

Acetylene

LPG

Oxygen

Argon

0 metres

3 metres

3 metres

0 metres0 metres

0 metres

ACTIVITY TWO


Site Requirements – As a provider of gas products we must ensure the following:


Areas where gas cylinders are located are not liable to physical damage, tampering or excessive temperature and access by any unauthorised persons.

Level base or floor constructed of non-combustible material (no standing water). Supagas dock okay.

Upright storage, i.e., SRV always in vapour space.

Internal LPG building stores should have non-combustible walls and ventilated by natural or mechanical means.

Cylinders in a mixed storage (2.1 – 2.2/5.1) are separated from each other by at least 3m.

The separation of Flammable Gases from Oxidising Gases can be made with at least a 3m Inert Gases storage, as a buffer.

Liquid withdrawal cylinders should be stored separately from vapour withdrawal cylinders.

Flammable Gases 2.1 Oxidising Gases 2.2/5.1Inert Gases 2.2

3 metres separated by Inert Gas


Separation Distances of Gas (Flammable 2.1) Cylinders Outdoors


150 Millimetres- Windows (openable - vertical)

1 Metre-Windows (lateral)-Air vents (weepholes not included)-Ducts-Door-Drain

3 Metres-LPG storage tank-Flammable liquid storage greater than 250Litres


Separation Distances of Gas (2.1 Flammable) Cylinders Indoors


Indoor storage should be avoided whenever possible as 2.1 gases are flammable and the potential for ignition in poorly ventilated enclosed spaces is greatly increased.

Gases also displace the air we breath and in an enclosed indoor space could lead to asphyxiation.

In some cases where it’s impractical to store outside, the following restrictions apply:

Cylinders are separated from other Dangerous Goods by at least 5m.

Except for Class 2.2 (no subsidiary risks), no minor storage is allowed in basements.

Adequate ventilation and monitors must be provided for gas cylinders stored indoors and in

enclosed areas.

A vapour barrier or firewall could be constructed if the separation distances cannot be adhered to.


Site Signage


Where quantities of 200 litres or greater of LPG is stored on a commercial site, WHS

Regulations require placarding of the site with a “HAZCHEM” outer warning placard.

This placard must be large enough to be clearly seen (600mm x 120mm – red lettering 100mm high)

with a white/silver background.

It clearly shows that the location has “Hazardous Chemicals” storage on site. HAZCHEM

The Flammable Gas Class 2.1 - Red Gas 2 Diamond sign (100 mm square) must be located at the entrance or adjacent where LPG is stored in cylinders along with a No Smoking sign at the entrance to the site.

AFTER HOURS EMERGENCY NUMBERS must also be placarded at the entrance of the site.Korean LP Gas Depot Explosion - Tanker and Underground Storage Explosion (1.48min)


What are the Separation Distances of Gas (Flammable 2.1) Exchange Cylinders Outdoors?

Supagas – LPG Installations

- Door ?

-Windows (open - vertical) ?

-Windows (lateral) ?

-Air vents ?

-LPG storage tank ?

-Ducts ?

-Combustible Materials ?

-Drain ?

-Flammable liquid storage

greater than 250Litres ?

ACTIVITY THREE

- 1mtr

- 150mm

- 1mtr

- 1mtr

- 3mtr

- 1mtr

- 5mtrs

- 1m

- 3m

These are 9kg, 13.5kg, 15kg and 45kg cylinders that are distributed to customers on a regular basis, e.g. daily milk runs, 3 times per week, weekly, etc.

ve

?

?

?

?

LPG will initially float above the cylinder before sinking to the floor surface.

If these distances are reduced, the gas could enter the building and form an explosive mixture.

If there is an ignition source within the building, the result could be an explosion.

The “EXCLUSION ZONE” shaded area should prevent a gas leak from entering a building and forming an explosive mix.

WHY? - GAS LEAK

Zone 1


Hazardous Zones for Exchange Cylinder Installations


Air conditioners

Water heaters

Electric meter boxes

Power points, lights and light switches

Compressors

BBQ’s

Electric motors (incl. ice-box motors)

Satellite dishes

Flue outlets

Hazardous zones refer to the presence of a FIXED IGNITION source in the (3-dimensional cone) surrounds of a gas cylinder. Fixed Ignition sources include fixed appliances such as:

NOTE:The hazardous zone distances are different to the safe distances we

previously discussed.

The safe distances referred to inlets and outlets into buildings and drains

(Zone 1 in the diagrams) whilst the hazardous zone distances are related

specifically to FIXED IGNITION sources.

(Zone 2 in the diagrams)


Hazardous Zones for Exchange Cylinder Installations


The previous slide (and other fixed ignition sources) are NOT permitted to be installed/fixed within the shaded area as per below, i.e. the 3-dimensional cone.

Cars moving into/out of the hazardous zones or someone smoking in these zones do not constitute fixed ignition sources.

The distance to a source of ignition or an opening to a building should be as great as practically possible. The minimum distances are shown below.

LP Gas Bushfire Safety

Click on the below hyperlink to learn more about cylinder safety


In Situ Filling


Cylinder filling process where a cylinder installed on a customer’s premises is filled from a Supagas tanker.

Cylinders include our “yellow-top”, fast-filled valve 45kg,90kg, 190kg and 210kg cylinders.

Liquid LPG is filled up under pressure, therefore a greater “EXCLUSION HEIGHT” is required.

Part of the valve is in contact with liquid LPG. With a liquid LPG leak possible (as compared to vapour LPG leak), liquid LPG will expand 270X if exposed to air which is why greater height clearance is a MUST.

Supagas and Elgas are but a few companies left in NSW that perform In-Situ fills as cylinder replacement becomes a more popular practice.


Separation Distances of Gas (Flammable 2.1) for In-Situ Fill Cylinders


500 Millimetres-Windows (open - vertical)( greater exclusion height)

1 Metre-Windows (lateral)-Air vents (weepholes excluded)-Ducts-Door-Drain

3 Metres-LPG storage tank-Flammable liquid storage greater than 250Litres

Air Vent Opening

Zone 1

Worker asphyxiated while working on gas system

Click on the below hyperlink to learn more about gas leaks and gas safety


Hazardous Zones for In Situ Filling


These occur mainly in the filling up of our 45, 90, 190 and 210kg Liquid Withdrawal cylinders found at

service stations.

LPG vapour is released into the surrounds; hence the large base clearance is required (7m).

An ice-box motor or air conditioner mounted at the top of wall only needs to be 1.5m away from the

cylinder to be within compliance.


General Precautions

Supagas – Minor Storage of LPG

Minor storage of LPG are those instances where the authorities deem the LPG quantities are so small, they present little real risk and therefore does not have to comply with the legislation of AS1596.

Cylinders are to be kept well away from artificial sources of heat. (e.g. radiators, boilers or steam pipes).

Clear of combustible matter for a distance of not less than 3m.

Good ventilation should be provided at all times.

Classes of gases shall be segregated within a store.

Refer to the table in your workbooks titled “Maximum Quantities for Minor Storage and Usage” which is extracted from AS1596 and is the Law, as it pertains to the maximum quantities of LPG that a customer can store, to be classified as Minor Storage and Usage.

If these quantities are exceeded, then the customer can still store LPG on their premises BUT all the minimum dimensions mentioned in the previous slides come into operation and must be adhered to.

If there is a violation of the law, WorkCover/Fair Trading gives the customer 2 weeks to rectify issues of non-compliance.


Maximum Quantities for Minor Storage and Usage


Location Max. Quantity of LPG, No of Cylinders & Non Re-fillable Containers

Residential Properties- A detached house or single storey attached

dwelling

Australia – Indoors Quantity (including balconies): 10kg per dwelling

Australia – Maximum Total Quantity (combined indoor and outdoor storage, cylinders not connected): 50 kg

Maximum cylinder size 15kg





Residential Properties- Multi-storey attached dwellings, up to and

including 3 storeys

Australia – Indoors Quantity (including balconies): 10kg per dwelling

Australia – Maximum Total Quantity (combined indoor and outdoor): 20 kg






Residential Properties

- Multi-storey attached dwellings, over 3 storeysAustralia – Maximum Total Quantity (combined indoor and outdoor): 10 kg





Location Max. Quantity of LPG, No of Cylinders &

Non Re-fillable Containers

Protected Places and Public Places- Outdoors including open air,

temporary structures (e.g marquees, tents, booths) and under awnings

- Outdoor areas of hotels, restaurants, cafes and take-away food shops

Per Site:

Maximum Total Quantity: 60kg


- Indoors, within buildings with a roof and three or more walls (e.g hotels, bars, restaurants, cafes, take-away food shops)

10kg per 10m2 floor area up to a maximum total quantity of of 30kg

Maximum cylinder size: 15kg

Outdoor areas include footpaths, enclosed gardens and public places.





Shops, Offices an Laboratories, Indoors Maximum Total Quantity : 30 kg per occupancy


Factories and Warehouses, Indoors 45kg per 50m2 floor area, up to a maximum total quantity of 180kg per occupancy


Vehicle fuel containers on fork lift trucks or installed in motor vehicles in accordance with

AS/NZS 1425, are not included in the quantities stated above.


Maximum Quantities of Industrial Gases Permissible for Classification as Minor Storage


Class of Gas Maximum Aggregate Water Capacity – Litres

2.1

Flammable Gases

500

2.2

Non- Flammable , Non-toxic

2000

2.2 with

Class 5.1 Subsidiary Risk 1000

2.3

Toxic Gases

50


Important to ensure the right cylinder is provided for the right location.

Supagas – Cylinders


Important to ensure the right cylinder is provided for the right location.

Supagas – Cylinders

https://www.youtube.com/watch?v=IQztig7KrCo


Gas Advertising – Props

In your same groups of 2-3 you are now marketing and advertising executives that need to create a Supagas Advertising Brochure that must get to market in 20 mins.

1.) Select a gas product you want to sell.

2.) Create a colourful advertising brochure where one side of the brochure must sell the benefits and features of your chosen Supagas gas product.

3.) The other side of your brochure needs to provide knowledge, advice and guidelines on the safe use of the product you are selling to our customers.

4.) As there are 2 sides of the brochure (“coin”) you need to be sell…sell…selling but also informative and compliant.

You have a pile of resources you can use to cut, paste, draw and make your brochures look dazzling. One of the Senior Management Team will judge the best selling brochure that also meets our compliance requirements. Winners receive a prize.

NOTE: You cannot go into the Sales or Office areas and you cannot ask anyone for information. Your facilitator will monitor. Each minute you are late submitting your brochure you lose points.

NOTE: The following activity is designed for new starters. See next slide for existing staff.


Gas Quiz – No Props

In your same teams as before you are now going head to head to determine which team once and for all has the best gas knowledge and therefore does not need to complete the test.

1.) Select LPG and another Supagas gas product.

2.) Using flipchart paper draft up 10 questions that you will quiz the other team with that covers the benefits, features and safety requirements of LPG and your chosen Supagas gas product.

3.) You will then be able to test the other team.

4.) The team with the best score does not need to complete the test.

You have your course handouts with you which you can use to develop your questions.You also have experience with gases from your own roles so use this as well….however, any questions and answers must be reviewed by the facilitator before being final.

NOTE: You can use any resources available to you in this room. You must be ready to submit your questions for the quiz in 20 mins starting from now.

NOTE: The following activity is designed for existing staff.


Q&A + FAQ’s

Gas Product Knowledge Booklet

Signed Sheet

Remember it’s up to each person

Take Responsibility

Thanks

Close

Business

Slides Gas Cylinder Storage V1.3