Handling High Pressure Cylinders

HANDLING HIGH PRESSURE CYLINDERS
Sources
T. Joiner (ed.). 2001. NOAA Diving Manual - Diving for Science and Technology, Fourth Edition. Best Publishing Company, Flagstaff, Arizona. Bill High, notes from PSI Cylinder Inspection Course US Code of Federal Regulations Title 49: 172.700
Goal of This Training

To increase your safety and the safety of those around you by familiarizing you with the policies and proper procedures for handling and filling cylinders containing high pressure gas
Objectives
After completing this training module you will be able to:
Identify the regulating bodies regulating hazardous materials training for handling high pressure cylinders and explain the regulations as they pertain to scientific diving Define a high pressure cylinder as it relates to diving
Objectives
After completing this training module you will be able to:
Identify and explain cylinder markings for steel and aluminum scuba cylinders List 25 safe handling procedures for high pressure cylinders Define the parts of a fill station and list procedures for filling high pressure cylinders common to all fill stations
Regulation
In the US:
The Department of Transportation (DOT) regulates transport of high pressure cylinders The Department of Labor, Occupational Safety and Health Administration (OSHA) regulates safety in the workplace
Regulation
The Code of Federal Regulations (CFR Title 49: 172.700) mandates employees of companies involved in commerce who handle compressed gas cylinders to receive appropriate safety training.
A new hire should receive this training within 90 days of hiring Training should be repeated every three years
Regulation
Discussions with US DOT have determined that most organizations involved in scientific diving are not involved in commerce and are exempt from the three year retraining updates Local regulations or standards may reimpose this requirement
Regulation
AAUS and NOAA scientific diving standards require all scientific divers to receive hazardous materials training for handling high pressure cylinders
High Pressure Cylinders

The capacity of a cylinder is the amount of gas at surface pressure that can be compressed into the cylinder at its rated pressure
This capacity is usually expressed in standard cubic feet or standard liters of gas
Cylinders with capacities from 26 standard cubic feet to over 100 standard cubic feet are used in scuba diving
High Pressure Cylinders

Scuba cylinders are generally made of steel or aluminum Cylinders used in diving fill to working pressures ranging from 1,800 to 3,500 psi (124 to 241 bar) or greater
Cylinder Markings
Data describing the cylinder must be clearly stamped on the shoulder of the cylinder
Image courtesy Best Publishing
Cylinder Markings
The precise manufacturing specifications of cylinders have been dictated by:
The Interstate Commerce Commission (ICC) until 1970 The Department of Transportation (DOT) after 1970 The TC/DOT (Transport Canada and DOT) most recently dictates specifications for aluminum cylinders
Steel Cylinder Markings
Steel Cylinder Markings

DOT (Department of Transportation may also read ICC if cylinder predates 1970) 3AA (indicates steel construction) Service pressure Serial number Cylinder manufacturers symbol Hydrostatic test date
Aluminum Cylinder Markings
Aluminum Cylinder Markings

DOT (or ICC) 3AL (indicates aluminum construction) Service pressure Serial number Service volume Manufacturer Hydrostatic test date
Safe Handling Procedures

Treat all cylinders designed to hold high pressure gas with respect Do not drop cylinders

Wear shoes when working around cylinders Have a clear path to avoid tripping or knocking over cylinders or other equipment

Cylinders are heavy and awkward; use proper lifting techniques and dollies to minimize the risk of personal injury

Handle charged cylinders carefully handling by the valve or body is preferred Cylinders should be stored at temperatures not to exceed 130o F (54 C)
handling by straps or backpack may allow the cylinder to slip or drop

Store charged cylinders in an upright position in a cool shady place and away from flammable materials Secure cylinders properly to prevent falling or rolling
Photo courtesy Steve Sellers

While in transit, cylinders should be secured from rolling
Preferably in a rack in the upright position

Open cylinder valves slowly Do not put your body in the gas stream
High pressure can force gas through the skin and into the body; bubbles in the circulatory system could result in an embolism Injuries of this nature are not uncommon, so please keep out of harms way

Cylinders that appear to be damaged by fire or physical abuse should be removed from service

Scuba cylinders should receive a visual inspection by a qualified inspector annually A cylinder with signs of damage or that has been totally emptied, should receive a visual inspection before being put back in service

Internal inspections, hydrostatic tests, and repair work should be performed only by trained technicians
Image courtesy PSI

Remove cylinder boot frequently to inspect for corrosion
Boots that inhibit rapid draining and drying should not be used because they allow water to remain in contact with the cylinder, forming corrosion

A cylinder that has been condemned during the visual inspection or hydrostatic testing process may never be returned to service Condemned cylinders should be made unserviceable (i.e. cut in two, hole drilled in the wall, threads destroyed, etc)

Do not use any cylinder that:
Is aluminum and has a rounded bottom Have the manufacturing codes SP6576, SP6688, or SP890 stamped into the cylinder Have large dents, bulges, or lines of corrosion Do not have a proper pressure relief device (burst disc)

Do not use any cylinder that:
Have manufacturing codes SP6498, E6498, SP7042, or E7042 stamped into the cylinder unless the cylinder is also stamped with the code 3AL
These were special aluminum alloys that were given the 3AL rating at a later date

Do not totally empty a cylinder without cause
Always try to leave 300 to 500 psi in the cylinder Empty cylinders should be internally visually inspected by a trained technician prior to refilling

Regulators or gauges may fail when a cylinder valve is opened it is important to stand to the side rather than in the line of discharge to avoid the blast effect in case of failure
Photos courtesy Dave Pence

Do not look directly at the face of any pressure gauge when turning on the cylinder because of the possibility of a blowout
Fill Stations and Filling Cylinders

Diving cylinders and associated high pressure equipment are manufactured and tested to standards in order to ensure a high degree of safety when they are properly used and maintained

Manufacturing standards and maintenance requirements do not eliminate the possibility of a catastrophic failure that could result in serious injury or death
Photo courtesy www.sealancers.org

An 80 cubic foot cylinder filled to 3000 psi (207 bar) has in excess of one million pounds of kinetic energy; sufficient power to blow apart brick walls or destroy vehicles
Photo courtesy connected.bc.ca/~baquatics/index.htm

90% of all cylinder explosions occur during the filling process Operator error has been linked to many of these incidents
Photo courtesy www.sealancers.org

Properly trained and attentive operators reduce their risk of being involved in a catastrophic incident Be familiar with the equipment you are working with and follow inspection requirements and safe operating procedures

A fill station consists of a source of high pressure gas, high pressure lines called whips that connect the gas source to the cylinders being filled, and valves and gauges to control and monitor the filling process

Fill stations come in a wide variety of configurations, the specifics of operating a given system are beyond the scope of this presentation and require additional training

Compressor basics:
High pressure compressors capable of producing breathing grade gas intake air, compress the air through a series of stages to increase the pressure, and filter the gas to remove impurities and excess moisture
Photos courtesy Bauerair.com

Compressor basics:
Each compressor has its own operational and maintenance requirements, but items common to all units include:
Checking oil levels prior to startup Monitoring compressor hours and filter life Monitoring the compressor intake to assure a proper air source, and monitoring stage pressures Keeping a log of regular maintenance and adhering to a maintenance schedule

Storage banks take two forms:
A series of cylinders connected by manifold to produce a desired storage capacity Or a single large storage cylinder such as a recycled submarine ballast tank
Cylinders connected by manifold have the advantage of allowing cascade filling A single large storage cylinder can offer the advantage of not requiring periodic hydrostatic testing

Storage banks have specific pressure limitations and are secured to prevent them from falling
Banked pressures of 4,500 psi (310 bar) are common

Cascade filling involves equalizing the pressure in the cylinder being filled with the pressure in a single cylinder in a series of storage cylinders, moving to the next cylinder in the series and repeating the process until the desired pressure is reached Cascade filling is the most economical use of banked gas

Fill station valves can be of a metering or ball valve design
A metering valve provides for slow and controlled pressure adjustments A ball valve is either open or closed
Photos courtesy Global Mfg. Corp.
Metering Valve
Ball Valve

Caution should be taken when using fill panels employing ball valves, a rapid pressure spike can increase the risk of a fire in the presence of gases with high oxygen content

High pressure lines:
Pipes and hoses that carry high pressure gas should be secured approximately every two feet and regularly inspected

Gauges:
Gauges that are used on the fill whips and yokes are not calibrated or tested
Photos courtesy Steve Sellers
Gauges in the fill panel are tested and calibrated

The Fill Station Operator has the responsibility to reject cylinders that do not meet standards

Before filling a cylinder:
Verify it has valid ICC or DOT stampings
Check for a current Hydrostatic Test Stamp

Hydrostatic testing must be done every five years

Verify a current visual inspection sticker
Verify it has a valve with a pressure relief device Check that there is air/gas in the cylinder

Check the rated pressure of the cylinder
Verify it has a valve O-Ring (yoke style valves)

Determine if the cylinder has a yoke or DIN valve and that the fill station has the necessary adaptors to allow for filling

Check the pressure in the cylinder and its contents (air, nitrox, etc.)
Cylinders containing gas mixtures other than air should not be allowed to equalize pressure through the fill whips with cylinders not containing the same gas; doing so modifies gas mixtures in all the cylinders and could compromise the safety of unsuspecting divers using them

Verify the general condition of the cylinder
On steel cylinders, strike the cylinder with a blunt object; it should sound like a bell, if not, dont fill it No visual signs of dents, bulges, scrapes, or line corrosion
Verify the fill setting on the fill panel regulator (if present)

Do not fill high-pressure cylinders if the date of the last hydrostatic test has expired (five years for steel and aluminum cylinders) or if more than one year has passed since the last formal visual inspection

Reject cylinders with the following markings or conditions:
SP6576 SP6688, SP890 SP6498, E6498, SP7042, E7042 All round bottom aluminum cylinders Steel, non-galvanized, vinyl coated cylinders

Only individuals trained in the handling and filling of high pressure cylinders should be in the room when cylinders are being filled Maintain an organized fill area, keep a clear path in and out and secure cylinders after filling

Preparing to fill:
Open cylinder valve to blow out dust/water Attach the fill whip to the valve Close the whip bleed valve and open the cylinder valve
If filling multiple cylinders containing the same gas, open all cylinder valves and equalize the pressure between cylinders
Open the fill whip valve Open supply valve

Charge cylinders at 300-600 psig/min (2041 bar/min) to prevent excessive heat buildup Never exceed the maximum allowable pressure for any particular cylinder Never perform maintenance or repairs on a cylinder valve while the cylinder is charged

A 3000 psi (207 bar) cylinder should take 5 to 10 minutes to fill Aluminum alloy cylinders should never be filled in excess of marked service pressure, and steel cylinders without a plus (+) after the current hydrostatic test date should also not be filled over their marked service pressure

Assure any cylinders filled are properly labeled with appropriate contents labels and that any logs have been filled out as required by local procedures or standards

When the filling process is complete, bleed excess pressure from the fill whips, close all valves, shut off power to the compressor, and secure the fill station per local procedures

To help ensure safety during the filling process, considered the following:
Placing the fill station away from work areas Consulting with an engineer before constructing a cylinder explosion diversion device Configuring controls away from the cylinder fill area

Safety considerations continued:
Secure high-pressure hoses and fittings at close intervals Locate the fill station away from critical building structural support and walls; provide a physical barrier between fill station operator and cylinders during filling Use an energy deflector to send explosive force in a safe direction

Safety considerations continued:
Regularly inspect compressor filters and piping Allow only trained, authorized persons to work at the fill station Post operating procedures and safety instructions Proper labeling of all valves, gauges, etc
Study Questions
Use the following study questions to review some of the information presented in this self study module. When you are finished you can print out your study questions results.
Self Study Questions

_____ require all scientific divers to receive hazardous materials training for handling high pressure cylinders. AAUS and NOAA scientific diving standards CFR Title 29: 1910 Sub Part T OSHA Individual State's Department of Transportation

_____ require all scientific divers to receive hazardous materials training for handling high pressure cylinders. AAUS and NOAA scientific diving standards CFR Title 29: 1910 Sub Part T OSHA Individual State's Department of Transportation

DOT regulations found in 49 CFR 172.700 mandate training requirements for employees of companies involved in commerce who handle compressed gas cylinders. A. True B. False

DOT regulations found in 49 CFR 172.700 mandate training requirements for employees of companies involved in commerce who handle compressed gas cylinders. A. True B. False

The codes 3AA 2250 PST 4~08+ stamped into the neck of a cylinder indicate:
This is a steel cylinder with a rated working pressure of 2250 psi, manufactured by Pressed Steel, hydrostatically tested in April of 2008, and capable of being over filled by 10%. This is an aluminum cylinder with a rated working pressure of 2250 psi, manufactured by Pacific Scuba Tanks, hydrostatically tested in April of 2008, and capable of being over filled by 10%. The serial number of the cylinder. This is a steel cylinder with a rated working pressure of 2250 psi, manufactured by Pressed Steel; last visually inspected in April of 2008, and capable of being over filled by 10%.

The codes 3AA 2250 PST 4~08+ stamped into the neck of a cylinder indicate:
This is a steel cylinder with a rated working pressure of 2250 psi, manufactured by Pressed Steel, hydrostatically tested in April of 2008, and capable of being over filled by 10%. This is an aluminum cylinder with a rated working pressure of 2250 psi, manufactured by Pacific Scuba Tanks, hydrostatically tested in April of 2008, and capable of being over filled by 10%. The serial number of the cylinder. This is a steel cylinder with a rated working pressure of 2250 psi, manufactured by Pressed Steel; last visually inspected in April of 2008, and capable of being over filled by 10%.

It is June 2008; a fill station operator conducting a pre-filling survey of a cylinder finds the hydrostatic test dates of 2 98+ and 10 04. The cylinder has a current VIP sticker, all other required markings, and shows no signs of dents, bulges, scrapes or line corrosion. The fill station operator: can fill the cylinder, but only to the rated working pressure since the current hydrostatic test mark does not have a +. should not fill the cylinder because the current hydrostatic test mark does not have a +. should not fill the cylinder because the current hydrostatic test has passed the five year limit for the test. can fill the cylinder to a pressure 10% greater than the cylinder's rated working pressure because of the presence of the + on the cylinder.

It is June 2008; a fill station operator conducting a pre-filling survey of a cylinder finds the hydrostatic test dates of 2 98+ and 10 04. The cylinder has a current VIP sticker, all other required markings, and shows no signs of dents, bulges, scrapes or line corrosion. The fill station operator: can fill the cylinder, but only to the rated working pressure since the current hydrostatic test mark does not have a +. should not fill the cylinder because the current hydrostatic test mark does not have a +. should not fill the cylinder because the current hydrostatic test has passed the five year limit for the test. can fill the cylinder to a pressure 10% greater than the cylinder's rated working pressure because of the presence of the + on the cylinder.

It is November 2008; a fill station operator conducting a pre-filling survey of a cylinder finds the hydrostatic test dates of 2 97 and 10 03. The cylinder has a VIP sticker dated 10/07. It has the stamp 3AL, along with all other required markings, and shows no signs of dents, bulges, scrapes or line corrosion. (Select all that apply) The cylinder is "out of hydro"; it has been longer than five years since the last hydrostatic test. This cylinder is within its second hydrostatic test period. The cylinder does not have a current VIP. This is a steel cylinder. This is an aluminum cylinder. The cylinder has a current VIP. The fill station operator should fill this cylinder. The fill station operator should not fill this cylinder.

It is November 2008; a fill station operator conducting a pre-filling survey of a cylinder finds the hydrostatic test dates of 2 97 and 10 03. The cylinder has a VIP sticker dated 10/07. It has the stamp 3AL, along with all other required markings, and shows no signs of dents, bulges, scrapes or line corrosion. (Select all that apply) The cylinder is "out of hydro"; it has been longer than five years since the last hydrostatic test. This cylinder is within its second hydrostatic test period. The cylinder does not have a current VIP. This is a steel cylinder. This is an aluminum cylinder. The cylinder has a current VIP. The fill station operator should fill this cylinder. The fill station operator should not fill this cylinder.

Safe handling procedures for high pressure cylinders include: (select all that apply)
Wear shoes when working around cylinders. Store charged cylinders in an upright position in a cool shady place and away from flammable materials. Handling cylinders by straps or backpack is preferred to handling cylinders by the valve. Cylinders that appear to be damaged by fire or physical abuse should be removed from service. Scuba cylinders should receive a visual inspection by a qualified inspector annually. Internal inspections, hydrostatic tests, and repair work should be performed only by trained technicians. A cylinder that has been condemned during the visual inspection or hydrostatic testing process may be returned to service after repairs have been completed.

Safe handling procedures for high pressure cylinders include: (select all that apply)
Wear shoes when working around cylinders. Store charged cylinders in an upright position in a cool shady place and away from flammable materials. Handling cylinders by straps or backpack is preferred to handling cylinders by the valve. Cylinders that appear to be damaged by fire or physical abuse should be removed from service. Scuba cylinders should receive a visual inspection by a qualified inspector annually. Internal inspections, hydrostatic tests, and repair work should be performed only by trained technicians. A cylinder that has been condemned during the visual inspection or hydrostatic testing process may be returned to service after repairs have been completed.

_____ is the most economical use of banked gas. Cascade filling Single bank filling Filling directly from the compressor The use of high pressure scuba cylinders

_____ is the most economical use of banked gas. Cascade filling Single bank filling Filling directly from the compressor The use of high pressure scuba cylinders

Select all that apply to the valve pictured here:
This is an example of a Ball valve This is an example of a Metering valve This valve provides for slow and controlled pressure adjustments This valve is either open or closed providing no means of pressure adjustments

Select all that apply to the valve pictured here:
This is an example of a Ball valve This is an example of a Metering valve This valve provides for slow and controlled pressure adjustments This valve is either open or closed providing no means of pressure adjustments

Match the item with its counterpart:
A. Cascade filling B. A ball valve C. A metering valve D. 4,500 psi E. Allows for cascade filling F. A single large storage cylinder such as a recycled submarine ballast tank G. 300-600 psi or 20-41 bar H. 5 to 10 minutes I. About 30 minutes Equalizing the pressure in the cylinder being filled with the pressure in a single cylinder in a series of storage cylinders, moving to the next cylinder in the series and repeating the process until the desired pressure is reached. Is either open or closed. Provides for slow and controlled pressure adjustments. 310 bar A series of storage cylinders connected by manifold to produce a desired storage capacity. Can offer the advantage of not requiring periodic hydrostatic testing. The rate per minute for filling cylinders. The amount of time it should take to properly fill a 3000 psi (207 bar) cylinder. The amount of time it will take someone with a surface air consumption of 20 psi/minute to breathe 2500 psi from a scuba cylinder while diving in 99 feet of seawater.










Select all of the items listed that the fill station operator should do before filling a cylinder:
Verify the cylinder has valid ICC or DOT stampings Check for a current Hydrostatic Test Stamp Verify a current visual inspection sticker (within the past year) Verify the cylinder has a valve with a pressure relief device Check that there is air/gas in the cylinder Check the rated pressure of the cylinder Check the pressure in the cylinder and its contents (air, nitrox, etc.) Verify the general condition of the cylinder Open the bleed valve on the fill whip Close the cylinder valve

Select all of the items listed that the fill station operator should do before filling a cylinder:
Verify the cylinder has valid ICC or DOT stampings Check for a current Hydrostatic Test Stamp Verify a current visual inspection sticker (within the past year) Verify the cylinder has a valve with a pressure relief device Check that there is air/gas in the cylinder Check the rated pressure of the cylinder Check the pressure in the cylinder and its contents (air, nitrox, etc.) Verify the general condition of the cylinder Open the bleed valve on the fill whip Close the cylinder valve

Putting part of your body in the air stream of an open high pressure cylinder valve can lead to embolism. A.True B.False

Putting part of your body in the air stream of an open high pressure cylinder valve can lead to embolism. A.True B.False

Preferably, cylinders should be transported and stored in a secure, upright position. A.True B.False

Preferably, cylinders should be transported and stored in a secure, upright position. A.True B.False

Caution should be taken when using fill panels employing _____ valves, a rapid pressure spike can increase the risk of a fire in the presence of gases with high oxygen content. metering ball J K yoke DIN

Caution should be taken when using fill panels employing _____ valves, a rapid pressure spike can increase the risk of a fire in the presence of gases with high oxygen content. metering ball J K yoke DIN

Fill Station Operator has the responsibility to reject cylinders that do not meet standards. A.True B.False

Fill Station Operator has the responsibility to reject cylinders that do not meet standards. A.True B.False

Only individuals _____ in the handling and filling of high pressure cylinders should be in the room when cylinders are being filled. trained interested participating tasked

Only individuals _____ in the handling and filling of high pressure cylinders should be in the room when cylinders are being filled. trained interested participating tasked

Handling High Pressure Cylinders

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HANDLING HIGH PRESSURE CYLINDERS

Goal of This Training

High Pressure Cylinders

High Pressure Cylinders

Image courtesy Best Publishing

Steel Cylinder Markings

Image courtesy Best Publishing

Steel Cylinder Markings

Aluminum Cylinder Markings

Image courtesy Best Publishing

Aluminum Cylinder Markings

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Photo courtesy Steve Sellers

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Image courtesy PSI

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Safe Handling Procedures

Photos courtesy Dave Pence

Safe Handling Procedures

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Photo courtesy www.sealancers.org

Fill Stations and Filling Cylinders

Photo courtesy connected.bc.ca/~baquatics/index.htm

Fill Stations and Filling Cylinders

Photo courtesy www.sealancers.org

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Photos courtesy Bauerair.com

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Fill Stations and Filling Cylinders

Photos courtesy Steve Sellers

Gauges in the fill panel are tested and calibrated

Fill Stations and Filling Cylinders

Photo courtesy Steve Sellers

Fill Stations and Filling Cylinders

Check for a current Hydrostatic Test Stamp

Photos courtesy Steve Sellers