Bcga Code Of Practice 1j2124

BCGA CODE OF PRACTICE 31 Safe Storage and Use of Cylinders in Mobile Workshops and Service Vehicles 1997

BCGA CODE OF PRACTICE 31 Safe Storage and Use of Cylinders in Mobile Workshops and Service Vehicles 1997

Copyright © 1997 by British Compressed Gases Association. First printed 1997. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, without permission from the publisher:

BRITISH COMPRESSED GASES ASSOCIATION 6 St. Mary’s Street, Wallingford, OX10 0EL Tel: 0044 (0)1491 825533 Fax: 0044 (0)1491 826689 Website: www.bcga.co.uk E-mail: [email protected] ISSN 0260-4809

BCGA 31 © 1997 – Re-printed September 2002

PREFACE

The various publications issued by the British Compressed Gases Association have the objective of establishing consistency in design, construction practices and operational and maintenance procedures, in order to establish high standards of reliability and safety in the interests of employers, employees and the general public. The Association endeavours to compile these documents using the best sources of information known at the date of issue. The information is used in good faith and belief in its accuracy. The publications are intended for use by technically competent persons and their application does not, therefore, remove the need for technical and managerial judgement in practical situations and with due regard to local circumstances, nor do they confer any immunity or exemption from relevant legal requirements, including by-laws. The onus of responsibility for their application lies with the . The Association, its officers, its and individual of any Working Parties can accept no legal liability or responsibility whatsoever, howsoever arising, for the consequences of the use or misuse of the publications. For the assistance of s, references are given, either in the text or Appendices, to publications such as British, European and International Standards and Codes of Practice, and current legislation that may be applicable. The intention of BCGA is that this document should be read and used in the context of these references where the subjects have a bearing on the local application of the processes or operations carried out by the . BCGA’s publications are reviewed, and revised if necessary, at three-yearly intervals. Readers are advised to check the list of publications on the Association’s website www.bcga.co.uk to ensure that the copy in their possession is the current version.

BCGA 31 © 1997 – Re-printed September 2002

CONTENTS Section

Page

1

Introduction

1

2

Scope

1

3

Transport of Gas Cylinders by Road

3

4

Properties of Gases

3

5

Specialist Vehicles - Types and Application

4

6

Design and Construction of Vehicles

5

7

Vehicle Maintenance

6

8

Training and Provision of Information

6

9

Emergency Procedures

7

10

References *

9

Appendix 1

Emergency Procedures : Incidents involving gas escapes from cylinders

10

Appendix 2

Emergency Procedures : Gas cylinders in fires

11

Appendix 3

Key Actions for dealing with acetylene cylinders in fires

12

History & Objectives of BCGA

* Numerals in brackets in the text refer to the references listed in Section 10.

BCGA 31 © 1997 – Re-printed September 2002

13

BCGA CODE OF PRACTICE 31 Safe Storage and Use of Cylinders in Mobile Workshops and Service Vehicles 1

INTRODUCTION A wide variety of gas cylinders is transported on vehicles every day for the use at work on equipment within the vehicle or some outstation work activity. These activities include repair work, site testing, heat processes, refrigeration, catering, personnel site comfort facility etc. Gases involved can be liquefied petroleum gas (LPG), oxygen, acetylene, refrigerant gases, nitrogen or special gases. In recent years a number of serious accidents have occurred involving gas cylinders during their carriage or use on mobile workshops and site service vehicles. Fatalities, injuries and serious damage have resulted from fire, explosions or asphyxiation when escaping gas has accumulated within the confines of a closed vehicle during transit or when parked. Unsecured cylinders have moved during journeys causing traffic accidents and serious injury to vehicle occupants. Incorrect use or substandard installation of equipment or appliances have resulted in incidents and accidents with serious consequences on outbased vehicles or work activities associated with them. Many of these events could have been prevented if due care had been taken in the design and construction of the vehicles to ensure that they were fit for the purpose intended and that operators had been suitably trained.

2

SCOPE

2.1

This Code of Practice will address the design and construction of mobile workshops and other specialist vehicles with regard to the safe storage of cylinders and the installation of gas equipment on such vehicles. It will also address procedures for safe use of gas cylinders and gas equipment on or with work activities associated with such vehicles including the training of operators to ensure high levels of safety awareness. A section dealing with action in an emergency has also been included.

2.2

The following types of vehicles are included within the scope of this Code:

2.3

a)

Mobile workshops fitted with cylinders for use in or carried on the vehicle. This includes mobile site facility vehicles, site catering units or other specialist vehicles using LPG which fall within the scope of this definition.

b)

Service vehicles transporting cylinders and equipment which will be used at a remote workplace.

Exclusions from this Code of Practice are: a)

Compressed or liquefied gas systems for vehicle propulsion.

b)

Road surfacing vehicles using LPG cylinders.

c)

Vehicles used solely for conveyance of gas cylinders.

BCGA 31 © 1997 – Re-printed September 2002 1

d)

Vehicles used by emergency services.

e)

Cylinders being carried of less than 5 litres water capacity.

f)

Mobile systems as defined by The Pressure Systems and Transportable Gas Containers Regulations, 1989 (1) built into vehicles.

3

TRANSPORT OF GAS CYLINDERS BY ROAD

3.1

Regulations Cylinders containing gases come within the scope of The Carriage of Dangerous Goods by Road Regulations 1996 (2). The implications of this for gas cylinder transport are explained in the BCGA leaflet “Carriage of Gas Cylinders by Road in Cars or Vans Guidance for Drivers at Work 1996” (3). Dependent upon the quantity of gases and their type, information must be carried in writing giving the nature of hazards of the load and procedures to be taken in an emergency. Fire extinguishers must be carried to deal with a fire in the load compartment of the vehicle. If the load is not within the scope of the Regulations it is recommended that these guidelines be generally considered for all situations where cylinders are carried in vehicles at work. This applies equally to full and nominally empty cylinders.

3.2

Recommendations for Safe Transport The vehicle should be suitable for the purpose intended. It may be required to display warning signs applicable to the hazards of the load being carried; refer to (3). Cylinders should preferably be carried in open vehicles. If carried in closed vehicles the cylinders should be in well-ventilated compartments separated from the driving cab and the number of cylinders carried should be limited where relevant to those specified in Code 27 of the LPGA (4). Cylinders should be secured against movement during transit and be stowed so that they do not project beyond the sides or ends of the vehicle. They should be transported in the upright position with valves uppermost unless designed otherwise. Before journeys, cylinders should be checked for gas tightness and during journeys all cylinder valves should be closed off and any fitted equipment isolated. APPLIANCES MUST NEVER BE TRANSPORTED WITH BURNERS LIT. Drivers should be made aware of the effects that cylinder carriage may have on vehicle weight distribution. Clear operating instructions, relevant safety information and statutory notices should be available or posted in or on the vehicle, for operators and s. This is to ensure their safety, the safety of others and safety of the vehicle at all times.

BCGA 31 © 1997 – Re-printed September 2002 2

4

PROPERTIES OF GASES

4.1

General Safety Data Sheets giving specifications and general safety information on gases are available from the suppliers. Mixed cylinder loads should be segregated as recommended whenever practicable. The gas pressure within a cylinder can be many times higher than atmospheric pressure and even small leaks can produce large volumes of free gases in a short time. Liquefied gases leaking in the liquid phase will vaporise to form a gas volume many times the original liquid volume. The boiling point of many liquid gases at atmospheric pressure is below O°C resulting in frost burn potential to exposed flesh when in with liquefied gas or liquefied gas installations. Appropriate personal protective clothing or equipment should be provided and worn when working on such systems and available for use during an emergency. Cylinders or sensitive materials, which may be affected or damaged by cold effects, should be separated or protected.

4.2

Asphyxiation With the exception of oxygen, any gas or vapour present in high concentrations in air will act as an asphyxiant by reducing the oxygen content needed to life. Gases may be inert, odourless, colourless and not readily detectable. They are often heavier than air, can accumulate in low-lying areas and are difficult to disperse. Concentrations can therefore build up in unventilated workplaces or areas without warning, for example during welding, purging and in refrigeration processes, etc. In addition, flammable gases which are also asphyxiants can also present fire and explosion risks in confined areas.

4.3

Toxic Effects The main hazard with gases such as nitrogen or carbon dioxide is that they are asphyxiants at high concentrations. Since collapse in these situations can occur without any warning, operators should not enter areas where significant escapes of such gases have occurred. Other gases such as sulphur dioxide, ammonia or carbon monoxide are directly toxic or can damage the respiratory system. Under the Control of Substances Hazardous to Health Regulations (COSHH), 1994 (5), all operators must be made aware of the Occupational Exposure Limits for the substances they are handling.

4.4

Flammability Some gases form flammable mixtures when mixed with air; these can be explosive if ignited in an uncontrolled manner. They include acetylene, butane, propane and hydrogen.

BCGA 31 © 1997 – Re-printed September 2002 3

4.5

Oxidants Several gases, of which oxygen and compressed air are the most common, have this property. They do not burn but are capable of intensifying fire. Materials, which are stable in atmospheric air such as diesel fuel and petrol, may explode in with compressed oxygen or compressed air.

4.6

Multiple Hazard Gases Some gases have more than one intrinsic hazard. Carbon monoxide for example is both flammable and toxic. Special gas mixtures for welding may present multiple hazard risks. s should be aware of any associated hazards of gases being used by referring to information provided by gas suppliers.

5

SPECIALIST VEHICLES - TYPES AND APPLICATION

5.1

Mobile Workshops Mobile workshops are defined as vehicles where cylinders or substances are carried for specific work processes on or in near proximity to the vehicle. These processes could involve welding, testing, site laboratory functions, etc. Various industrial or special gases could be used, eg acetylene, butane, propane, hydrogen, nitrogen and ammonia. Hotwork should preferably be carried out outside the vehicle compartment. Where carried out within the vehicle special precautions should be taken to ensure that fire extinguishers are located nearby and that exit routes are clear. Additional ventilation should be considered for the work to be done and for the comfort and safety of the persons in the vehicle.

5.2

Special Site Service Vehicles Special site service vehicles are defined as vehicles with cylinder installations supplying appliances or equipment fitted within them to provide cooking, heating or lighting facilities at remote locations for outbased personnel. Gases generally used are propane or butane. Appliances should be manufactured to the appropriate British Standards and installed to the manufacturers’ instructions. Each appliance should have a gas isolation valve for use during maintenance work or for emergency shut off. Appliances should not be lit during transit (with the exception of refrigerators fitted with flame failure devices). Catering devices should not be left unattended when in use. Adequate ventilation to the vehicle interior should be provided for complete combustion of the fuel and comfort of the occupants. Where possible balanced flue appliances should be installed. Interior ventilation should be equally divided between

BCGA 31 © 1997 – Re-printed September 2002 4

high and low level with ventilators of fixed and non-adjustable type. Where the interior is divided into compartments the ventilation requirements apply to each compartment. 6

DESIGN AND CONSTRUCTION OF VEHICLES

6.1

General Design When deg a vehicle, consideration should always be given to the potential hazards of the gases to be carried. Specialist information is available from gas suppliers, equipment manufacturers, etc. giving valuable safety information and data. The vehicle design and construction shall conform to the Road Vehicles (Construction and Use) Regulations 1986 and Amendments (6). Installation of cylinders and associated equipment fitted on the vehicle should be carried out by competent gas installers to meet statutory design standards, British Standards, etc. Ventilation of closed vehicle spaces where cylinders are carried should have a minimum of 2% of floor area as ventilation area which is fixed and non adjustable at low level and also a fixed vent, preferably a roof spinner or similar vent at high level (4). Installed piping systems should be readily accessible for regular inspection or maintenance work.

6.2

Cylinder Storage Cylinders should be located in secure positions either in the open air, or in wellventilated containment attached to the vehicle, or within a separate ventilated compartment sealed from the interior of the vehicle and driver’s cab. The cylinder compartment or containment should be constructed to provide a minimum of 30 minutes’ fire resistance in accordance with BS 476 (7). Separate compartments may be necessary depending on the nature of gases being carried, ie compressed gases, flammable, corrosive, etc. Cylinder compartments should be vented at high and low level so that adequate free airflow is available to the load space when stationary. Vents should not be located near engine exhaust systems or other heated surfaces.

6.3

Access to Cylinders/Hazard Warning Access to cylinder compartments should be from the outside and relevant warning diamond signs should be displayed on the outside of the access doors. Other signs should comply with the requirements of the Carriage of Dangerous Goods (Classification, Packaging and Labelling) and Use Of Transportable Pressure Receptacles Regulations 1996 (8). The location of any emergency shut-off valves should be indicated; these should, whenever practicable, be operable from outside the compartment.

BCGA 31 © 1997 – Re-printed September 2002 5

6.4

Protection to Drivers Suitable methods should be used to secure cylinders from movement during transport. Where cylinders are being carried within a closed vehicle for use off the vehicle, the load space should be separated from the driver’s cab by a gas-tight bulkhead of suitable strength to protect the driver from possible impact from cylinders or equipment if unshipped during a traffic accident. This would also protect the driver from any effects should a gas leak occur during transit or as the result of an accident.

6.5

High Pressure Systems High-pressure connections on cylinders or installations should, wherever possible, be located external to the vehicle. Suitable safety devices (non return valves, flashback valves, flame arrestors, etc.) should be fitted as necessary to cylinder equipment and manifold/pipework systems. All relief devices should be vented outside the vehicle.

6.6

Fire Extinguishers Suitable fire extinguishers for use in fires involving the gases and substances to be carried should be provided at readily accessible points to the load space. Extinguishers should also be carried to deal with fires on the vehicle.

7

VEHICLE MAINTENANCE The vehicle must be roadworthy and comply with statutory requirements when in use. Planned maintenance programmes should be drawn up for the vehicle, the installations and equipment fitted and suitable records should be kept of maintenance work carried out. Any work on fitted equipment should be carried out only by competent gas engineers. Daily visual checks are recommended before journeys and immediate action taken to rectify any faults.

8

TRAINING AND PROVISION OF INFORMATION Adequate training should be given to personnel operating vehicles. Training should include basic knowledge of the gases being carried on the vehicle as well as action to take in an emergency. Training records should be kept and retraining carried out as considered necessary. Drivers of vehicles within the scope of The Carriage of Dangerous Goods by Road (Driver Training) Regulations 1996 (9) should receive appropriate training as follows: a)

Vehicle permissible maximum weight greater than 3.5 Te: Suitable Vocational Training Certificate as defined in Reference (9).

BCGA 31 © 1997 – Re-printed September 2002 6

b)

Vehicle permissible maximum weight less than 3.5 Te, but quantities above the threshold level defined in (9) are carried: Product hazards and emergency action, knowledge of Health & Safety at Work etc. Act 1974 and requirements of CDG Road.

Clear instructions should be provided and displayed to ensure the safety of the vehicle and occupants at all times whether in transit or at the work location. Emergency procedures should be displayed in the vehicle and training in the use of fire extinguishers provided for dealing with fires. In all cases relevant TREM-CARDS shall be carried. 9

EMERGENCY PROCEDURES Correct location of cylinders, correct assembly of equipment and correct operation will all contribute to minimising the risk of an incident involving the cylinders. The operator should ensure that fire extinguishers are readily available at all times when oxy-fuel gas equipment or other flammable gases are in use. The most common incidents to occur are ignitions of leakages of fuel gas from hose connections or defective hoses. If this occurs, the cylinder valve should be closed and the fire extinguished as quickly as possible. If this action is not possible, the fire may be first extinguished by prompt use of a dry powder or CO2 extinguisher, followed by the closing of the cylinder valve to avoid re-ignition. If the fire is in the vicinity of the regulator, it may be possible to release the pressure adjusting screw on the regulator with a gloved hand. If this action would involve injury to the operator, the fire may be extinguished by prompt use of a dry powder or a CO2 extinguisher. If it is not possible to extinguish the fire with the use of an extinguisher, further attempts should not be made. Evacuate the area if this has not already been done because of the danger of explosion. Key actions for dealing with gas cylinders in a fire:

9.1

•

Sound the alarm.

•

Secure the vehicle.

•

Switch off the ignition if safe to do so.

•

Evacuate the area.

•

Call the fire brigade.

Incidents Involving Gas Escapes Leakage of product from cylinders or their fittings may occur. The product may be oxidising, flammable, asphyxiant or toxic. Appropriate action should be taken as shown in Appendix 1.

BCGA 31 © 1997 – Re-printed September 2002 7

9.2

Actions for Dealing with Gas Cylinders in a Fire Cylinders exposed to fire may rupture in an explosive manner and hazards may arise from flying pieces, flammable, toxic or corrosive contents, hot gases or pressure shocks. Appropriate action for dealing with gas cylinders in fires is recommended in Appendix 2.

9.3

Key Actions for Dealing with Acetylene Gas Cylinders in a Fire Acetylene decomposition may have started inside the cylinder, which if not quenched by prolonged cooling, may lead to an explosion of the cylinder. The procedure shown in Appendix 3 has been developed to provide guidance on the safe treatment of such a cylinder.

BCGA 31 © 1997 – Re-printed September 2002 8

10

REFERENCES (1)

SI 1989 No 2169

The Pressure Systems and Transportable Gas Containers Regulations.

(2)

SI 1996 No 2095

The Carriage of Dangerous Goods by Road Regulations.

(3)

BCGA leaflet

Carriage of Gas Cylinders By Road in Cars and Vans Guidance for Drivers at Work: 1996.

(4)

LPGA Code 27

Carriage by Road of LPG Cylinders in Closed Vans, 1992. ISBN 1 873891 024.

(5)

SI 1994 No 3246

The Control of Substances Hazardous to Health Regulations (COSHH).

(6)

SI 1986 No 1078

The Road Vehicles (Construction and Use) Regulations and Amendments.

(7)

BS 476 Part 2023, 1987

Test Methods and Criteria for the Fire Resistance of Elements of Building Construction.

(8)

SI 1996 No 2092

The Carriage of Dangerous Goods (Classification, Packaging and Labelling) and Use of Transportable Pressure Receptacles Regulations.

(9)

SI 1996 No 2094

The Carriage of Dangerous Goods by Road (Driver Training) Regulations.

Other sources of information: HSE Guidance Note CS4

The keeping of LPG in cylinders and similar containers.

BS 5482 : Part 2

Domestic butane - and propane - gas-burning installations: installations in caravans and non-permanent dwellings.

BS 5306 : Part 3

Fire extinguishing installations and equipment on premises: Code of Practice for the selection, installation and maintenance of portable fire extinguishers.

BS 5423 and Amendments

Specification for portable fire extinguishers.

HSE leaflet IND (G) 78L (Rev)

Transport of LPG cylinders by road.

BCGA 31 © 1997 – Re-printed September 2002 9

Appendix 1 EMERGENCY PROCEDURES Incidents Involving Gas Escapes from Cylinders

BCGA 31 © 1997 – Re-printed September 2002 10

Appendix 2 EMERGENCY PROCEDURES Gas Cylinders in Fires

BCGA 31 © 1997 – Re-printed September 2002 11

Appendix 3 Key actions for dealing with Acetylene Cylinders in Fires Raise alarm and call emergency services

Do not approach or move the cylinder

Apply cooling water copiously for 1 hour after the fire has been extinguished. Re-apply cooling water for 1/2 hour. Interrupt cooling

Is cylinder surface steaming?

YES

Interrupt cooling. NO

Re-apply cooling water for 1/2 hour.

Does entire cylinder surface remain wetted?

NO

Interrupt cooling. YES Does entire cylinder surface remain cold for 1/2 hour?

NO

YES Wait for a further 1/2 hour.

NO

Is the entire cylinder cold?

YES Remove carefully. Submerge in water for 12 hours. Notify gas supplier.

BCGA 31 © 1997 – Re-printed September 2002 12

Re-apply cooling water for 1/2 hour.

HISTORY AND OBJECTIVES OF BCGA The British Compressed Gases Association was established in August l971 as the successor to the British Acetylene Association, formed in l901. Its consist of producers, suppliers of gases equipment and container manufacturers and s operating in the compressed gases field. The main objective of the Association is the advancement of technology and safe practice in the manufacture, handling and use of all gases and the design and manufacture of all containers, apparatus, appliances, plant, etc. BCGA also provides advice and makes representations, insofar as these relate to particular problems of the compressed gases industry, on behalf of its to all regulatory bodies, including the UK Government, concerning legislation both existing and proposed. Policy is determined by a Council elected from Member Companies, with detailed technical studies being undertaken by a Technical Committee and its specialist Sub-Committees appointed for this purpose.

Further details of the Association may be obtained from: BRITISH COMPRESSED GASES ASSOCIATION 6 St. Mary’s Street, Wallingford, OX10 0EL Tel: 0044 (0)1491 825533 Fax: 0044 (0)1491 826689 Website: www.bcga.co.uk E-mail: [email protected]

BCGA 31 © 1997 – Re-printed September 2002 13

British Compressed Gases Association, 6 St. Mary’s Street, Wallingford, OX10 0EL