MODULE 2 BRAZING CYLINDER TRANSPORT, STORAGE AND EQUIPMENT ISSUED BY REVISION NUMBER REVISION DATE DOCUMENT NUMBER S. GINBEY 0 7 th Nov 2016 QP74
Module 2 Cylinder Transport, Storage & Equipment ADR Regulations (Carriage of dangerous goods by road) The new ADR Regulation 2007 is a European agreement, which supersedes the ADR 2003, ADR 2005 and the 1996 Carriage of Dangerous Goods. Its main purpose is to standardise transport regulations across Europe. ADR applies to everyone carrying gases in the course of his or her work in a vehicle except when: Loads are under the exemption limits (small load exemptions) When private individuals carry dangerous goods, which are packaged for retail sale and intended for personal use. E.g. A person collecting a cylinder of propane for a home barbecue. 1. How do the ADR regulations work? Every cylinder is assigned a number of transport units dependent on its capacity or the maximum weight of product. There is a threshold below which certain basic legal safety regulations apply, above this threshold, the full ADR legislation applies. All gases have been classified by ADR into four categories, relating directly to the hazard diamonds for each product. The calculation and threshold limit depends on whether the customer is transporting: A load containing one transport category A mixed load containing gases with multiple products of different categories Product Type of Gas / Liquid ADR Threshold (units) Toxic Gases - litre/kg 50 Ammonia & chlorine - litre/kg ammonia & chlorine 20 Flammable gasses acetylene, hydrogen, 333 - litre/kg Asphyxiants & oxidants - litre/kg propane, propylene argon, carbon dioxide, nitrogen, CFC s, HCFC s, HFC s, (not HC s) 1000 Mixed loads (see mixed loads any of the above 1000 below) Empty cylinders Any of the above Unlimited Copyright 2016 Tradewinds Engineering Ltd Page 2
2. How do you calculate Transport Units? To determine the quantity of product in a cylinder the following rules apply:- For compressed gases (e.g. oxygen, nitrogen) use the cylinder water capacity of cylinder in litres For liquefied gases (e.g. refrigerant) use the net mass of gas in kg For dissolved gases (e.g. acetylene) use the net mass of gas in kg The regulations require different sizes to be added together, some in litres of water capacity and some in kilograms. These values are referred to as transport units. 2.1 For mixed loads: Each category of gas carried has an associated calculation. You must do this calculation for each individual category of gas, and then add the transport units together. There are five steps: 1. Calculate toxic gas transport units, T Transport Units Transport Units per cylinder x number of cylinders x 50 For ammonia and chlorine the calculation is: Transport Units per cylinder x number of cylinders x 20 2. Calculate flammable gas transport units, F Transport Units Transport Units per cylinder x number of cylinders x 3 3. Calculate asphyxiant/oxidant gas transport units, A Transport Units Transport Units per cylinder x number of cylinders 4. Add the three values together to acquire Transport Units for the total mixed load T toxic Units + F flammable Units + A asphyxiant / oxidant Units = Total Transport units. 5. Determine whether your load is above or below the threshold (1000 units) If the total Transport Units for the load is: below 1000, the small load requirements apply above 1000 the regulations must be observed in full Example for a Mixed Load: - 1 x K Acetylene cylinders (water capacity = 1 l) 1 x E Oxygen cylinders (water capacity = 5 l) 1 x X Nitrogen (oxy free) cylinders (water capacity = 10 l) 1 x 12 kg 134a cylinder 1 x 9 kg 404A cylinder 1 x 10 kg 407C cylinder 1 x 12 kg 410A cylinder 1 x 12 kg R22 cylinder Mixed load transport units for above product load = 73 Transport Units (See table on next page for further clarification) Copyright 2016 Tradewinds Engineering Ltd Page 3
ADR Calculator No of Cylinders Carried Cylinder Size TU per Cylinder Multiplier for Mixed Load TU for Mixed Product Load Flammable Gas Acetylene 1 K 1 3 3 Compressed Gas Oxygen 1 E 5 1 5 Nitrogen 1 X 10 1 10 Refrigerant R134a 1 12 12 1 12 R404A 1 9 9 1 9 R407C 1 10 10 1 10 R410A 1 12 12 1 12 R22 1 12 12 1 12 TU for Mixed Product Load TOTAL TU 73 The threshold for a mixed load is 1000 transport units so the above load is below the ADR regulations threshold and small load exemptions apply see section below. 2.2 For loads containing one transport category (see product table on page 1) Transport units per cylinder x number of cylinders = Total load Transport Units 3. What should I do if I am above the threshold? Note - this will apply to very few RAC engineers. If you are carrying products above the ADR transport unit threshold professional advice should be taken from you gas supplier. Do not proceed with the journey as you will be breaking the law unless you comply with the ADR regulations! Copyright 2016 Tradewinds Engineering Ltd Page 4
4. Basic legal safety requirements for a load below the ADR threshold (small load exemptions) Note this will apply to most RAC engineers. 4.1 Driver training Drivers should be trained in: The hazards and dangers of the goods Safe handling of gas cylinders Emergency procedures and the use of firefighting equipment All training should be recorded and kept by both the employee and employer. The training should be periodically supplemented with refresher training to take account of regulation changes and should be verified upon commencing a new employment. 4.2 Vehicle ventilation Vehicles used for the transportation of gas cylinders should be open. Most refrigeration engineer s vehicles are not so the vehicle should be well ventilated. Toxic gases (e.g. Ammonia) must not be carried in a closed vehicle unless specifically designed for the purpose 4.3 Safety Equipment A 2 kg fire extinguisher is required on all vehicles carrying gas cylinders. (Dry Powder recommended) 4.4 Basic safety Cylinder valves must be closed whilst in transit and all equipment such as cylinder adaptors disconnected Cylinders should be secured properly and should not project beyond the sides or end of the vehicle Cylinder labels must never be removed or defaced 4.5 Marking of vehicles This is not strictly required when under the ADR threshold but extremely useful to the Emergency services in an accident, especially if you are knocked unconscious! 4.6 Information about the load It is strongly advisable to carry the material safety data sheet or a TREM card (Transport emergency card available from the gas supplier) for any gas that is in your vehicle This should be visible to the emergency services in case you are unable to tell them about your load, and to hand. Copyright 2016 Tradewinds Engineering Ltd Page 5
Cylinder labels are attached to all cylinders. The label is produced in accordance with the current legislation, and you must never remove or deface these labels. Carriage of Cylinders Frequently Asked Questions Q. What does ADR regulation stand for? A. The European Agreement Concerning the International Carriage of Dangerous Goods by Road (ADR). Q. I am just a small company (sole trader) do I have to comply with the ADR regulations A. Yes everyone carrying gas cylinders in the course of their work in a vehicle must follow basic safety requirements. Q. I have heard that there are different requirements for ADR defined large loads. As a service engineer am I ever likely to be caught by these a large load? A. Typically someone falling into the large load criteria (i.e. 1000 transport units, TUs) is likely to be a bulk delivery driver. Most service engineers will be covered by small load requirements. Q. What are the small load requirements? A. Note: this will apply to most RAC engineers Drivers should be trained in the hazards and dangers of the goods eg Safe handling of gas cylinders and Emergency procedures and use of firefighting equipment Q. How do I determine the number of transport unit per cylinder? For compressed gases (e.g. Oxygen Nitrogen) use the cylinder water capacity in litres. For liquefied gases (e.g. refrigerants) use the net mass of gas in kg For dissolved gases (e.g. acetylene) use the net mass of gas in kg Q. How do I calculate my mixed load transport units? 1. For flammable gases F - Transport units per cylinder x number of cylinders x 3 2. For asphyxiant/oxidant gases (e.g. compressed gases refrigerant gases) A - Transport units per cylinder x number of cylinders x 1 3. These two totals added together will determine the total transport units. 4. If the total is below 1000 units the small load requirements apply Copyright 2016 Tradewinds Engineering Ltd Page 6
Q. Do vehicles need ventilation? Do I have to have a van or can I use a normal passenger car or estate to carry cylinders? A. Vehicles used for the transportation of gas cylinders should be open. If the vehicle is closed in it must be well ventilated (top and bottom). Toxic gases (e.g. ammonia) must not be carried in a closed vehicle unless specifically designed for the purpose. Cylinders must be restrained to avoid load movement. You should carry out a risk assessment to see if your vehicle is suitable. Many companies are now moving to the exclusive use of vans with a sealed bulkhead for this reason. Q. What Safety Equipment do I need to carry on my vehicle? A. Two 2kg fire extinguishers are required on all vehicles carrying gas cylinders. (Dry powder recommended). Normally one is sited in the rear of the vehicle and the other in the drivers compartment. Q. What else should I know about carrying cylinders safely in my van? A. Cylinder valves must be closed whilst in transit and all equipment such as gauges regulators and adaptors should be removed Cylinders should be secured and should not project beyond the sides and end of vehicle Acetylene cylinders should be stored upright. Cylinder labels must never be removed or defaced Q. Do I have to have Hazard Diamonds on my car? A. Marking of vehicles (Hazard Diamonds) is not strictly required when under the ADR threshold but extremely useful to the emergency services in an accident, especially if the driver is unconscious. You might want to remove these when not carrying cylinders in which case magnetic signs are advisable. Q. What other Information about the load should I carry with me? And what paperwork do I have to carry legally? A. It is mandatory to carry the material safety data sheets or a TREM card (transport emergency card available from the gas supplier) for any gas that is in your vehicle. These should be visible to the emergency services in case the driver is unable to tell them about the load. Q. Are there any other chemicals that I am carrying that are likely to be covered by these regulations? A. Most of these are likely to be carried in small quantity and will not take you over the low transport unit limit. However you must ensure that you have carried out a risk assessment, are carrying the relevant COSHH datasheets and that all chemicals have been safely restrained. Q. Where can I find out more about this regulation and requirements? Refer to SES Datasheet 19 (2007) ADR Carriage of Dangerous Goods Contact your HSE adviser within your company. The Health and Safety Executive have a section on their website which includes a Carriage of Dangerous Goods Manual Copyright 2016 Tradewinds Engineering Ltd Page 7
Safe Handling of Gas Cylinders Cylinders must not be subjected to violent impact. If, after an accidental collision, a cylinder exhibits any sort of deformation (dent), even shallow, it should be considered as hazardous and must be removed from the use. Cylinders must not be dragged, rolled or slid along the ground even for short distances. When handled on a flat surface, they may be pivoted into a slightly inclined position, or transported by means of a hand truck. Never drop cylinders or permit them to strike each other violently. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or placed in a cylinder stand or proper storage area, and is ready to be used. No part of a cylinder should be subjected to a temperature higher than 55ºC. A flame should never be permitted to come in contact with any part of a compressed gas cylinder. For the safe use of cylinders users must know the gas nature (i.e. toxicity, corrosiveness, flammability, reactivity and asphyxiate) of the content and follow its safety instructions (refer to MSDS). Use gas cylinders in a vertical position, unless specifically designed to be used in any other position. The pressure regulating devices should be those suited to the physical and chemical properties of the gas contents. Safe Handling of Transportable Gas Containers Where cylinders are being moved within the workspace they should wherever possible be moved on trolleys. In all cases whether at the position where brazing is being carried out or while being transported on trolleys, cylinders must be secured and upright. This is especially important as regards cylinders of acetylene. Before moving a cylinder the valve must always be closed. Do not attempt to move a cylinder with the hose and regulator attached unless it is secured on a purpose built trolley. Never transport gas cylinders with the regulators attached. Copyright 2016 Tradewinds Engineering Ltd Page 8
Handling Assess the risk before moving cylinders or drums Always moved and secured to a trolley Use appropriate PPE Valves closed, regulators removed. Get help if needed Use correct lifting methods Never have cylinders free standing Storage Gas cylinders can be large, heavy and relatively unstable due to the small base diameter to height ratio. It is important to adhere to a few simple rules when storing your gas cylinders: - Store cylinders in a well-ventilated covered area, preferably outside on one level, and well drained surface - Store cylinders vertically and securely to prevent them from toppling - Store full and empty cylinders separately, rotating your cylinder stock holdings so the oldest cylinders are used first - Segregate cylinders by the properties of the gas (flammable, inert, oxidant and so on) - Ideally in a caged structure which is lockable and signed clearly with relevant safety symbols Copyright 2016 Tradewinds Engineering Ltd Page 9
Brazing Equipment Copyright 2016 Tradewinds Engineering Ltd Page 10
Regulators Oxygen, Acetylene & Nitrogen Always treat a regulator as a precision instrument. Do not expose it to knocks, jars or violent pressure caused by the sudden opening of the cylinder valve. Release the pressure on the control spring when shutting down. Never use the regulator on any gas except for that for which it was designed and do not use a regulator with broken gauges. Never use oil or grease. Flashback Arrestors A flashback arrestor and a non-return valve (check valve) should be installed to prevent flame or oxygen-fuel mixture being pushed back through the lines into either cylinder and damaging the equipment or making a cylinder explode. European practice is to fit flashback arrestors at the regulator and check valves at the torch. US practice is to fit both at the regulator. Check Valves A check valve lets gas flow in one direction only. Not to be confused with a flashback arrestor, a check valve is not designed to block a shock wave. The pressure wave could occur while the ball is so far from the inlet that the pressure wave gets past before the ball reaches its off position. A check valve is usually a chamber containing a ball that is pressed against one end by a spring: gas flow one way pushes the ball out of the way, and no flow or flow the other way lets the spring push the ball into the inlet, blocking it. Copyright 2016 Tradewinds Engineering Ltd Page 11
Copyright 2016 Tradewinds Engineering Ltd Page 12