Class 2 Gases Learning Tool This work has been produced by DGL (Aust) Pty Ltd This Learner s Guide is about the skills and knowledge required to store and warehouse Class 2 Gases at DGL (Aust) facilities. This includes operational requirements for the safe and efficient control of all functions and effective management of hazardous situations. This is an uncontrolled document when printed. Page 1
Contents Getting the most out of this learning tool...3 What you are required to do before completing this learning tool...3 Section 1...4 Definition of a Class 2 Gases...4 Properties of Class 2...4 Class 2 labels for Gases...5 Classification of Class 2 Products...6 Section 2... 7 Storage... 7 Section 3... 8 Management of spills and leaks... 8 Section 4... 10 Personal Habits... 10 Section 5... 11 First Aid... 11 Activity 1, 2 & 3... 12 Key Safety Points... 13 Additional resources... 14 Feedback and Evaluation Sheet... 15 Statement of Completion... 16 This is an uncontrolled document when printed. Page 2
Getting the most out of this learning tool It is important that you complete all sections in this learning tool as it has been designed so that You can abide by the procedures of our organization. You can apply what you have learnt in this package in your day to day activities This Learning Tool is designed to be relevant only to DGL (Aust) Pty Ltd employees and only applied whilst employed with DGL (Aust) Pty Ltd You may have already acquired knowledge in the area identified in this package as you may have completed some specialized training. Or you may have been working within the industry for some time. Should you identify any improvement opportunities in the information contained in this package or have difficulties completing the package please contact National Training and Compliance Manager DGL (Aust) Pty Ltd PO BOX 1594 EAGLE FARM QLD 4009 Ph 07 3868 1001 Fax 07 3868 1055 For any words that are in bold and italic text (example) the meanings can be found in the definitions section of this package What you are required to do before completing this learning tool Before using this package it is important that you have checked that this is the current version of the package on the DGL (Aust) Pty Ltd quality management system (QMS) You also are required to: Obtain a signed proof of delivery of a DGL outwards movement docket with class 2 products that is currently stored on site. Obtain a copy of the Material Safety Data Sheet for the product shown on the outwards movement docket Obtain a copy of the site map Obtain a copy of the sites Dangerous Goods Manifest This is an uncontrolled document when printed. Page 3
Section one Section 1: Definition of a Class 2 A gas is a substance which: (a) at 50 C has a vapour pressure greater than 300 kpa; or (b) is completely gaseous at 20 C at a standard pressure of 101.3 kpa. NOTE: Carbonated beverages are not subject to this Code (Note 1) Section 1: Properties of Class 2 Substances of Class 2 are assigned to one of three divisions based on the primary hazard of the gas during transport. (a) Division 2.1 Flammable gases Gases which at 20 C and a standard pressure of 101.3 kpa: (i) are ignitable when in a mixture of 13 per cent or less by volume with air; or (ii) have a flammable range with air of at least 12 percentage points regardless of the lower flammable limit. Flammability should be determined by tests or by calculation in accordance with methods adopted by ISO (see ISO 10156: 1996). Where insufficient data are available to use these methods, tests by a comparable method recognized by the competent authority may be used; (b) Division 2.2 Non-flammable, non-toxic gases Gases which: (i) are asphyxiant gases which dilute or replace the oxygen normally in the atmosphere; or (ii) are oxidizing gases which may, generally by providing oxygen, cause or contribute to the combustion of other material more than air does; or (iii) do not come under the other divisions; (c) Division 2.3 Toxic gases Gases which: (i) are known to be so toxic or corrosive to humans as to pose a hazard to health; or (ii) are presumed to be toxic or corrosive to humans because they have an LC50 value (as defined in 2.6.2.1) equal to or less than 5,000 ml/m3 (ppm). Note (1) Source the Australian Dangerous Goods Code 7 th Edition page 53 Note (2) Source the Australian Dangerous Goods Code 7 th Edition page 54 This is an uncontrolled document when printed. Page 4
Section 1: Class 2 labels for Gases The below image is a class label used for Class 2 dangerous goods (Note 1). Note (1) Source the Australian Dangerous Goods Code 7 th Edition page 425 This is an uncontrolled document when printed. Page 5
Section 1: Classification of Class 2 Products The transport condition of a gas is described according to its physical state as: (a) Compressed gas a gas which when packaged under pressure for transport is entirely gaseous at -50 C; this category includes all gases with a critical temperature less than or equal to -50 C; or (b) Liquefied gas a gas which when packaged under pressure for transport is partially liquid at temperatures above -50 C. A distinction is made between: High pressure liquefied gas a gas with a critical temperature between 50 C and +65 C, and Low pressure liquefied gas a gas with a critical temperature above +65 C; or (c) Refrigerated liquefied gas a gas which when packaged for transport is made partially liquid because of its low temperature; or (d) Dissolved gas a gas which when packaged under pressure for transport is dissolved in a liquid phase solvent. (Note 1) Note (1) Source the Australian Dangerous Goods Code 7 th Edition page 53 This is an uncontrolled document when printed. Page 6
Section 2: Storage The following precautions shall be observed when storing and handling gases in cylinders: (a) Areas in which cylinders are kept shall be (i) away from any artificial sources of heat, e.g. radiators, boilers or steam pipes, except when there has been prior consultation with the cylinder supplier on the particular circumstances; and (ii) kept clear of combustible materials, vegetation and refuse for a distance of not less than 3 m from any cylinder. (b) All cylinder stores shall be provided with adequate ventilation at all times. NOTES: 1 Ventilation should be adequate to maintain exposure levels to any gases in the store below recommended workplace exposure standards and lower explosive limits, and to maintain safe oxygen levels. 2 Reference should be made to AS 1668.2 for requirements for mechanical ventilation of enclosures. (c) Classes of gases shall be segregated within the store, but need not be separated. (d) The floor should be flat, solid, and constructed from non-combustible materials. It should drain away from the cylinders. Concrete flooring is preferred. Note (1) Source the Australian AS 4332-2004 The storage and handling of Gases in cyclinders Page 12 & 13 This is an uncontrolled document when printed. Page 7
Section 3: Management of Leaks General The following general procedures apply to the management of leaks. They should only be attempted by trained personnel, when it is safe to do so, and when wearing suitable personal protective equipment, and where the characteristics of the gas involved are well understood. Additional special considerations are required in confined spaces or where ventilation is poor. LARGE LEAKS If there is a large leak, the procedure set out below should be followed: (a) Evacuate the area after providing maximum ventilation if it is possible and safe to do so. If a flammable gas is leaking, remove or isolate any ignition sources. (b) Immediately contact the gas supplier for advice, giving location and a return contact. Where appropriate, contact the emergency services. (c) Consult the MSDS for the hazards of the gas involved and activate the site emergency plan (d) Do not approach the cylinder until trained personnel and expert advice are available, especially if the gas is flammable or toxic. SMALL LEAKS If there is a small leak, the procedure set out below should be followed: (a) If it is safe and possible to do so, quickly close the cylinder valve. Back off any regulator (i.e. reduce downstream pressure to zero) and shut off any downstream valves. If a flammable gas is involved, isolate any electrical equipment. Consider evacuating the area. NOTE: Do not use excessive force to shut off a cylinder valve as this can damage the valve seat or break the spindle, making the leak worse. (b) Ventilate the area as well as possible. Open windows and doors; and start up any existing fume extraction system. (c) Turn off any air conditioning system to prevent spreading the hazard. (d) If appropriate, contact the gas supplier or emergency services for assistance. (e) Consult Appendix A and the MSDS about the characteristics of the gas. (f) Wearing appropriate PPE, approach the cylinder from an upwind area and attempt to locate the leak point. An appropriate leak detection method should be used. NOTE: In many cases, soapy water or a proprietary leak detection solution may be used. However, some gases could react with water and make the leak worse. This is an uncontrolled document when printed. Page 8
(g) Attempt to minimize or stop the leak. The method chosen will depend on the location of the leak and type of gas, and the following should be taken into account: (i) If the leak is on the cylinder Do not attempt to repair a leaking cylinder safety device, tighten a valve into a cylinder or tighten a leaking valve gland that is under pressure. (ii) If the leak is through the valve seat outlet Close the cylinder valve, but do not over-tighten. If a suitable regulator is available, back it off fully and screw it onto the cylinder valve outlet. If the cylinder has been provided with a gas-tight outlet cap or plug, screw this onto the valve outlet and close it. (iii) If the gas is flammable Remove all sources of ignition, sparking or static electricity from the area. (iv) If the gas is toxic Ensure that the correct PPE is used, including self-contained breathing apparatus (SCBA) if necessary. (v) If the gas is a liquefiable gas Attempt to position the cylinder so that the leak point is in the vapour space (i.e. highest point) to prevent a liquid leak. (h) Once the leak is minimized or controlled, and it is safe to do so, relocate the cylinder to a safe, well ventilated area where any leaking gas can dissipate safely, e.g. outdoors, or in a fume cupboard with an extraction fan. (i) Securely tag the cylinder as faulty, giving reason and leak location. (j) Arrange for the supplier of the cylinder to collect and remove the cylinder Note (1) Note (1) Source the Australian AS 4332-2004 The storage and handling of Gases in cyclinders Page 52 & 53 This is an uncontrolled document when printed. Page 9
Section 4: Personal habits Personal habits and hygiene practices have an important bearing on health and safety. The following rules shall be followed by all persons whose work involves the handling of Class 2: (a) Do not introduce, keep, prepare or consume any food or drink, or use tobacco. In any place where dangerous goods are stored or handled. (b) Always wash your hands before eating, drinking or smoking, and after work. This is an uncontrolled document when printed. Page 10
Section 5: First Aid The following first aid procedures shall be adopted for the treatment of accidents relating to the handling of Class 2 - Gases: First aid station A first aid station shall be provided in a clean area. It shall comprise, as a minimum, an appropriate first aid kit and first aid instructions, e.g. MSDS for all gases being kept or handled on the premises. Safety shower and eye wash facilities Provision of a readily accessible safety shower (or plunge bath ) and eye wash facilities, both complying with ANSI Z 358.1, should be considered, especially where corrosive or toxic gases or cryogenic or refrigerated fluids are handled. First aid procedures The first aid procedures set out in the relevant MSDS shall be adopted. Note (1) Note (1) Source the Australian AS 4332-2004 The storage and handling of Gases in cyclinders page 33 This is an uncontrolled document when printed. Page 11
Activity 1 Complete the following activity Read the Material Safety Data Sheet (MSDS) for the product on your outwards movement docket. Match and highlight on both the Material Safety Data Sheet and the Outwards Movement Docket any information that is identical. Go to the storage area of the product at the facility and confirm the current stock levels of the product as per the sites Dangerous Goods Manifest Physically view the nearest spill equipment and mark the location on the site map. Physically view the nearest location of Personal Protective Equipment (PPE) and mark the location on the site map. Physically view the nearest fire extinguisher and mark the location on the site map. Physically view the nearest first aid facilities and mark the location on the site map Activity 2 Complete the following activity Read the section in the specific risk assessment for procedure P-110 Goods inward and receipt that is relevant to the handling of 2 products.. Activity 3 Complete the following activities Complete the test to show competency for this learning tool T-971 Test For Class 2 - Gases This is an uncontrolled document when printed. Page 12
Key Safety Points For Class 2 products remember the following safety points Leave space for cool air circulation in storage areas Have fire extinguishers available Always refer to the Material Safety Data Sheets Know your site s emergency response chemical spill procedure Talk about your class 2 products in site meetings Know the location of Personal Protective Equipment (PPE) Know the location of spill equipment This is an uncontrolled document when printed. Page 13
Additional Resources For more information on Class 2 products the following sources may be of assistance Australian Dangerous Goods Code 7 th Edition Available to all DGL employees via the company s intranet Australian The storage and handling of Gases in cylinders Available to all DGL employees via the company s intranet This is an uncontrolled document when printed. Page 14
Training feedback and evaluation sheet Your feedback is appreciated Your Details Name Division of DGL What do you believe is the key issue identified in this training tool Areas you believe where you believe further training will benefit the employees of DGL Please fax completed feedback and evaluation sheet to 07 3868 1011 National Training and Compliance manager to complete Feedback requires Review of training Review of risk assessment Review of procedures Yes No Yes No Yes No Name Signature Date This is an uncontrolled document when printed. Page 15
Statement of Completion Class 2 Gases Learning Tool I... understand the information that is contained in this learning tool and agree to abide by the procedures and safe working practices identified in this leaning tool I confirm that I have checked that this learning tool and / or any identified procedures where the current version in the DGL (Aust) Pty Ltd quality management system (QMS) I confirm that I have read and understood the QMS procedures referenced in this learning tool I confirm that I have completed the activity in this learning tool and have placed a copy of the documents mentioned in sites training records Signed... Employee number... Date... This is an uncontrolled document when printed. Page 16
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