C2 Split Systems Learning Resource Book V17

During planning, special attention should be given to location of fittings, bends, ends of runs, branch joints, and to those areas where heat from brazing or soldering has softened the tube causing a localised loss in strength. The stressing produced from expansion effects usually concentrates in these regions and these are the most likely sites for corrosion fatigue failures. To minimise the effect of localised stressing, it is necessary to make sufficient allowance for the free movement of the tube. This implies not only a loose fit between the tube and its surroundings, but also that adequate allowance is made for the increase in length resulting from thermal expansion. The amount of longitudinal movement depends on the length of the run and the expected temperature change. Minimum practical values can be obtained from Table 1. TUBE TABLE 1 LENGTH ALLOWANCE FOR LENGTH INCREASE [mm] (metres) Temperature Increase °C Up to 3 40 50 60 70 80 90 100 Over 3 to 5 3344556 Over 5 to 9 4567889 Over 9 to 12 7 8 10 12 13 15 16 Over 12 to 15 9 11 13 15 17 20 22 Over 15 to 20 11 14 16 19 22 24 27 Over 20 to 25 15 18 22 25 29 32 36 18 23 27 31 36 40 45 Table based on the formula: Expansion [mm] = tube length (m) x temperature rise (°C) x 0.0177 A useful “rule of thumb” for normal hot water lines is to allow for 1 mm expansion for every 1 metre of straight run. The effects of expansion and contraction may be minimised by installing tubes in ducts or clear space and this should be done wherever possible. ©Industry Development Training Pty Ltd 54

Expansion loops, bellows or bends may also be used for larger installations that have relatively long runs and for tubes of large diameters or in situations where significantly large temperature differences occur repeatedly. The following diagrams show standard dimensional loops and offsets with suitable radii being given in Table 2 on the following page. Expansion loops and offsets must be placed horizontally to avoid forming air locks at the top of the loops and to ensure proper circulation of the water. It is preferable to locate the bend or loop as close to the mid point of the straight run as possible. 217 of 267 55

EXPANSION TABLE 2 (mm) RADII FOR EXPANSION LOOPS AND BENDS 'R' (mm) 10 Nominal Tube Size 15 DN15 DN20 DN25 DN40 DN50 DN65 DN80 DN90 DN100 DN125 20 180 210 250 320 350 400 430 470 510 560 25 220 270 290 370 410 440 500 540 600 650 30 250 300 380 430 510 560 620 670 710 790 40 300 350 400 500 550 630 680 730 810 910 50 320 370 430 530 610 660 740 780 840 950 60 340 430 490 620 720 770 870 920 1000 1130 70 400 480 550 680 780 880 1000 1050 1150 1300 80 450 530 630 760 880 960 1060 1160 1260 1350 90 460 560 660 790 910 1020 1130 1220 1320 1450 100 510 610 710 860 990 1120 1220 1320 1410 1530 610 640 740 920 1020 1150 1250 1350 1430 1550 680 760 840 990 1120 1190 1340 1420 1470 1570 * For pipe sizes DN18 and DN32 the next larger pipe is used. Provision for expansion must be considered when designing tube runs and fixing points by allowing freedom of movement at bends, branches and offsets. Allowance for expansion should incorporate: I. A clear space to permit movement - refer Table 3 [B] II. Sufficient free length of tubing around the bend or along the branch to prevent over-stressing the tube - refer table 3 [A]. L TABLE 3 B (run length) A (for 60°C temp rise) m (Free length) Min. Min. mm Up to 4.5 mm 5 Over 4.5 to 9 600 10 Over 9 to 18 900 20 1200 ©Industry Development Training Pty Ltd 56

Fatigue cracks have sometimes occurred at bends in hot water lines where the tube passes from one structure to another, e.g. from a concrete floor up into a wall. To reduce stressing of the tube in this region, the bend radius should be as large as possible. These cracks usually occur on the sides of the bend where the tube is oval and result from flexing of the wall of the tube at these points. Additional precautions should be taken to ensure that hot water lines are not damaged by flattening or twisting as these faults can act as stress concentrators and lead to failure by fatigue. 218 of 267 57

Copper and Brass Tubes for Sanitary Plumbing It is well known that copper and brass tubes offer significant advantages to designers of sanitary plumbing systems. Some attributes are the material’s light weight, ease of installation, flexibility, space saving capacity, corrosion resistance and ability to be prefabricated. Nevertheless, careful attention must be given to material selection and installation practice if a system is to perform satisfactorily. The complete internal and external operating environment is to be considered when selecting pipeline materials. Corrosive discharge liquids or aggressive surrounds could reduce the life of a system. MATERIAL LIMITATIONS Copper Pipes and Fittings > Pipes and fittings shall not be used for urinal discharges only, but may be permitted where the flow is diluted by discharges from regularly used upstream fixtures. They shall not be used in conjunction with grease arrestors. > Type B pipes shall not be field bent beyond a 10 degree offset angle. > Type D pipes shall be used in straight lengths only and shall not be offset by bending. > Type D pipes shall not be used for sanitary drainage below ground. > Bends and junctions at the base of stacks up to 9m in height shall be formed from no thinner than Type B pipe. > For stacks greater than 9m in height, bends and junctions at the base are to be cast or hot pressed copper alloy. Brass Pipes and Fittings > Pipes shall only be used in the as-supplied 1/2 hard temper. > Pipes shall not be bent, offset or misaligned. > Pipes shall not be used with compression fittings. > No fitting other than a junction shall be fabricated in the field. > Local annealing is only permitted where necessary for making joints. It is important to note that some cleaning chemicals have contributed to the corrosion of metal pipes. Both copper and brass may be affected by some undiluted discharges from commercial dishwashers, glass washers and bar sinks. ©Industry Development Training Pty Ltd 58

Pipe Support Vertical and graded pipes are to be supported at maximum intervals of 3 metres. Pipes are not to be supported or spaced by means of brazing or welding short sections of material to the surface of each pipe. All brackets are to be lined with an inert, non-abrasive material where they contact pipes. Other than at expansion joints, the brackets shall, when fully tightened, permit tube to move longitudinally. Brackets are to clamp expansion joints securely and prevent their movement. Expansion Joints STACKS Where a stack passes through more than 2 floors, whether above its base or above any offset bend, expansion joints are to be fixed: > At the base of the stack or in the vertical pipe above an offset bend. > At alternate floor levels where the stack is unrestrained or at each floor level except the top floor when the stack is restrained or is subject to hot discharges. > The expansion joint at any intermediate floor is to be placed immediately above the junction of the highest discharge pipe connected to the floor concerned. GRADED DISCHARGE PIPES An expansion joint is to be installed as close as practicable to the stack in any restrained, graded discharge pipe exceeding 6 metres in length. BED PAN SANITISER AND WASHER An expansion joint is to be installed at each floor in any soil stack, soil vent and steam relief vent pipe connected to a bed pan sanitizer and washer supplied with steam. Freedom From Restraint A pipe is considered to be unrestrained provided that: > No restraint on longitudinal movement occurs where it passes through walls or floors. A 6mm annular space is to be provided and the space may be filled with an approved flexible sealant (see page 60). > No restraint on movement shall occur on any branch discharge pipe for a distance of 450mm from its junction with a stack. Where the discharge pipe penetrates any floor or wall within such distance, a 6mm annular space is to be provided. The space may be filled with an approved flexible sealant. 219 of 267 59

©Industry Development Training Pty Ltd 60

Penetration Sealants The installation of pipes through fire rated members is critical. Particular attention is needed where pipes penetrate various adjoining fire rated compartments. In the event of a fire, flames must be restricted from passing from one compartment to another at points where pipes penetrate. Special installation techniques have been developed, tested and certified to satisfy PCA requirements for copper and brass pipes. Specific caulking compounds are available to close off pipe penetrations and provide a fire rated seal. Sealant suppliers will assist in the identification of product suitable for specific fire rating requirements. Pipe Grade Conversions PIPE GRADE CONVERSION CHART Percentage % Ratio (gradient) Percentage % Ratio (gradient) 20.00 1 in 90 6.65 1 in 5 1.10 1 in 100 5.00 1 in 120 3.35 1 in 15 1.00 1 in 140 2.50 1 in 150 2.00 1 in 20 0.85 1 in 160 1.65 1 in 200 1.45 1 in 30 0.70 1 in 250 1.25 1 in 300 1 in 40 0.65 1 in 50 0.60 1 in 60 0.50 1 in 70 0.40 1 in 80 0.35 220 of 267 61

Copper Tube for Fire Services Copper tube is permitted to be used in fire hydrant, hose reel and automatic sprinkler systems. However, limitations apply. When considering piping for these applications, it is important that: > Design and installation is performed by competent, accredited personnel. > Reference is made to current relevant Standards, some of which are listed on page 9. > The local regulatory authority approves of the work to be performed and materials to be used. FIRE HYDRANT SYSTEMS In accordance with AS2419.1, copper pipes used above or below ground in hydrant systems are required to comply with AS1432 Types A or B or AS1572 where thicker tube is necessary. Tube shall have a test pressure of 1700kPa, or 1.5 times the highest working pressure, whichever is the greater. Soft soldered joints are not permitted. Copper is prohibited to be used in above ground situations in non-fire sprinklered buildings unless protected using materials that will provide a FRL of not less than -/60/60 or be located in a floor or ceiling system that achieves a resistance to the incipient spread of fire of not less than 60 minutes. FIRE SPRINKLER SYSTEMS Copper is permitted to be used in wet fire sprinkler systems only as defined in AS2118.1 for hazard classifications up to OH3 Special, AS2118.4 [Residential] and AS2118.5 [Domestic]. Copper pipes are an ideal option for Domestic combined and independent systems – see the latest edition of AS 2118 Part 5. > Tube shall be to AS1432 and minimum Type B. Thickness may be to Type A depending on applicable test pressures as outlined on page 69. > Capillary and compression fittings to AS3688 are permitted to be used. > Joints may be brazed with minimum 1.8% silver-copper-phosphorus filler metal. > Soft soldered joints, where approved, are permitted for residential and domestic systems as well as light and ordinary hazard 1 occupancies when piping is concealed in ceilings or void spaces. > Copper may be bent to a minimum radius of 6 diameters for sizes DN50 or smaller and 5 diameters for larger sizes. ©Industry Development Training Pty Ltd 62

Copper for Gas Piping Copper is approved for fuel gas piping in AS 5601 - Gas Installation Code. It is suitable for conveyance of Town Gas, Natural Gas, and Liquefied Petroleum Gas in the vapour phase, Tempered Liquefied Petroleum Gas and Simulated Natural Gas: > AS1432 Type A or B tube is required for pressures up to and including 200kPa. > Copper is not permitted in the ground beneath a building at pressures above 7kPa unless protected with either a manufactured plastic coat or a proprietary wrapping acceptable to the authority. Where pipe is coated, the entire length is to be protected and made water-tight, including ends. > Permissible joints are: flared copper alloy compression, capillary, press-fit, expanded sockets and formed branches [in hard tube only]. > Soft soldered joints and olive type fittings are not permitted. > When copper alloy [brass] fittings are to be buried in the ground, they must be DR or effectively protected against corrosion. The use of Copper tube and fittings for main to meter applications is allowed in most circumstances. There are restrictions on the allowable joining methods and reference should be made to your local network provider, AS/NZS 4645.1 Gas Distribution Networks and AS 4809 Copper pipe and fittings – Installation and Commissioning. Protection During Building Construction Care is to be taken to ensure that water service pipes are not damaged during normal building activities. Concealed piping is to be maintained under normal water pressure while subsequent building operations are being carried out which could cause damage to the pipes. The service must be flushed with clean water at regular intervals until the building is occupied. Disinfection treatment may be necessary – refer to AS 4809. 221 of 267 63

Bending Copper Tubes GENERAL CONSIDERATIONS The making of good bends in copper tube requires care and skill. One essential requirement is that the material must have sufficient ductility for it to deform into the shape of the bend without seriously weakening the tube wall or giving rise to undesirable distortion or fractures. Distortion and fractures are usually caused by: bending tool wear, excessive tube hardness or lack of proper bending techniques. Good bends are produced with a smooth action of the bender without jerks or relative movement between bender and tube. Annealed temper tube is desirable for hand bending since it can be worked with the least amount of strain, and is more suited to the small radiused bends used in plumbing installations. When using hand bending tools, the presence of oil or grease in the groove or on the tube, can lead to excessive wrinkling on the inside of the bend. A similar fault can result if the groove has been excessively worn. Kinking can occur if the wiper shoe is not positioned correctly at the start of bending. ANNEALING (SOFTENING) FOR BENDING Heating for too long, or at too high a temperature, causes excessive grain growth with little or no additional softening. It results in coarsening of the grains and can cause an undesirable “orange peel” surface to develop during bending. In the worst case, it can lead to rupture of the metal. The typical range for annealing Copper and 70/30 DR Brass is 450°-600°C. This temperature range is distinguished by the heated metal changing to a “dull red” colour. ©Industry Development Training Pty Ltd 64

Annealing Procedures 65 These can vary from large-scale furnace annealing, to the use of a gas torch where only localised annealing is required. Where torches are used, care must be taken to avoid concentrating the heat on one spot or heating for an excessive time. The annealing of thin-wall tube should be approached with extreme care as incorrect procedures can result in burning of the metal or loss of thickness due to oxidation. If undesirable grain growth is to be avoided, an accurate estimation of temperature is important. Furnace annealing normally utilises pyrometers for this purpose, but with torch annealing the use of temperature-sensitive crayons is recommended. The Effects Of Time On Annealing The time at temperature can vary from just a few minutes to 1/4 hour or more. To achieve a fine grain size, it is best to anneal at lower temperatures and correspondingly increase the “soak” time. Optimum properties can best be obtained by experimentation. Cooling After Annealing Copper and 70/30 DR Brass tubes may be cooled by either quenching in water or allowing to cool naturally in air. Surface Cleaning (Pickling) Any scale or other oxide products that develop on the surface of copper and brass tubes when heating in air may be removed by immersion in appropriate acid solutions. STRESS RELIEF AFTER BENDING When tubes are bent cold, the metal is usually left in a state of internal stress. These residual stresses may cause some metals to crack when they are exposed to certain agents such as ammonia, mercury, or liquid solder. The stresses can also cause a loss of shape that may be important if, for example, the bent tube has to be brazed to form part of a fabricated assembly. If the tube is required to operate under onerous conditions, or if there is any doubt about the need for such treatment, then it is always advisable to stress relieve. Stress relief is not normally required with copper, but is essential for 70/30 DR Brass. Treatment consists of heating in the temperature range 300°-360°C, and holding for a time sufficient to reduce the internal stresses to a safe level. 10-15 minutes should be an adequate soak time for all tubes. An undue increase in temperature or soak time is liable to produce a slight softening of the metal. There is no need for stress relief if the tubes have been bent hot and cooled naturally, or if the tubes are to be annealed soon after bending. If there is any doubt about the adequacy of stress relieving treatment, or a need to test for susceptibility to stress corrosion cracking, then this can be done by means of stress corrosion test. Details of this test are given in Australian Standard AS 2136 and British Standard International Standard BS ISO 6957. 222 of 267

COLD BENDING Provided correct tempers and tube thickness are chosen, copper and 70/30 DR Brass can be bent cold. The single, most important requirement in cold bending is that the material should be sufficiently ductile. Typical elongation values for copper and 70/30 DR Brass are given on page 67. Due to elastic recovery of the metal, some small allowance may be necessary for springback when accurate alignments are required. There is always a tendency for the outside wall to flatten, and if this becomes objectionable, it may be overcome by the use of internal support in the form of a mandrel, suitable filler material or by the use of bending springs. HOT BENDING Most metals can be bent hot providing there is adequate internal support by mandrels or suitable fillers to prevent distortion. Large diameter tubes, principally those with thick walls, require mechanical means for bending and are therefore commonly bent hot as this reduces the load required to effect the bend. Hot cracking from embrittling agents or unsuitable fillers may occur and examples of these are some low melting point alloys containing bismuth and cadmium, and sodium hyposulphite (hypo) filler. Ordinary phosphorus deoxidised copper tubing (C12200) as used for plumbing, may be bent hot, but very high temperatures and prolonged heating should be avoided as excessive oxidation and grain growth can occur. In extreme cases this can lead to a loss of grain boundary cohesion causing the metal to crack during bending. Copper tube may be bent hot in the range 700°-800°C, but excessive heating times should be avoided. 70/30 DR brass tube may be hot bent in the range 725°-825°C, but temperatures of 250°-550°C should be avoided as the material is susceptible to hot-short cracking in this temperature range. TUBE BENDING CALCULATIONS The minimum bend radius to which a tube can be bent depends on the amount of ‘stretch’ the outside wall of the bend will withstand without causing undue distortion or fracturing. Good ductility is thus an essential requirement. Other significant factors are tube material, diameter, wall thickness, and the type of bending equipment employed. There is relatively little difference in the bending characteristics of copper and brass although power requirements necessary to form bends will increase as alloy strengths increase. ©Industry Development Training Pty Ltd 66

It is general practice when designating minimum bend radii, to refer to the dimension of the centreline of the bend in the case of round tubes and to the inside of the bend in the case of square or rectangular tubes. The following formula, which takes into account the tube’s ductility, may be used as a rough guide for determining minimum bend radii: R= tube diameter (O.D. in mm) x 50 E Where R = minimum centre line radius and E = % elongation in 50mm. Typical Elongation Values (E) COPPER Soft - 55 Hard - 10 70/30 DR BRASS Soft - 65 Hard - 15 Example: determine the minimum bend radius of a 50.8mm outside diameter soft copper tube. Min. bend radius (R) = 50.8 x 50 = 2450 = 46.18mm 55 55 No minimum radii are available for hot bending. Buckling can be reduced by peening the inside of the bend. The more difficult bends are done slowly. Hot bending can result in some metals cracking and details of this have been given in the section on hot bending. For making a given bend there is no precise demarcation as to whether tools are necessary, but guidance on their use may be obtained from the following chart. 223 of 267 67

BENDING WITHOUT TOOLS OUTSIDE DIAMETER(O.D.) 50 APPROXIMATE LINE WALL THICKNESS (wt) 40 SPECIAL TOOLS OF DEMARCATION FOR ANNEALED TUBE REQUIRED 30 wt O.D. 20 C.L.R. 10 RATIO OF TUBES CAN BE HAND BENT WITHOUT USE OF SPECIAL TOOLS SUCH AS MANDREL OR WIPER DIES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 RATIO OF CENTRE LINE RADIUS (C.L.R.) OUTSIDE DIAMETER (O.D.) TEMPURATURES BY COLOUR APPEARANCE APPROX. TEMP °C Lowest red heat visible in the dark 335 Red hot in the dark 400-500 Faint red Dark red 516 Brilliant red 650-700 Cherry red Bright cherry red 800 900 1000 ©Industry Development Training Pty Ltd 68

Test Pressures Australian Standards for various systems specify that the piping is to be tested to the following pressures. It is strongly recommended that installed piping be tested prior to burial or concealment. Adherence to this procedure will facilitate the location and repair of any leak exposed by the pressure test. SYSTEM PRESSURE AUSTRALIAN Cold Water 1500kPa for 30 minutes minimum STANDARD Hot Water (excluding AS/NZS 3500.1 storage container or hot water heater) 1500kPa for 30 minutes minimum AS/NZS 3500.4 Sanitary Plumbing Hydrostatic test to flood level or air AS/NZS 3500.2 Gas Piping pressure test at 30kPa for 3 minutes - specific practice is minimum AS 5601 outlined in AS 5601 a) New piping before appliances are AS 2419.1 - only applies for connected or repaired/altered system AS/NZS 3500.1 with appliances isolated: test pressures not - pressurise to 7kPa or twice operating exceeding 400kPa pressure, whichever is greater. - no loss of pressure during an Fire Hydrant isolation period of 5 minutes after Fire Hose Reel stabilisation plus an additional 5 Fire Sprinkler minutes for every 30 litres [0.03m3] of - Domestic pipe volume. - Residential - AS 2118 b) New piping or repaired/altered systems with appliances connected: - Wall-wetting - pressurise to operating pressure. (drencher) - test period as for ‘a’. Not less than 1700kPa for a period of 2 hours or 1 .5 times the highest working pressure whichever is the greater. 1500kPa for not less than 30 minutes. Not less than 1500kPa. AS 2118.5 Not less than 1500kPa. AS 2118.4 1.4MPa for a period of 2 hours or AS 2118 400kPa in excess of the maximum static working pressure, whichever is the greater. 1.4MPa for a period of 2 hours or AS 2118.2 400kPa in excess of the maximum static working pressure, whichever is the greater. 224 of 267 69

Corrosion Rating of Copper and 70/30 DR BRASS ENVIRONMENT COPPER 70/30 DR BRASS Acetone AA Acids: DD - Chromic AC - Citric CD - Hydrochloric DD - Nitric BD - Phosphoric CD - Sulphuric AB - Tanic AC - Tartaric Alcohols AA Aniline dyes CC Animal/excreta and D C decomposed undiluted urine Ashes DD Asphalt AA Atmosphere: AB - Industrial BB - Marine AB - Rural Beer AB Benzene, Benzol AA Bleaching Powder BD Brines BD Carbon tetrachloride (m) B D Fruit juices BD Fuel oil AB Gases: DD - Acetylene DD - Ammonia (m) CD - Bromine (m) AA - Butane BC - Carbon Dioxide (m) AA - Carbon Monoxide CD - Chlorine (m) AA - Freon - Hydrogen AA - Hydrogen Sulphide (m) D C - Methane AA - Natural Gas BA - Nitrogen AA - Oxygen AA - Propane AA - Steam AC - Sulphur Diox©idIend(mu)stry Development TraBining Pty Ltd D 70

Corrosion Rating of Copper and 70/30 DR BRASS (Cont...) ENVIRONMENT COPPER 70/30 DR BRASS A A Gasoline A A Kerosene A A Lacquers D D Magnesite D D Mercury and Salts D D Silver salts B D Sodium Chloride C D Sodium Hypochlorite A B Sugar solution A A Trichlorethylene [dry] B C Trichlorethylene [m] A A Varnish - solvents Water: B C - Carbonated A B - Potable B C - Sea water C D - Mine water A B - Soapy A C - Sewage RATINGS A Excellent - Under most conditions. B Good - May be considered in place of ‘A’ when some other property governs use. C Fair - May only have limited life. D Poor - Not recommended. Note: > [m] moist > Both materials unsuitable for use with ammonia, ammonium compounds and amines. > Tinning may be required if used in contact with food products. > Some cleaning chemicals have contributed to the corrosion of metal pipes. Both copper and brass may be affected by some undiluted discharges from commercial dishwashers, glass washers and bar sinks. More information of the Corrosion Rates of other material and for particular circumstances can be obtained by contacting the ICAA on the numbers shown on 225 of 267 71

Index Accessories..............................................................................................................34 Air Lines....................................................................................................................22 Alloy C12200.............................................................................................................10 Annealing (Softening) For Bending..........................................................................64 Antimicrobial Benefits of Copper..............................................................................37 AS1432 Copper Tubes Approximate Mass per Length..........................................24 Bed Pan Sanitiser And Washer................................................................................59 Bendable Temper Tubing - Available Sizes.............................................................16 Bending Copper Tubes............................................................................................64 Bending without Tools..............................................................................................68 Branch Forming........................................................................................................30 Cleaning....................................................................................................................50 Cold Bending............................................................................................................66 Colour Identification Of Silver Brazing Alloys In Accordance With AS 1167...........29 Compression Joints..................................................................................................27 Concealment Of Copper Water Services.................................................................51 Contents......................................................................................................................5 Copper And Brass Tubes For Sanitary Plumbing....................................................58 Copper For Gas Piping.............................................................................................63 Copper Press-Fit Fittings..........................................................................................32 Copper Refrigeration Tube Chart 1..........................................................................20 Copper Refrigeration Tube Chart 2..........................................................................21 Copper Tube For Fire Services................................................................................62 Copper Tube For Refrigeration.................................................................................18 Copper Tube Identification.......................................................................................12 Copper Tube Properties...........................................................................................10 Copper Tubes Exposed To Freezing Conditions.....................................................47 Copper Tubes For Plumbing, Gasfitting And Drainage Applications To Australian Standard 1432 – 2004................................................................. 13-15 Corrosion Protection Systems for Pipe and Fittings.................................................35 Corrosion Ratings of Copper and 70/30 Dr Brass............................................. 70-71 Dead Legs................................................................................................................37 Earth Rods................................................................................................................50 Electrical Earthing.....................................................................................................49 Expanded Joints.......................................................................................................30 Expansion Joints.......................................................................................................59 ©Industry Development Training Pty Ltd 72

Fire Hydrant Systems................................................................................................62 73 Fire Sprinkler Systems..............................................................................................62 Fitting Loss Factors...................................................................................................42 Fitting Specification and Size Ranges......................................................................26 Flow Rates At Fixtures Or Appliances......................................................................38 Foreword.....................................................................................................................4 Freedom From Restraint...........................................................................................59 General Considerations............................................................................................64 Graded Discharge Pipes..........................................................................................59 Heated Water Piping Insulation................................................................................48 Hot Bending..............................................................................................................66 Installation and Design.............................................................................................50 Installation Of Hot Water Lines.................................................................................53 Installation Practice – Safety Precautions................................................................49 Jointing Methods......................................................................................................27 Large Diameter Copper Tubes.................................................................................16 LP Gas Pipelines For Vehicle Engines.....................................................................18 Material Limitations...................................................................................................58 Medical Gas Tubes...................................................................................................19 Minimum Thickness for Thermal Insulation to Prevent Freezing.............................48 Other Relevant Standards..........................................................................................9 Penetration Sealants.................................................................................................61 Pipe Grade Conversions..........................................................................................61 Pipe Sizing................................................................................................................38 Pipe Spacing.............................................................................................................47 Pipe Support.............................................................................................................59 Plumbing Precautions...............................................................................................50 Pre-Insulated Copper Tube......................................................................................17 Press-Fit Joints..........................................................................................................31 Press-Fit – Perfecting your Press Installation Instructions.......................................33 Pressure Loss And Flow Data For Copper Pipes And Fittings Calculation Formulae...................................................................................40 Pressure Loss Estimates For Type B Copper Tubes......................................... 43-45 Protection During Building Construction..................................................................63 Protection For Joints.................................................................................................53 Protection Of Potable Water Supplies......................................................................50 Proximity Of Water Pipes to Other Services.............................................................49 Push Fit Joints...........................................................................................................31 226 of 267

Recommended Water Velocities..............................................................................39 Recycled Water Tubes.............................................................................................18 Roll Grooved Joints...................................................................................................30 Roof And Trenchwork...............................................................................................49 Safe Working Pressure Calculations for Copper Tubes..........................................23 Silver Brazed Joints..................................................................................................28 Size Ranges Chart....................................................................................................26 Soft Soldered Capillary Fittings................................................................................27 Stacks........................................................................................................................59 Standard Copper Plumbing Tube Details................................................................12 Standards Applicable To Copper And Alloy Tubes...................................................8 Standards Applicable to Copper and Copper Alloy Fittings...................................26 Steam Lines..............................................................................................................22 Stress Relief After Bending.......................................................................................65 Supply Tanks............................................................................................................50 Temperatures by Colour...........................................................................................68 Test Pressures..........................................................................................................69 Thermal Conductivity of Insulating Materials...........................................................48 Tube Bending Calculations......................................................................................66 Tube Mass Calculation Formula...............................................................................25 Tube Specification And Size Ranges.........................................................................8 Tubes In Chases, Ducts Or Conduits.......................................................................51 Tubes In Concrete....................................................................................................52 Tubes Inwalls............................................................................................................51 Tubes Under Concrete.............................................................................................51 Tubing Below Ground...............................................................................................52 Water Composition...................................................................................................36 Water Flow Rates......................................................................................................41 Water Hammer..........................................................................................................46 Water Mains..............................................................................................................37 Water Supply Piping Design.....................................................................................36 ©Industry Development Training Pty Ltd 74

The information in this publication has been assembled for guidance only. Care has been taken to ensure accuracy, but no liability can be accepted for any consequences that may arise as a result of its application. It may not be reproduced in whole or part without the written consent of the Copper Development Centre Australia. All plumbing work should be performed by competent, accredited tradespersons in accordance with current relevant Standards and specifications required by the authority within whose jurisdiction the work is to be performed. To ensure an installed system will provide satisfactory performance and the expected life, Industry practitioners should refer to Australian Standard AS4809 and give careful consideration to all aspects of: > design > operating condition > the internal and external environments > use of approved materials 227 of 267 75

Australian Office Suite 1, Level 7, Westfield Towers 100 William Street, Sydney NSW 2011 Tel: (+612) 9380 2000 Fax: (+612) 9380 2666 www.copper.com.au www.smartwiredhouse.com.au www.antimicrobialcopper.com Proudly Supported by: MM Kembla Gloucester Boulevarde PO Box 21 Port Kembla 2505 Phone: (+612) 4223 5201 Fax: (+612) 4223 5235 www.kembla.com.au ©Industry Development Training 2P2ty8 Lotfd267 76

�WBOC A Member of The Linde Group Guidelines for Gas Cylinder Safety ror the latest version visit www.boc.com.au ©Industry Development Training Pty Ltd 229 of 267

02 Guidelines for Gas Cylinder Safety Contents. 04 Introduction. 05 Know your gases. 11 About your cylinders and valves. 16 Ordering, transport and handling of cylinders. 23 Storing your cylinders safely. 25 Care of cylinders. 27 Working with gas cylinders. 31 Keeping your equipment safe. 32 If something goes wrong. 35 Keeping your environment safe. 38 Glossary. ©Industry Development Training Pty Ltd 230 of 267

Guidelines for Gas cylinder Safety 03 BOCis committed to practising and communicating safe operations around the world as part of its commitment to robust product stewardship. It is as important for BOC to impart safe working methodologies to customers and suppliers as it is to have clear, established and measurable performance standards practised by all BOC plants, depots and distributors - regardless of plant, product or service. BOC has: · Safety as its highest priority. · One simple goal: zero incidents and injuries. · Well-established programmes to drive improvement in SHEQ (Safety, Health, Environment, Quality) performance. ©Industry Development Training Pty Ltd 231 of 267

04 Guidelines for Gas Cylinder Safety Introduction. Many people across a wide range of industries, including Scope of these guidelines manufacturing/maintenance, medical, hospitality, science and education use gases from compressed gas cylinders. The pressure at These guidelines cover compressed and liquefiable gas cylinders as which gases are contained in gas cylinders can be extremely high. shown on the 'Gas cylinder colour identification' on pages 8-9. Continual advances in cylinder technology will enable pressures to be increased even further. Please note that the identification of the gas contents of any cylinder is given by the label on the cylinder and is qualified by the colour(s) of To maintain and continue to improve the current safety record for the the cylinder, and the cylinder valve outlet. use of these cylinders, increased knowledge and understanding of the DO's and DON'Ts is essential. These guidelines touch on toxic gases (e.g. Ammonia which is used as a refrigerant) but do not cover these gases in detail as these are For new users of gas cylinders, it is essential that they receive considered generally the domain of special gases. adequate training and guidance prior to use. Legislation and standards These guidelines distill the experience and knowledge of various experts in an effort to provide guidance for safer handling of This gas cylinder information booklet is intended as a guide. Product gas cylinders. users should also refer to relevant legislation, regulations, codes of practice and Australian Standards They focus on a number of known issues and on situations where the same or similar incidents have reoccurred. BOC is committed to promoting the safe handling of gases wherever possible and hopes that this document will serve as an educational Every possible issue or occurrence can neither be anticipated tool outlining the potential hazards of working with gases as well as nor covered. promoting safer practices around their use, handling and transport. If in doubt, call the BOC Emergency Response line on 1800 653 572 in situations or occurrences that fall outside guidelines. It is recommended this document be kept for handy reference by every: • Manager • Engineer • Foreman • Tradeperson • Storeperson • Operator • OHS personnel ©Industry Development Training Pty Ltd 232 of 267

Guidelines for Gas Cylinder Safety OS Know your gases. Main gases hazard classifications. _o_x_id_i_si_n_,.g_G_a_s_ _ _ _ _ _ _ Fl_a_m_m_a_b_le_G_a__s _ _ _ _ _ _ _ To_x_i_c_G_a_s_ _ _ _ _ _ _ _ _ Non-flammable, non-toxic Gas Division Diamonds ♦ Division 2.2/5.1 Division 2.1 Division 2.3 Division 2.2 Diamond: Red Diamond: Green OXlllSING Diamond: Yellow Lettering: Black Diamond: White lettering: Black GAS Lettering: Black or White Lettering: Black 2 TOXIC GAS 2 Australian standards Definition Agas which will burn in air at a pressure Agas that is known to be Agas which is non-flammable,non-toxic, Agas which gives up oxygen readily, of 101.3 t::Paabsolute. nacotnio-noxuidnidseinrgn,oarnmdaisllyreesnisctoaunnttteorecdhemical rreemadoilvyeaschcyedprtosgeelnecftroromnsa. compound, or a toxic or corrosive to humans as to pose conditions. a hazard to health; or b hpuremsuamnsebdetocabuesetoitxihcaosracnoLrCro5s0ivevatolue equal to or less than 5000ml/m' (ppm). General Definition Flammablegas in the presence of the A gas that is known to be so toxic or Agas which is non-flammable,non-toxic, correct mix of air and an ignition source corrosive to humans as to pose a hazard non-oxidising,and is resistant to chemical Many materials which will not burn in will lead lo combustion. to health. action under normally encountered air may readily ignite and or burn in Hues of Red ocronadiritbioynasn.Tinheertdigsapslamceamy epfoltseofaorxisykgeoffl the presenceof an oxidising gas - e.g. asphyxiation. aonxdygmena.nyThmisaintecrluiadlsecsownosirdkecrleodthnionng flammable. Hues of Yellow Hue of Brown, Green or dark Blue Cylinder colour Identification Hues of Black, While, or bright Blue Associated risks and hazards of handling gases Additional Information In the interests of personal safety, customers MUST familiarise Since gases are invisible their presence is not readily identifiable, but themselves with the respective SOS and gas equipment they do have the potential to asphyxiate, burn or harm users. operating manuals. An important part of the label is the Division (Class) Diamond which Copies of current SDSs for each of the gases stored and used must represents the characteristics of the gas (see above). be collated and kepi in a convenient location for quick reference in relation to: Each year in Australia, there are incidents which involve the use of compressed or liquefied gases. • storage • Handling Many of these could have been avoided if the user had followed •Transport issues information contained in the Safety Data Sheet (SOS) or had referenced • Personal Protective Equipment this document or other similar freely available information. • Incident response Label soss for BOC gas products are available from www.boc.com.au or by The cylinder label is the primary means for identifying the contents of a gas cylinder and the nature and hazards associated with the gas contacting the BOC customer Service Centre on 131 262. contained in the cylinder (see next page). DO NOT use a gas cylinder ii the label is missing or illegible, or if the heat tag has been damaged. Return it to BOC or the agent/outlet you purchased it from for a satisfactory replacement. Cylinder colour The cylinder colour is the secondary means for identifying the nature and hazards associated with the gas contained in the cylinder. ©Industry Development Training Pty Ltd 233 of 267

06 Guidelines for Gas Cylinder Safety BOCcylinder and pack identification label. BOC cylinder label BOC Gas Trade Name 2 United Nations (UN) number and proper shipping name for safe handling, transport and storage 3 Dangerous Goods Classification 4 BOC gas code and cylinder size 5 Contents of cylinder at standard temperature and pressure i.e. (IS° C @ 101.3 kPa) 6 Nominal filling pressure at standard conditions (for permanent gas) 7 Caution - indicated major hazards· 8 General safety information• •Always refer to Safety Data Sheet (SOS) Main pack identification label Caution label (gas & contents) Q Labels vary in shape, size and their positioning on cylinders and packs. ©Industry Development Training Pty Ltd 234 of 267

Guidelines for Gas Cylinder Safety 07 Primary hazards for commonly used industrial gases _M_a._jo_r_H_a_za_r_d_ _ _ G_as_ _ _ _ _ _ _ cyli_n_de_r_C_o_lo_u__r _ Characteristics Asphyxiant Carbon Dioxide Green Grey No.N32 • Slightly pungent (can cause the nose to sting) • Heavier than air and will collect in ducts, drains and low lying areas, e.g. cellars • At high concentrations, instant unconsciousness may occur followed by death Asphyxiant Nitrogen Pewter No.N63 • Odourless Peacock Blue No.TS3 •At high concentrations almost instant unconsciousness may occur, Asphyxiant Argon Brown No.X54 oSrilvGear,lvGarneiyseNdo.N24 followed by death Asphyxiant Helium • No warning signs before unconsciousness occurs • Cold Nitrogen is heavier than air Flammable LPG • Does not burn Extremely hazardous • Largely Inert. • Odourless •At high concentrations almost instant unconsciousness may occur, followed by death • No warning signs before unconsciousness occurs •Argon is heavier than air • Does not burn • tnert • Odourless •At high concentrations, instant unconsciousness may occur, followed by death. DO NOT INHALE UNDER ANY CIRCUMSTANCES. • No warning signs before unconsciousness occurs • lighter than air • Does not burn • Inert • 'Stenched' (odourised) and has a distinctive odour • Will ignite and burn instantly from a spark or piece of hot metal • Heavier than air and will collect in ducts, drains etc., and low lying areas • Fire and explosion hazard • Highly flammable •Eliminate all ignition sources Flammable Acetylene Claret No.RSS • Distinctive garlic smell Extremely hazardous • Fire and explosion hazards are greater than LPG but it is slightly lighter than air and less likely to collect in ducts and drains • Requires minimal energy to ignite in air or oxygen • DO NOT use with copper, high copper or brass alloys because copper materials form explosive compounds with Acetylene Flammable Hydrogen Red No.RB • Odourless Extremely hazardous Black No.N61 •Much lighter than air and will collect at the highest point in any enclosed Oxidising Oxygen space unless ventilated at high level • Fire and explosion hazard Strongly supports and • very low ignition energy acceleratesa flame or fire • Burns with an invisible flame • Odourless • Generally considered non-toxic at atmospheric pressure •Will not burn, but supports and accelerates combustion • Materials not normally considered combustible may be ignited by sparks in oxygen rich atmospheres • No oil, grease or lubricants should come into contact with oxygen Imagesabove are intended for illustrationpurposesonly. They neither reflect the size or shape of the cylinders, nor show the cylinder valve or guard (where fitted). This lists identifies primary hazardsonly. Other hazards may apply. Colour names refer to AS2700. ©Industry Development Training Pty Ltd 235 of 267

0 8 Guidelines for Gas Cylinder Safety Gas cylinder colour identification. Oxygen Nitrogen Carbon Dioxide Argon Helium Industrial Grade Industrial Grade Industrial Grade Welding Grade High Purity Grade Laser Grade Laser Grade <•••liable 1npa,i� only) laser Grade High Purity Grade High Purity Grade High Purity Grade Laser Grade FOGG® VinAr High Purity Grade Body: Black Body: Pewter Body: Green Grey Body: Peacock Blue Body: Brown Acetylene Hydrogen Air ARGOSHIELD® 40 ARGOPLAS® S STAINSHIELD® ARGOPLAS® 20 Industrial Grade Industrial Grade Industrial Grade SPECSHIELD® Copper ARGOPLA5® 35 Instrument Grade High Purity Grade Instrument Grade Body: Claret Body: Signal Red Band: Black Band: Black Band: Signal Red Body: Pewter Body: Peacock Blue Body: Peacock Blue ARGOSHIELD® 52 ARGOSHIELD® Light ARGOSHIELD® Heavy ARGOSHIELD<l Universal ARGOSHIELD® 100 STAINSHIELD® 69 STAINSHIELD® 66 ARGOSHIELD® MCW ARGOSHIELD® 54 STAINSHIELD® Heavy ARGOSHIELD® Pipeline STAINSHIELD® light Bands: Slack, Green Grey Bands: Green G1ey, Brown Bands: Black, Brnwn Bands, Signal Red, Green Grey Body: Peacock Blue Body: Peacock Blue Body: Peaco k Blue Body: Peacock Blue ALUSHIELD<t> Light ALUSHIELD® Heavy STAINSHIELD® Duplex STAINSHIELD® Pipeline ALUSHIELD<t> Universal Band: Brown Band: Peacock Blue Bands: Pewter Bands: Green Grey, Peacock Blue Body: Peacock Blue Body: Brown Body: Peacock Bh1e Body: Brown Refrigerant Refrigerant Ammonia Refrigerant {EdU<tOr rube fitted) R134a R22 Refrigerant R717 R404A R407C Band: Aqua Band: Moss Green Band: Slate R408A Body: Galvanised or Whrte Body: Galvanised or White Body: Galvanised or White R409A R410A R416A Refrigerant R507 Bands. Brown Body: Galvanised or White Notes I. Colom names refer to AS 2700 2. rhe colour coding/colours al cyhnders lilied m Aullraha comply with AS4484, colours of imponed cylinders may difler. 3. Cylinder valves 01 guards not shown, except for valve P101ec1ion Rings. 4. Refer 10 Austrahan Standard defin1hons 5. Images above are intended for illustra11ve 1>u1poses only. They neither reflect the size 01 shape of the cylinders. ©Industry Development Training Pty Ltd 236 of 267

Guidelines for Gas Cylinder Safety 09 Nitrous Oxide Methane Ethylene INSECTIGAS® D AGRIGAS®M (Imported) (Methyl Bromide)(lmported) Body: ultramarine Band: Signal Red Body: Violet Band: Golden Yellow Band: Signal Red Body: Silver Grey Body: Green Grey Body: Blue PESTIGAS® VAPORMATE® RIPEGAS® OEODOURGAS® BACTIGAS® Sand, Moss Green Band, Violet Band: Signal Red Band: Deep Rose Bands: Slgnal Red, Oeep Rose Body: Green Grey Body: Sky Blue Body: Green Grey Body: Green Grey Body: Green Grey MULTIMIX® Sulphur Dioxide Carbon Monoxide HANOIGAS® LPG HANOIGAS ® L P G CELLAMIX® (Imported) Industrial Grade liquid withdrawal Gas withdrawal Band: Green Grey !land: Golden Yellow Band: Golden Yellow Body: Silver Grey or Galvanised Band: Royal Blue Body: Pewter Body: While or Galvanised Body: Signal Red Body: Sliver Grey or Galvanised LASERMIX ® 690 LASERMIX®321 LASERMIX®320 (Imported) LASER MIX ® 331 LASER MIX ® 3 3 2 LASERMIX®341 LASERMIX® 344 Bands: Green Grey, Brown Bands: Green Grey, Pewter Bands: Signal Red,Golden Yellow Body: Pewter Body, Brown Body: Pink HiQ Scientific Gas Mixtures (Examples for Australia) Flammable Toxic Toxic and Flammable AS4484 Hydrocarbon Mixture 2 Component Mixture Specified Gases Eg: Ethane, Ethylene, carbon 2 Component Mixture 2 Component Mixture Eg: Methanol in Carbon Dioxide 4 Component Mixture Dioxide, Nitrogen in Methane Eg, Hydrogen in Helium Eg: Sulphur Dioxide in Nitrogen Eg: Hydrogen, Nitrogen, Methane in Argon Band: Signal Red Band: Golden Yellow Bands: Golden Yellow, Signal Red Bands: Silver Grey, Pewter, Signal Red Bands, Silver Grey, vJolec, Green Grey, Body: Brown Body: Pewee, Body, Green Grey Body: PeacO<k Blue Pewter Body: Silver Grey Non-Toxic, Oxidising Notes Non-flammable Body colour denotes balance gas or major component, Multi-component Mixture Multi-component Mixture Band colour/s denote minor components or mixture characteristics. Eg: 25ppm H2S, lO0ppm CO, 25% CH4, 18% 02 in Nitrogen Eg, 1% Carbon Dioxide, Gas Mix!Ures Sand Colour Legend 1% Helium, 1% Nitrogen, - Gold: Mult!·componenc 25% Oxygen in Argon - Brown: Non·toxic, non-flammable - Slack: Oxidising or oxygen component Silver, Hydrocarbons - Signal Red, Flammable Golden Yellow: Toxic Bands, Brown, Gold Bands: Blad, Gold BOdy, Peacock Body; Pewter Blue ©Industry Development Training Pty Ltd 237 of 267

10 Guidelines for Gas Cylinder Safety Medical gas cylinder colour identification. INHALO® Oxygen Nitrous oxide ENTONOX® Air o, o, N,O N,0/02 C Body:Whlte Band, Ultramarine Band: Ultramarine and White Band: Black and White Body: White Body: White Body, White Body: White Carbon dioxide CARBOGEN Helium HELIOX Carbon dioxide CO, Liquid withdrawal co,;o, co, He He/0, Band, Green Grey I Sand, Green Grey and White Band: Brown Band, Brown and White Body: While Body: White Body: White Body: White Band, Green Grey Body: White For information regarding the transport of medical cylinders in use, please refer to the Home Oxygen Therapy Patient Information Booklet available from BOC, or contact BOC Healthcare on 1800 oso 999. Notes l. Colour names refer to AS 2700 2. The colour coding/colours of cylinders filled in Australia comply with AS 4484, colours of imported cylinders may differ. 3. Refer to Australian Standard definitions 4. Images above are Intended for illustration purposes only. !hey neither reflect the size or shape of the cylinders, nor show the cylinder valve or guard (where fitted). ©Industry Development Training Pty Ltd 238 of 267

Guidelines for Gas Cylinder Safety 11 About your cylinders and valves. High Pressure Cylinders 1.SOm Image is for illustrative purposes only. Design and construction of gas cylinders BOC gas cylinders are designed and constructed in accordance with International and Australian Standards as applicable. These Standards define the cylinders': • Material • Method of manufacture • Test pressure • Maximum permissible filled pressure and • Method of periodic inspection Compressed gas cylinder sizes Manifolded Cylinder Pack Single cylinders 1 Contents Pressure Indicator BOC offers a wide range of single high pressure cylinders suitable for NEVER remove individual cylinders from Manifolded Cylinder Packs. small volumes of gas, available in many sizes and pressures. These are designed and supplied as integral units with gas content BOC cylinder sizes are denoted by a letter code. The gas content of labels to suit. Removal of individual cylinders renders the label contents cylinders is measured in cubic metres, litres or kilograms. If volume incorrect and may have safety implications. unit is given, it refers to standard temperature of 1s0c and pressure of 1O1.3kPa. Maintenance and testing of gas cylinders In most cases BOC is the owner of the cylinder. As the owner, BOC is Not all cylinder sizes shown are available for each product, please responsible for complying with the statutory requirements relating to consult BOC on 131 262 for details. maintenance and periodic testing of cylinders. Manifolded Cylinder Pack {MCP, Pack or Bundle) Australian Standard AS2030 details the statutory requirements in Cylinders are normally used individually or collectively. A Manifolded respect to design, manufacture, inspection and filling. Cylinder Pack describes cylinders used collectively, interconnected by a manifold - a portable frame. These are often bundled in packs of 4, 9 or 15 cylinders for onshore products and 16 or 64 cylinders for offshore products. Collective use of cylinders is necessary for customers who require larger quantities of gas. Where customers do not have adequate handling facilities for on and off loading from the delivery vehicle, BOC can deliver on vehicles with suitable manual handling equipment. ©Industry Development Training Pty Ltd 239 of 267

12 Guidelines for Gas Cylinder Safety Low Pressure Cylinders 1.25m ' Acetylene Cylinders 1.00m 0.75m 0.50m 0.25m Image is for illustrative purposes only. Cylinder contents identification All BOC cylinders are labelled in accordance with the requirements of the Australian Dangerous Goods Code (ADGC) for transport of dangerous goods by road and rail. Cylinder labels identify the gas contents of the cylinder and provide basic safety information (see page 6). NEVER use any cylinder or pack unless it is clearly labelled and can be positively identified. NEVER repaint or obscure a cylinder label, even if the cylinder is rusty, dirty or damaged. This can result in unsafe situations. NEVER apply any unauthorised labels or markings to cylinders, unless advised by BOC to identify faulty cylinders. ©Industry Development Training Pty Ltd 240 of 267

Guidelines for Gas Cylinder Safety 13 Permanent gas seamless cylinder (Oxygen) Welded steel cylinder (Acetylene) Welded aluminium cylinder Markings on a Permanent Gas Markings on Welded Steel Cylinders Markings on Welded Aluminium Cylinder Seamless cylinder • Owner Stamp Mark • Owner Stamp Mark • owner stamp Mark • Weight empty with mass embossed by BOC • Empty weight & Tare weight • Weight •serial No. • Serial No. • Serial No. •Test pressure of shell • Test pressure of shell •Test pressure of shell • Manufacturer's stamp · Manufacturer's stamp • Manufacturer's stamp •Test date (retest date) • Test date (retest date) • Test date (retest date) • Porous mass manufacturer/type • specification • Specification • BOC - Inspector's approval stamp • Water capacity • Water capacity • Water capacity Typical permanent identification marks on cylinders Typical single stage regulator For seamless cylinders, permanent identification markings are usually found on the shoulder or base of the cylinders. For fabricated cylinders, 1 Regulator Outlet Connection markings are found on the valve protection ring (VPR). 2 Cylinder Valve 3 Inlet Spigot (regulator) It is dangerous to change the contents or external colour of a cylinder 4 Regulator Multi-Spanner (Inlet Spigot) NEVER change a cylinder's contents from what was otherwise Important note: intended Shu1 off the valve and remove the regulator when the cylinder is not in use. NEVER repaint a cylinder NEVER change a cylinder's markings or identification Cylinder valves All BOC cylinders are fitted with a valve. The valve MUST NOT be tampered with or removed by anyone other than a BOC certified and MP48 Certified Gas Cylinder Test Station. Removing fittings under pressure may result in serious personal injury as fittings may be ejected at high velocity. Each valve outlet is specially threaded to receive commercially available pressure regulators. They can be obtained from BOC Gas & Gear centres and agents. Regulators are first screwed to the cylinder valve outlet by hand and then tightened using the regulator multi-spanner (inlet spigot). ©Industry Development Training Pty Ltd 241 of 267

14 Guidelines for Gas Cylinder Safety t;;l DO NOT connect incompatible regulators; this could lead to valve and regulator thread damage, and an uncontrolled release of gas. DO NOT over-tighten or use excessive force to connect equipment. DO call BOC for a replacement cylinder if the regulator does not connect properly. Valve Guard Valve Protection Cap Valve Protection Ring Operating a cylinder valve Valve guards, valve protection caps and valve protection rings OPEN by turning the handwheel or cylinder valve key anti-clockwise. Only use reasonable force. Some cylinders are fitted with valve guards or valve protection caps. CLOSE by turning the handwheel or cylinder valve key clockwise. Only DO NOT remove valve guards or valve protection rings. use reasonable force. 00 replace valve protection caps whenever the cylinder is not NEVER use force when opening or closing valves. secured or not in use. When in use, cylinder valves used in the fully open position may DO return your cylinder to BOC with the valve in the closed position become stuck in this open position. To prevent this ensure that the and with the protection cap on (refer to Opening or Closing cylinder handwheel or cylinder valve key is turned back half a turn. valves). Valve outlets threaded For safety reasons, flammable gases and non-flammable gases have their cylinder valve outlets threaded opposite hand. This prevents the connection of the incorrect regulator to cylinder valve outlets. Valve outlets for flammable gases are Open Close screwed LEFT-HAND (anti-clockwise In the case of a key operated cylinder valve, turn the rectangular key to tighten). Identifiable by its notched ANTICLOCKWISE using the cylinder valve key (see below). Cylinder valve appearance or 'LH' marking near the keys are available from BOC Gas & Gear centres. valve outlet. Nearly all cylinder valves are fitted with and operated by handwheels Cylinders containing flammable gases so the need for a cylinder valve key is rare. like acetylene, hydrogen, propane and mixtures containing fuel gas all have left-hand threads. Left-hand thread- Notched Valve outlets for non-flammable gases Cylinder valve key Turn anticlockwise to open key are screwed RIGHT-HAND (clockwise operative valve. (Close not shown). to tighten). Right-hand thread- Plain Cylinder valves with an integrated regulator (applicable currently Cylinders containing non-flammable/ to 300 bar lilied cylinders and MCPs e.g. nitrogen, shielding gases) non-toxic gases all have conventional right-hand threads. Non-flammable BOC cylinders are filled to a variety of pressures e.g. 137, 163, 175 gases can be oxidising e.g. oxygen; or and 200 bar. The largest capacity cylinders are filled to 300 bar to non-flammable, non-toxic e.g. nitrogen, allow more gas to be filled at a higher pressure in an equivalent sized argon and air. cylinder. Controlling the pressure within these 300 bar cylinders to operating level (i.e. 200 bar or less) is an integral pressure regulator. The only exception to this rule are The cylinder valve complete with this regulator is known as a Pressure cylinders used on forklift trucks. Regulating Valve (PRV). These cylinders have right-hand thread valve outlets. BOC's 300 bar cylinder valves come fitted with PRVs. This PRV is typically set lo a maximum output of 60-80 bar pressure at any given As an additional safety precaution, in 2006 air and nitrogen cylinder time. Therefore an existing regulator of 200 bar or less can be used with valve outlet sizes and threads were differentiated from oxygen to these 300 bar cylinders. prevent the: As a result of the PRV, when a 200 bar regulator is fitted, the gauge on • Incorrect connection of an oxygen cylinder to applications where an this 200 bar regulator will only display a 60/80 bar inlet pressure even inert gas is required. though the cylinder has actually been filled to 300 bar. • Incorrect connection of an oxygen cylinder to applications where only air (21%) oxygen is required. ©Industry Development Training Pty Ltd 242 of 267

Guidelines for Gas Cylinder Safety 1S Burst disc Fusible plug Pressure relief valves The only exception to this are the laser Manilolded Cylinder Packs will be accompanied by a high pitched noise and a jet of gas at high (MCPs) which come fitted with a high flow rate 300 bar regulator. This speed. There are three types of commonly used pressure relief devices, regulates the outlet of the MCP to the selected outlet pressure which is • Burst disc (most common) adjustable from o to 35 bar. • Fusible plug (e.g. acetylene) • Pressure relief valve (e.g. LPG) Burst disc In the event of overpressure, this is designed to burst, leaving an open passage for gas contents to escape completely. e.g. Carbon Dioxide (CO2) cylinders are fitted with a burst disc which operates at approximately 207 bar and is fitted on the cylinder valve. 300 bar filled cylinder fitted with cross section view displaying the Fusible plug a cylinder valve featuring an This is designed lo melt when the cylinder is exposed to high integrated regulator tiny integrated regulator on the temperatures and will completely release the cylinder contents. right side e.g. Acetylene cylinders are fitted with fusible plugs which melt at Handy hints for identifying the cylinder contents pressure approximately 100°c. • 300 bar MCPs have a centrally mounted pressure gauge which indicates Pressure relief valves the MCP's contents pressure (approx. 300 bar when lull). This valve is designed to relieve excess pressure and close again alter relieving the excess pressure. • For cylinders the contents label indicates the pressure when full. As gas is consumed, the regulator inlet pressure gauge (if fitted) will show the e.g. BOC Handigas\"' (LPG) cylinders are fitted with pressure relief valves cylinder contents pressure. which operate at approximately 26 bar. To convert from MPa/KPa/psi to bar refer to the pressure cross Safety tip reference chart in the glossary. Alternatively contact BOC on 131 262. Cylinders can be dangerous and can release contents given the right Note, Gauge$ are to be used for indication purposes only. circumstances. BOC recommends proper Personal Protective Equipment (PPE) be worn at all times, consult your Occupational Health Er safety Pressure relief devices officer or BOC on 131 262 for further details. Most cylinders or manifolded cylinder packs are fitted with a relief Storage guidelines appropriate to the gas specified must be adhered device. In a situation where excess pressure is encountered, this is to. In the event your cylinder activates any of these devices contact designed to discharge cylinder contents either completely or only Emergency Services on ooo and then BOC on 1800 653 572. discharge the excess pressure. Discharge of a pressure relief device ©Industry Development Training Pty Ltd 243 of 267

16 Guidelines for Gas Cylinder Safety Ordering, transport and handling of cylinders. Vehicle explosion caused by a leaking flammable gas cylinder Damage from inappropriately stored and unrestrained cylinders in a vehicle, which stopped suddenly. Please note, Image is for illustrative purposes only. Cylinder colours do not comply with Australian Standards. Ordering gas • If you are transporting the cylinder inside a trade vehicle: Take care when ordering gas. Specify the: - Keep the cylinder in a purpose built sealed compartment or cabinet • Gas name {in full) that provides adequate ventilation of any leaking gas to the outside • BOC account number (Ship to or delivery account) of the vehicle. • BOC Gas Code • Cylinder Size - A side-mounted sealed compartment with its own door, externally accessed and ventilated to the outside of the vehicle is best For example: practice. ---'----------Gas Specifics Example (Oxygen) • DO arrange for delivery of cylinders. This is the safest option. Goods delivered by BOC will be loaded, restrained, transported and off loaded Gas Name Compressed Industrial oxygen in accordance with legislative requirements. Grade (purity) 99.5% If you must transport cylinders yourself, BOC Gas Code 020 • DO find out about transporting cylinders prior to your purchase. confirm the requirements for the transportation and handling of BOC Cylinder Size Code G goods being collected with BOC's Customer Service Centre prior to making collection. Receipt of cylinders • DO transport cylinders in an open vehicle. BOC does not condone the • Many gases cannot be seen; so the primary means of identification of transport or storage of flammable gas (e.g. Acetylene, lPG) cylinders a cylinder's contents is the label. in enclosed vehicles (unless the vehicle is fitted with a purpose built sealed compartment that provides adequate ventilation of any leaking • only gas cylinders with clearly legible shoulder or body labels are to gas to the outside of the vehicle). There have been several violent be used. vehicle explosions as a result of transporting and storing flammable gas cylinders in enclosed vehicles. Fatalities have occurred. • If this is not the case, do not accept ii but make arrangements to return and replace the cylinder. • DO transport cylinders properly restrained and in an upright position. Cylinders and cylinder packs are heavy and need to be properly loaded • Also check that what you ordered is what is stated on the label and and restrained prior to despatch to prevent them working loose and clearly sign the delivery docket. becoming a hazard to others. Transportation • DO close the cylinder valve and disconnect regulators or equipment (e.g. hoses and torch) prior to transport. When transporting small gas cylinders in a vehicle, VENTILATION is the key to reducing the risk of a fire, explosion and/or asphyxiation. • DO regularly check for leaks. • DO use an open vehicle such as a utility, as this provides the best • DO remove cylinders from the vehicle immediately upon arrival at ventilation and avoids the risks of gas accumulation. your destination. • DO check that cylinders are properly labelled and have not been tampered with. ©Industry Development Training Pty Ltd 244 of 267

Guidelines for Gas Cylinder Safety 17 TOXIC GAS 2 The Dangerous Goods Division (Class) is normally clearly marked on the product label Example of correct positioning and restraining of gas cylinders Risks - Dangerous Goods Divisions • Division 2.1 Flammables (e.g. Acetylene, Ethylene, Hydrogen, Transporting gas cylinders For information regarding the transport of medical cylinders in use, LPG) - may cause flammable or explosive atmospheres in the vehicle please refer to the Home Oxygen Therapy Patient Information Booklet compartment. available from BOC, or contact BOC Healthcare on 1800 050 999. • Division 2.2 Inerts (e.g. Nitrogen, Argon, Shielding Gases) - Hazards may cause an asphyxiating atmosphere leading to drowsiness, compressed and liquefied gases are potentially hazardous for the unconsciousness and death. following reasons, • Division 2.3 Toxic (e.g. Sulphur Dioxide) may lead to a toxic • some gases are very flammable and a leakage can create an explosive atmosphere which is hazardous to health by breathing and/or atmosphere in an enclosed vehicle. skin contact. • Oxygen enrichment causes material to ignite easily and will increase • Division 2.2/S.1 Oxidising (e.g. Oxygen, Nitrous Oxide) - may cause the intensity of a fire. Any oxidizing gas, e.g. Nitrous Oxide (laughing some materials to easily ignite (e.g. oil) and will increase intensity of gas) has similar properties. a fire. • Inert (Non-Flammable/Non-Toxic) gases can cause oxygen deficiency • Division 9 - Dry Ice (Solid CO2) and Division 2.2 Refrigerated Liquids and asphyxiation. (e.g. Nitrogen, Argon, Oxygen)- evaporate to large volumes of inert gas (see Division 2.2 Inerts). •Toxic or corrosive gases are hazardous to health. • The gas pressure is high and a ruptured cylinder or valve can cause Note: The Dangerous Goods Division (Class) is normally clearly marked on the product label. serious injury or damage. The above information is sourced from the brochure Transporting gos cylinders 01 cryogenic liquid receptacles in vehicles and is reproduced with the permission • Unsecured gas cylinders may cause injury when projected out of place of ANZIGA. in cases of accidents or rapid traffic movements. Carrying a load safely • Cryogenic liquids are very cold and can cause cold skin burns and metal brittle fracture. Cryogenic liquid vaporises to create large amounts Choosing a vehicle wisely of gas. The vehicle must be suitable for the size and type of load. • When a liquefied gas is released, it vaporises and creates large The vehicle must be equipped to conform to the requirements of the amounts of gas. transport of dangerous goods regulations. • Heat may cause any safety device fitted to activate and release the gas The maximum payload of the vehicle must not be exceeded. contents of the cylinder. Positioning the load correctly Information on the hazards can be found on the cylinder label, and in The load must be correctly positioned on the vehicle to maintain the safety Data Sheet that is freely available from BOC. its stability. Acetylene, LPG and Liquefied gas cylinders must always be transported in an upright position. Using suitable restraint equipment unrestrained or inadequately restrained cylinders are heavy and may cause injury or damage to vehicles and can lead to a violent cylinder rupture in transport. When transporting cylinders always ensure they are properly restrained to avoid movement. Every load must be restrained to prevent unacceptable movement during all expected conditions and operation The load restraint equipment and the vehicle body and attachments must be strong enough tor each type of load carried, and must be in good working condition. The above information is sourced from ANZIGA guideline Transporting gas cylinders and other gas products and is reproduced with the permission of ANZIGA. ©Industry Development Training Pty Ltd 245 of 267

18 Guidelines for Gas Cylinder Safety Restraining gas cylinders for transport in commercial or passenger vehicles under 2.5 tonne. Example of the potential consequences of transporting a gas cylinder within an enclosed vehicle General guidelines For flammable or toxic gases: • The vehicle must have a flat bed with sides, a tailboard, and a cab Precautions which is separately ventilated from the load carrying area. Flammable The safest and recommended method for transporting cylinders (e.g. gases may be carried in closed compartments separated from the driver gas cylinders and cryogenic receptacles) is by using the transport provided there is sufficient ventilation to prevent the build-up of a services provided by BOC. Occasionally, there may be a need to use dangerous atmosphere. In Australia, curtain sided vehicles are deemed other transport methods in which case it is then essential to follow to be closed compartments. safety instructions for full and empty cylinders: • Toxic gas cylinders should always be restrained in a well-ventilated • Restrain all cylinders from moving during transport (consider the forces compartment separated from the driver. generated in a traffic accident) • When transporting toxic gas cylinders, ensure that the valve outlet cap • Limit the number of cylinders to be transported. and protective cap are securely fitted (see page 14). • use open vehicles or trailers in preference to any enclosed vehicles or • Flat bed vehicles without sides must not be used, except where the trailers. 00 NOT cover the gas cylinders with a tarpaulin. cylinders are conveyed in approved pallets. • Ensure that the contents label on the cylinder can be clearly read. • Vehicles conveying drums over 300 kg need not have sides provided the drums are chocked, roped and sheeted. • NEVER drop cylinders or submit them to shock. This is an extremely hazardous practice which may result in serious injury. • NEVER transport flammable gas cylinders lying down. • Where possible, use mechanical lifting devices and trolleys to move cylinders. • wear safety shoes or boots, safety glasses or goggles, and leather protective gloves when handling cylinders. • smoking is strictly forbidden when loading, transporting, and unloading any gas cylinder. The above information is sourced from the brochure Transporting gos cylinders or cryogenic liquid receptacles in vehicles and is reproduced with the permission of ANZIGA. For non-flammable, non-toxic gas loads: • An open vehicle with sides is preferable. • Panel vans and pantechs may be used provided the driver's cab is separate from the load carrying area. This means that the driver's cab and load carrying areas are separately ventilated. ©Industry Development Training Pty Ltd 246 of 267

Guidelines for Gas Cylinder Safety 19 DO NOT carry loose gas cylinders in the rear DO NOT place cylinders on seats Purpose built sealed compartment Enclosed Vehicles Enclosed vehicles used to continually transport gas cylinders ventilation is the key to reducing the risk of a fire or explosion. When cylinders are continually transported in enclosed vehicles (such as ambulances, service vans with welding equipment, etc.) the Trades Vehicles following is recommended: • Use an open vehicle such as a utility as this provides the best • A permanent system should be in place to secure the gas cylinders (and ventilation and avoids the risks of gas accumulation. cryogenic liquid receptacles); • If you are transporting the gas cylinder inside a trade vehicle: • Gas cylinders should be carried in a side mounted sealed compartment - keep the gas cylinder in a purpose built sealed compartment or with its own door, ventilated externally. cabinet that provides adequate ventilation of any leaking gas to the outside of the vehicle; loading a cylinder into an enclosed vehicle - A side-mounted sealed compartment with its own door, ventilated Before loading a cylinder into an enclosed vehicle: externally is best practice. • Tighten (do not overtighten) the cylinder valves and check that they • DO close the gas cylinder valve and disconnect the regulator, hoses and are properly closed; torch prior to transport; • Check carefully for gas leakage. NEVER transport a cylinder, if a leak has • DO regularly check for leaks from valves; been detected during loading; • DO secure the gas cylinders and keep them upright; • Check that the valve outlet protection cap Is fitted where required. • DO ensure the vehicle is well ventilated; NEVER remove any valve protection device (if fitted) during transport; • DO unload the cylinder from inside the vehicle immediately on reaching • NEVER transport gas cylinders with a regulator or any other equipment your destination, unless the vehicle has a purpose built sealed attached. compartment vented externally. When loading gas cylinders at a gas supplier's site or shop, the Passenger Vehicles personnel responsible for the sale and/or loading the cylinders should provide the safety instructions on loading and transport to the driver. DO NOT transport gas cylinders in the passenger compartment of any vehicle due to the difficulty of providing appropriate load restraint. Gas suppliers may refuse to load certain vehicles based on their assessment of the risk associated with the product to be loaded, Transporting gas cylinders inside the driver or passenger compartment the particular vehicle and the method of loading and restraining of passenger cars is extremely dangerous and could cause an explosion, the product. fire, exposure to toxic gas, or asphyxiation. The above information is sourced from the brochure Transporting gas cylinders Note: For information regarding the transport of medical cylinders or cryogenic liquid receptacles in vehicles and is reproduced with the permission in use, please refer to the Home Oxygen Therapy Patient Information of ANZIGA. Booklet available from BOC, or contact BOC Healthcare on 1800 050 999. ©Industry Development Training Pty Ltd 247 of 267

20 GuideIines for Gas Cylinder Safety Transporting cylinders upright Transporting cylinder lying down. (Note: NEVER transport LPG cylinders, Dissolved Acetylene cylinders or liquefied gas cylinders lying down) Transporting cylinders in a van • Position the cylinders with the valves facing rearwards, with the base • DO NOT transport gas cylinders in the passenger compartment of a van blocked against the headboard or another strong part of the load. • DO NOT carry loose gas cylinders in the rear load compartment of a van •Vans are only suitable for the transport of gas cylinders if they are •Apply at least two tie-down straps (as shown above). fitted with a purpose built sealed compartment or cabinet that provides The above information is sourced from ANZIGA Guideline 4 Restraining individual gas adequate ventilation of any leaking gas to the outside of the vehicle cylinders and other gas products for transport and is reporduced with the permission of ANZIGA. Transporting cylinders in utilities and box trailers If you transport cylinders in a style-side or drop-side utility, DO NOT • NEVER transport LPG cylinders, Dissolved Acetylene cylinders and place them in the cab. liquefied gas cylinders such as carbon Dioxide lying down. Transporting cylinders upright Emergencies and accidents Restrain cylinders by lashing them to the vehicle body using webbing • If a gas leak occurs during the transportation of gas cylinders, where straps or containing them in a purpose-built frame. practical, stop and park the vehicle as far away as possible from other vehicles or people. Leave the vehicle and call 1800 653 572 If transporting cylinders upright against a headboard: BOC Emergency Response Line for specialist advice. • The total weight of the cylinders should not exceed 250 kg. • Apply at least two horizontal webbing straps, as shown above. • In the event of a fire or any other emergency, call the fire brigade on Webbing straps must be at least 38mm wide with a minimum lashing 000 and advise them of the details of your load. capacity of 1ooo kg. • Call the emergency services should the transport vehicle be involved in a road accident whilst carrying cylinders and advise them of the details DO NOT use the following materials for restraining cylinders: of your load, and your location. • Elastic straps • Rope • Duct tape Transporting cylinders lying down If transporting cylinders lying down: • Place the cylinders lengthwise on the deck. • Place the cylinders on chocks to prevent them rolling sideways and to provide more grip to stop them sliding. ©Industry Development Training Pty Ltd 248 of 267

Guidelines for Gas Cylinder Safety 21 00 NOT use chains or slings to move cylinders Lift cylinder packs by forklift or by crane. Ensure cylinder valve is closed before moving or disconnecting equipment Lifting Manifolded Cylinder Packs (MCPs) Moving cylinders - manual risks to be aware of when handling cylinders MCPs (weight 1.5 tonnes or higher) can be lifted either by crane (using the lugs located on pack) or forklift truck. It is in the customer's interest •Always close the cylinder valve before relocating a cylinder. to check that their vehicles and lilting devices are of adequate load capacity before ordering cylinder packs. In particular that the tynes • When using a cylinder trolley to move cylinders, make sure cylinders of forklifts are sufficiently long. If side access is required for forklifts, are properly secured, and the cylinder valves are closed. longer than standard (1070mm long) tynes are required, with a maximum thickness of somm or less. If the stirrups in any of the forklift · NEVER transport cylinders with the pressure regulator and hose tyne pockets are damaged then forklifts must not be used to lift them. attached unless on a purpose designed trolley or carrier complete with webbing retainers. Lifting cylinders • NEVER use cylinders in a storage compound. Cylinders should always be • Cylinders must be secured for lifting. For steel cylinders, magnets, slings removed rrom the storage compound, transported by a cylinder trolley and chains are not effective as they may slip. For aluminium cylinders, (see next page) and positioned adjacent to the workstation to enable magnets will not work and chains may cause damage. immediate access to the cylinder valve and regulator. • Cylinders, being round, are inherently difficult to secure and handle. • Once in place, the cylinder must be secured by cylinder wall brackets, There is a tendency for them to slide or slip away when lifting from before ancillary equipment is connected (see next page). their initial position (whether vertical or horizontal). • DO NOT attempt to catch a falling cylinder. They are designed to withstand such an impact. Let it fall and move away from the direction of impact. Most cylinder handling injuries occur when people try to prevent cylinders from falling. • NEVER roll a cylinder horizontally along the ground as this may cause the valve hand wheel to become damaged or open if the cylinder valve handle strikes something. If the surface is rough it will damage the coloured paintwork Identification of the cylinder. • The use of cylinder trolleys is preferable for large cylinders (> 12 kg). • NEVER lilt a cylinder by the cylinder valve or valve handwheel. ©Industry Development Training Pty Ltd 249 of 267

22 Guidelines for Gas Cylinder Safety Cylinder trolley Cylinder wall brackets Cylinder bracket on welding machine Handling gas cylinders -general safety DO NOT bear-hug cylinders to effect a lift. 00 NOT lift or lower cylinders where the operators hands are above DO use mechanical aids (ramps, trolleys, forklifts, scissor lifts) in shoulder height or below mid-thigh height. preference to direct manual handling of cylinders. DO NOT edge-roll cylinders up or down steps of 250 mm or higher. DO NOT edge-roll cylinders over discontinuous or soft surfaces. DO remove any connected equipment (e.g. regulator) ANO refit any oo NOT edge-roll more than one cylinder at a time supplied valve protection cap and/or valve outlet gas tight cap/plug DO NOT attempt to catch or restrain a falling cylinder. prior to moving cylinders. DO NOT attempt to handle cylinders if you are fatigued, physically compromised or under the adverse influence of medication or alcohol. DO ensure cylinders are properly restrained to mechanical lifting/ DO NOT drop cylinders as a method of transfer - this may seriously handling devices prior to movement. damage the cylinder or its valve, resulting in their failure and product release. DO familiarise yourself with and observe appropriate safe lifting techniques/postures prior to manually handling heavy or large The above information is sourced from ANZIGA document Manual Handling Gos gas cylinders. Cylinders and is reproduced with the permission of ANZIGA. DO assess the load weight and dimensions before attempting any lift. oo use suitable personal protective equipment {PPE) - wear safety footwear and leather gloves to protect against falling/ slipping cylinders crushing hands or feet during moving. oo ensure a positive hand grip prior to commencing a manual lift. oo ensure proper coordination of the lift and that the load is equally shared when attempting a two-person lift. DO note environmental conditions prior to handling cylinders - wet, hot or cold cylinders may diminish the quality of hand grip and footing may be compromised. ©Industry Development Training Pty Ltd 250 of 267

Guidelines for Gas Cylinder Safety 23 Storing your cylinders safely. · Storage locations Plan for emergencies • Small quantities of cylinders may be stored in a variety of locations, Ensure free and clear access to cylinder storage areas. provided Dangerous Goods and local government regulations and the principles given in the following paragraphs are followed. All persons with a responsibility for storage or use of gas cylinders must be familiar with the hazards and emergency procedures. Store layouts • Larger quantities of cylinders should be kept in a purpose-designed and emergency procedures need to be structured accordingly and to store or storage area, following the same principles. cater for possible incidents. Ideal storage Cylinders should be stored in dedicated cylinder-only areas. Full or empty compressed gas cylinders should be stored You must not store any other products in a cylinder store, particularly oil, paint or corrosive liquids. • In a well ventilated area • Preferably in the open Rotate your stock • With some weather protection Your storage arrangements should ensure adequate turn around of The area on which cylinders are stored must be well-drained to prevent stock. DO NOT store empty cylinders longer than necessary; return them corrosion of cylinder bases. The location must be free from the risk of to BOC as soon as possible. This applies particularly to cylinders which fire and well away from sources ot heat or ignition. contain flammable or toxic gases. Store cylinders standing vertically and restrain them Wear the correct Personal Protective Equipment (PPE) 1 It is recommended to store cylinders vertically. All persons handling gas cylinders must wear the correct PPE. Safety 2 Vertically stored cylinders must always be restrained or under your shoes, safety glasses plus ear protection are essential. The correct grade of gloves (where appropriate) may also be required. direct control. When standing or rotating and 'walking' cylinders about their vertical axis, be aware of the hazards of uneven sloping, slippery In many places, safety signs will designate where and what PPE is to and unstable surfaces as well as loose surfaces. Restrain cylinders to be worn. Loose clothing and hair is an entanglement hazard, and steps prevent them falling as unrestrained cylinders are a potential hazard must be taken to avoid this. to users and passers-by should they inadvertently bump them. 3 Acetylene and LPG must never be stacked hori20ntally in storage or in use. 4 Whenever possible use a cylinder trolley for transporting cylinders higher than one's waist height. ©Industry Development Training Pty Ltd 251 of 267

24 Guidelines for Gas Cylinder Safety Oxygen Fuel Gas >3 metres Fuel gases should be stored at least 3 metres from oxygen cylinders A fire wall must be higher than the tallest cylinder by at least 1 metre Storage and segregation of cylinders Storing your cylinders safely Within the storage area, oxidising gases such as oxygen must be stored All cylinders should be considered and treated as full, regardless of their at least 3 metres away from fuel gas cylinders (e.g. Acetylene, LPG, content. This means: Hydrogen). The use of an appropriately fire rated wall may provide the required separation. • Keep cylinders away from artificial heat sources (e.g. flames or heaters). Full cylinders must be stored separately from the empty cylinders, and • DO NOT store cylinders near combustible materials, flammable liquids or cylinders of different gases whether full or empty must be segregated incompatible materials. from each other. • Keep flammable gases away from sources of ignition. Where security is an issue, there is available a wide variety of Gas Cylinder Storage Systems which satisfy the cylinder storage • Keep cylinders in well drained areas, out of water pools or ponds. requirements of AS 4332. •The storage area should be kept well ventilated and clean at all times. Contact BOC on 131 262 for details. • DO NOT store in confined spaces. Storage of toxic gases •Avoid below-ground storage where possible. Where impractical, Toxic gases must be stored separately from all other gases and the consider atmospheric monitoring or other risk control measures. detailed instructions on the individual BOC Safety Data Sheet (505) must be followed. •There should be good access to the storage area for delivery vehicles. The ground surface should be reasonably level and firm II is essential that when handling or storing cylinders containing (preferably concrete). toxic gases that the cylinder valve outlet threaded plug or cap is always replaced in the valve outlet when the cylinder is not in use or •The storage area should be designed to prevent unauthorised entry, connected to a manifold or regulator. The cylinder valve outlet threaded to protect untrained people from hazards and to guard cylinders plug or cap acts as a secondary valve to the valve itself and provides from theft. increased safety against leakage. • Different types of gases must be stored separately and in accordance In an emergency involving a toxic gas or any other BOC gas, call 000, with relevant Dangerous Goods legislation. Also refer to AS 4332 (The then inform BOC on the Emergency Response line 1800 653 572. Storage and Handling of Gases in Cylinders) For full details of local storage requirements consult the State •Stores must clearly show signage in accordance with state Dangerous Dangerous Goods regulations, and AS 4332. Goods regulations. This includes Division Diamonds; HAZCHEM; no smoking and naked flame warning signs. Storage of fuel gases Within the storage area, oxygen should be stored at least 3metres • Full and empty cylinders should be kept separate. from fuel gas cylinders. The use of a fire wall may provide the required separation. If volume is greater than 20Dm3 a separation distance of •Toxic and corrosive gases should be stored separately, away from all 5 metres needs to be executed. other gases. Note: wall must be a minimum of one metre higher than the tallest cylinder. • Liquefied flammable cylinders must be stored upright, to keep the safety devices in the vapour phase, on a firm, level floor (ideally concrete). This is also preferable for most other gas cylinders. • Store cylinders away from heavy traffic and emergency exits. • Rotate stock of full cylinders, and use cylinders on a 'first in, first out' basis. •Avoid storing cylinders below 0° c . some mixtures may separate below this temperature. • DO NOT store cylinders at temperatures greater than 65° ( (see Care of cylinders). ©Industry Development Training Pty Ltd 252 of 267

Guidelines for Gas Cylinder Safety 25 Care of cylinders. -- Before After Top outlet valve showing a test date tag Heat indicator test date tags (view from tag underside- without markings} Most accidents are avoidable cylinder test shop to determine if they are safe to be returned back into gas service or if they are lo be scrapped. The majority of accidents involving compressed gas cylinders are avoidable with increased training and awareness of safety issues. Keep cylinders away from electric welding tools, red-hot metals, furnaces or any heat sources Handle cylinders carefully Keep electrical welding equipment well away from cylinders. DO NOT Take care when handling cylinders to avoid impact damage. DO NOT allow welding torches to contact or get near cylinders. drop cylinders off vehicles or docks when unloading or allow heavy objects to fall on them. An accidental arc between the tool and the cylinder could cause localised ove,heating of the cylinder wall and thereby weaken Impact damage can potentially reduce the cylinder wall thickness, the cylinder. which could lead to premature cylinder rupture. Anything hot must be kept away from cylinders. Barcodes are to alert the fillers and operators when the cylinders are due for re-test, and for identification purposes. DO NOT under any Take care not to allow welding and cutting sparks, flames or red hot circumstances lamper with or remove these. slag to make contact with the exterior of cylinders, or thei, associated cutting equipment and/ or hoses. Keep cylinders a safe distance from Cylinders need to be kept cool potential accidental spillages of molten metal. DO NOT store cylinders at temperatures greater than 65° C. If any of these hot items reach an acetylene cylinder, it will melt the fusible plugs and cause a release of acetylene gas and lire from On extremely hot days every effort should be made to keep the the cylinder. cylinders in the shade. DO NOT put any cylinders adjacent to a furnace; Excessive heat- results in an increase in internal pressure. DO NOT put LPG cylinders near boilers or heaters. Excessive heat can reduce the strength of the cylinder resulting in localised bulging at the source of the heat and in extreme cases cylinder rupture. Care must be taken with an oxy-fuel gas torch when in use. DO NOT allow the flame from an oxy-fuel gas torch or other appliance to point onto cylinders. The plastic Test Date Tags (TDTs) fitted by BOC on the cylinder valve inlet connection will distort or melt at a predetermined temperature when heat-affected. This is to alert BOC (and customers) of any heat damage to the cylinder. Any heat-affected cylinders are sent to a BOC ©Industry Development Training Pty Ltd 253 of 267

26 Guidelines for Gas Cylinder Safety Keep cylinders, valves and fittings clean NEVER disguise damage to cylinders If a cylinder has been damaged (e.g. impact, involved in a lire), never NEVER paint over the damaged, discoloured or heat affected areas. Damaged cylinders must be notified to the gas company so that a detailed • NEVER let oil or grease contact your cylinder or its valve and fittings. examination can be carried out to determine whether the cylinder(s) • NEVER apply sealants (liquid or tape form) or lubricants to any cylinder concerned can be repaired or need to be condemned. valves or connecting fillings. Incidents have occurred where third parties have disguised damage • NEVER use cylinders, whether full or empty, as any kind of support to a cylinder which has resulted in a rupture of the cylinder when next refilled. structure. • NEVER roll them along the ground. Cylinders must never be tampered with, repainted or relabelled by anyone other than the cylinder owner. High pressure oxygen will react violently with oils and grease and cause a violent explosion or localised ignition leading to injury of the user and NEVER mix gases in a cylinder damage to equipment. NEVER mix gases in a cylinder; this must only be undertaken by Oxygen equipment is at most risk from oil and grease so keep greasy authorised competent gas specialist personnel with suitable equipment hands, rags and gloves away from any part of the cylinder and fittings. and facilities under controlled conditions. Wipe hands clean and try to minimise hand contact with surfaces which might be subject to oxygen under pressure. Keeping cylinder valves clean NEVER transfer gas to another cylinder Cylinders are supplied with their cylinder valve outlets capped or NEVER transfer, transfill or siphon gas from one cylinder to another. This plugged and in some cases PVC shrink wrapped. can result in serious accidents. The purpose of this is two fold: NEVER scrap a cylinder you do not own 1 To indicate the cylinder is full and Most gas cylinders are owned by gas companies. There are however 2 To keep the outlet clean and contamination free. small numbers of privately owned cylinders e.g. individuals, companies or Government institutions. Ownership is indicated by the cylinder label. Top outlet valves, are particularly prone to dirt getting in the outlet. II the label is missing, ownership can be established by the permanent stampings on the cylinder shoulder. If grit, dirt, oil or dirty water enters the cylinder valve outlet, this may cause damage to the valve internals and result in leakage. scrap metal merchants and recyclers must never buy gas cylinders as scrap metal unless the cylinders have been condemned by an Before assembling regulators and fittings make sure there are no authorised Test Shop. particles of dirt in the cylinder valve outlet. II a supply of clean compressed oil free air or nitrogen is available, then, whilst wearing If intact valved cylinders are discovered amongst recycled scrap, these appropriate eye and ear protection, use this to blow out any loose must be set aside and the owner contacted (in most cases this will be particles of dirt from the valve outlet. one of the gas companies) with relevant particulars (i.e. colour, service, number and markings), to make arrangements for their collection If a supply of clean compressed oil free air or nitrogen is unavailable, and return. then use a clean lint free rag to clean the cylinder valve outlet, in particular the sealing surfaces. NEVER use equipment with cylinders for which they are not intended NEVER open a cylinder valve to clear the outlet. For flammable gases DO NOT attempt to make any adaptors or pipework to cross connect this often leads to the ignition of the escaping gas. Ejected particles cylinders as this is potentially dangerous. and resultant noise can also injure adjacent personnel. NEVER attempt to repair a cylinder and/or its cylinder valve If a cylinder is involved in an incident (especially cylinders involved in fires) it must be: • Withdrawn from service • Set aside and made clearly identifiable • Identified to BOC (contact the BOC Emergency Response Line 1800 653 572) Note: 00 NOT immediately handle an Acetylene cylinder that has been involved in an incident. ©Industry Development Training Pty Ltd 254 of 267

Guidelines for Gas Cylinder Safety 27 Working with gas cylinders. Use of gas cylinders and associated equipment. Safe connection of equipment For the few cylinders now still fitted with cylinder valve keys, only use the recommended cylinder valve keys. Cylinder valve operation Use care when opening cylinder valves. Cylinder valves should not , NEVER increase the leverage of keys by fitting handle extensions. be opened unless a pressure regulator has been fitted. Slowly open • NEVER use spanners with long handles. (anticlockwise) the cylinder valve using the hand wheel or (in a · NEVER use badly worn cylinder valve keys. small number of cases) the cylinder valve key (obtainable from BOC Gas & Gear centres). Any of the above will damage the square end of the spindle or the valve's soft plastic (usually Nylon) seat. N.B. soft seat, spindle key operated cylinder valves should not be subjected to excessive torque. Use the correct spindle key and only use moderate hand torque. If the valve spindle is too stiff to open by hand with the cylinder key, return the cylinder for exchange. An opened valve should never be left against the backstop (i.e. fully opened until resistance is encountered), but should be turned back at Sheared valve keys least half a turn to avoid seizure in an open position. This can occur if the valve is left open for long periods of time. N.B. Most cylinders are now supplied with hand wheels so this will be a rarity. When you shut the valve turn it clockwise just enough to stop the gas If you believe your cylinder valve has a broken or damaged spindle, completely. NEVER over tighten. (e.g. the cylinder valve key rotates without the valve opening), tag the cylinder valve as defective (include the date and a contact phone Remember all cylinder valves are closed by turning the hand wheel number on the tag), and call BOC on 131 262 for a replacement cylinder. in a clockwise direction. If you are going to stop work for a while (e.g. morning tea break, etc.) then close the cylinder valve. Only use equipment that is fit for purpose Acetylene cylinders are to be used standing vertically on their base The gas cylinder and outlet valve are designed to supply gas through pressure regulators that meet the requirements of the relevant Acetylene cylinders are designed to be transported, stored and used in Allstralian Standards. an upright position. Pressure regulators thread directly to the cylinder valve outlet (also Should Acetylene cylinders have been stored or transported applies to cylinder packs) so it is vital that the size and tolerance are to horizontally, place the cylinders in a vertical position and allow 4 hours specification and meet the specified machining tolerance. before use. This will allow the contents to settle and avoid release of solvent that can quickly vaporise potentially leading to an explosive NEVER install additional piping or fittings between regulators and the atmosphere. It can also damage equipment. Equipment that has been outlet valves of cylinder packs. affected by solvent should be immediately disconnected and placed in an open area where the liquid can evaporate safely. When individual cylinders of the same gas are manifolded together to a common outlet, the pressure regulator must be connected to this single manifolded outlet. ©Industry Development Training Pty Ltd 255 of 267