THE UNIVERSITY OF NEWCASTLE - DISCIPLINE OF MEDICAL BIOCHEMISTRY STANDARD OPERATING PROCEDURE Procedure Type:

General Equipment Procedure

Title:

Gas Regulators and Cylinders

1.

PROCEDURE NO: MOD: Page:

GEP 002 1st Issue 1 of 6

Risk Assessment: This Risk Assessment is to be used as a general guide and as such, cannot accommodate all the varying factors that may be encountered when using this equipment. Therefore, personnel are requested to conduct their own Risk Assessment before using this equipment to include any extra hazards introduced by the task performed.

TASK PERFORMED Operation of Gas Cylinder and Regulator HAZARDS 1. Leak - slow leak resulting in exposure to hazardous gas/asphyxiation 2. Leak - rapid leak resulting in burns or tissue damage 3. Back/muscle strain when maneuvering cylinder 4. Explosion of cylinder RISK ASSESSMENT 1. Risk of a leak is present whenever the cylinder contains gas. 2. Risk of a rapid leak is present while ever the cylinder contains gas. 3. Risk of serious muscle injury is present whenever the cylinder is being handled. 4. Risk of cylinder explosion is practically impossible, provided guidelines are followed. RISK CONTROL 1. Test for leaks regularly, especially when using hazardous gas. Constantly maintain equipment and monitor gas usage rate for early leak detection. Always house cylinders in well-ventilated areas. 2. Ensure regulators are well maintained. If deemed safe to do so, only approach a rapidly leaking cylinder while wearing gloves, lab coat, safety glasses/full face shield and breathing apparatus (if required). 3. Ensure all users are properly trained in manual handling. Never attempt to move cylinders (full or empty) without a gas cylinder trolley, to which they can be secured. Exercise arms

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NAME (signed) DATE Distributed To:

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THE UNIVERSITY OF NEWCASTLE- DISCIPLINE OF MEDICAL BIOCHEMISTRY STANDARD OPERATING PROCEDURE Procedure Type:

General Equipment Procedure

Title:

Gas Regulators and Cylinders

PROCEDURE NO: MOD: Page:

GEP 002 1st Issue 2 of 6

and wrists before removing/attaching regulators. Ensure that the correct tools are used. 4. Follow storage directions for all cylinders. Keep away from heat, water puddles and naked flames (where appropriate). Do not expose cylinders to sudden shocks and do not drop. Always secure cylinders. 2.

Calibration:

3.

Monitoring: 3.1

N/A

Rapid gas consumption may be indicative of a leak. Monitor regulators often to ensure that a uniform gas supply is delivered to the equipment. (Monitoring Record Sheets are included in the GEPs for all equipment that require gas cylinders. If required, use these Sheets to record gas level measurements).

4.

General Operation: 4.1

REGULATORS 4.1.1

Regulators must be used only for the purpose for which they were designed.

4.1.2

Do not remove the plastic caps in cylinder valve outlets until the cylinder is required for use.

4.1.3

Before connecting the regulator to the cylinder, momentarily open and close the cylinder valve (a process known as 'cracking') to blow out accumulated foreign matter. Stand well back from the cylinder, wear safety glasses, a lab coat and gloves, and ensure all personnel keep clear during the cracking procedure.

4.1.4

Fit the regulator to the cylinder and tighten the inlet connection firmly. Do not hammer or tighten excessively.

4.1.5

Connect the equipment to be used to the regulator outlet, ensuring that all flow control valves are turned off.

4.1.6

Open the cylinder valve slowly. Rapid opening of the cylinder valve may damage equipment. When the gauge needle stops moving open the valve fully.

4.1.7

Individual pieces of equipment require different regulator flow rates. Refer to the equipment manual to determine the optimum flow rate setting.

THE UNIVERSITY OF NEWCASTLE- DISCIPLINE OF MEDICAL BIOCHEMISTRY STANDARD OPERATING PROCEDURE Procedure Type:

General Equipment Procedure

Title:

Gas Regulators and Cylinders 4.1.8

PROCEDURE NO: MOD: Page:

GEP 002 1st Issue 3 of 6

Check for any leaks in the system by closing the cylinder valve and ensuring that pressure is maintained on the gauge. If the pressure falls, indicating a leak, check the tightness of all connections. If necessary, leaks can be located using a weak solution of soapy water (sparingly). Ensure that all soapy residues are removed after use.

4.1.9

After use, close the cylinder valve and open the equipment flow control valves to release pressure from the system. If a regulator is full of gas and the cylinder is turned on, the ensuing pressure build up may damage the regulator or cause it to blow out.

4.1.10 Do not allow oil or grease to contact the regulator or associated equipment at any time - if oxygen is being used, it may react explosively with oil or grease. Never use oxygen cylinders near ignition sources. 4.2

CYLINDERS 4.2.1

"A cylinder weighing about 64kg often contains gas at pressures of about 3000psi or more. Should the valve connection on top of the cylinder be broken off, the cylinder would correspond to a rocket capable of punching a hole through most laboratory walls and would represent a major danger to all occupants in any area where such an incident occurred". (Extract taken from the CRC Handbook of Laboratory Safety, 3rd Edition.)

4.2.2

Gas cylinders must always be stored in an upright position, never on their side. All cylinders should be stored in an area where it is possible to secure them in an upright position to prevent them from falling over. Even empty cylinders must be stored and handled as if it were full (as a full cylinder may easily be mislabeled as empty).

4.2.3

Single cylinders in use in the laboratory must be secured and kept away from any heat sources. They must not be positioned in a place where the cylinder bottoms rest on a wet floor, as this may encourage corrosion.

4.2.4

All cylinders should be stored and used in well-ventilated areas. If a cylinder is used in an enclosed area, a leak may not only cause direct harm but asphyxiation due to oxygen displacement.

4.2.5

If a leak occurs the cylinder valve should be closed. If the valve cannot be shut off, and it is safe to do so, move the cylinder to a secure place

THE UNIVERSITY OF NEWCASTLE- DISCIPLINE OF MEDICAL BIOCHEMISTRY STANDARD OPERATING PROCEDURE Procedure Type:

General Equipment Procedure

Title:

Gas Regulators and Cylinders

PROCEDURE NO: MOD: Page:

GEP 002 1st Issue 4 of 6

outside and contact the supplier. If it is considered unsafe to remain in the building in the event of a leak (i.e. toxic or flammable) the building must be evacuated and emergency services contacted. 4.2.6

All cylinders, empty or full, must always be transported on a trolley to which they can be secured. Never move cylinders by holding the valve with one hand and rolling the base with the other.

4.2.7

No cylinders, not even empty ones, should be in the laboratory unless they are connected to an instrument or regulator and are secured. All other cylinders must be stored in the outdoor compound.

5.

6.

Cleaning: (Regulators) 5.1

Keep the regulator O-ring clean at all times.

5.2

If anything is spilled onto the regulator wipe it clean immediately.

Maintenance: (Regulators) 6.1

Check the O-ring regularly for signs of deterioration.

6.2

Check for leaks by closing the cylinder valve and observing that the pressure is maintained on the gauge.

6.3

Record all maintenance details on the Gas Regulator Maintenance Record Sheet (Illustration 9.1).

7.

Instruction Manual: 7.1

8.

9.

See specific ERN for availability

Repairs: 8.1

Check ERN for Service Company and warranty details

8.2

Contact the University Workshop for advice and repairs

Illustrations: 9.1

Gas Regulator Maintenance Record Sheet

THE UNIVERSITY OF NEWCASTLE- DISCIPLINE OF MEDICAL BIOCHEMISTRY STANDARD OPERATING PROCEDURE

PROCEDURE NO: MOD: Page:

Procedure Type:

General Equipment Procedure

Title:

Gas Regulators and Cylinders

10.

Change History: 10.1

Issue Number: Date Issued:

10.2

Issue Number: Date Issued: Reason for Change:

1st Issue

GEP 002 1st Issue 5 of 6

THE UNIVERSITY OF NEWCASTLE- DISCIPLINE OF MEDICAL BIOCHEMISTRY STANDARD OPERATING PROCEDURE Procedure Type:

General Equipment Procedure

Title:

Gas Regulators and Cylinders

PROCEDURE NO: MOD: Page:

ILLUSTRATION 9.1 GAS REGULATOR MAINTENANCE RECORD SHEET ERN# DATE

MAINTENANCE

SIGNED

GEP 002 1st Issue 6 of 6