USE AND MAINTENANCE MANUAL

Gas distribution systems

for automatic cut system supply

General Documentation

Client:
Code:
Address:
Town: ZIP code:

Branch:
Reference:
System No. (Job Number):

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 CONTENTS

Warnings page 3

1) Introduction page 5

1.1) Definitions “ 5

1.2) Cylinder Boxes “ 6

1.3) Reference Standards “ 7

2) Gas distribution system for automatic cut systems page 8

2.1) Block diagram and system structure “ 8

2.2) Lasing gas distribution system “ 8

2.3) Cutting gas distribution system “ 9

2.4) Vaporizer cutting gas distribution system “ 9

3) Use and Maintenance Instructions page 11

3.1) Bleeding operation for the first starting “ 11

3.2) Pipework fluxing “ 11

3.3) Exhausted cylinder/bundle replacement “ 11

3.4) Operation conditions “ 11

3.5) Periodical checks “ 12

3.6) Routine Maintenance “ 13

3.7) Extraordinary Maintenance “ 13

4) Cylinder Exhaustion Monitoring System page 14

4.1) Control and warning panel “ 14

Attached documentation 15

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 Warnings

The following instructions are for qualified users with a deep knowledge of the main
principles and safety measures for proper gas handling.

If you are not familiar with these measures, please contact Siad technical service.
Any technical modification or repair must be performed by qualified staff and with prior
consent of the supplier.

A copy of the use and maintenance manual must be kept in the gas cylinder stocking area and
in all laboratories where gases are used.

Read carefully the following instructions before handling the system devices, in order to work
safely:

 The mishandling of gases can be extremely hazardous: refer to SIAD product sheets
attached to this manual, in order to learn more about the chemical and physical properties of
the gas used.
 Identify the gas by reading the cylinder label.
 Handle and move carefully gas tanks, cylinders, bundles or cans, even though they are
empty, as gas traces may remain in the containers.
 Keep gas tanks away from direct sunlight or equipment/systems producing sparks and/or
electrostatic charges. Before storing the gas tanks, close firmly the delivery valve.
 Use the relevant reducer for each gas: the use of materials which are not compatible with the
gases may damage the system and harm the staff. For more details, contact your supplier.
 Do not smoke or use open flame devices in all areas with gas-consuming systems.
 The room ventilation must always be adequate: according to their features, gases may
saturate the room and cause asphyxia and/or inflammable mixtures.
 Check thoroughly all staff safety and emergency equipment.
 Do not release any toxic, inert, inflammable or corrosive gas near the users. Use the relevant
bleeding devices piping gases outside the working area.
 Do not use any oil or greasy substances with gas-consuming systems, as they may easily
ignite or react violently with some gases (especially Oxygen).
 Handle all instruments with slow movements and do not open/close suddenly any valve or
pressure regulator, to avoid dangerous sudden pressure changes and strong stresses on the
equipment or system.
 If you find out any fault or defect on the system, always report them.
 Maintenance operations must always be performed by qualified users, only with original
spare parts.

Please remind that according to the DL - Law Decree no. 626 of 19 September 1994
(“Implementation of the directives no. 89/391/CEE, 89/654/CEE, 89/655/CEE, 89/656/CEE,
90/270/CEE, 90/394/CEE, 90/679/CEE about the improvement of worker safety and health in

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work environments”), the employer must check that the equipment proper installation and
periodical maintenance comply with the manufacturer instructions.

S.I.A.D. cannot be held responsible for direct or indirect system damages due to:
- misuse of technical components;
- lack of maintenance;
- tampering;
- non-respect of attached instructions;
- non-compliance with the gas or component safety standards.

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 1) Introduction

1.1) Definitions

Gases:
 Compressed gases: all gases with a critical temperature under –10°C which
are stored in gaseous state under pressure
 Liquefied gases: all gases with a critical temperature equal to or over –
10°C which are stored in liquid state under pressure or in refrigerated
containers
 Toxic gases: all compressed or liquefied gases defined as toxic in the Royal
Decree no. 147 of 9.1.1927 and its following amendments and updates and
in the present directive.

Containers:
All containers for the storage of compressed, liquefied or dissolved gases are usually
defined improperly as cylinders (to simplify the instructions, this definition will be used
in this manual as well); however, the relevant standards identify the following container
classification:
 Cylinders: steel (or light alloy) one-piece cylinders without longitudinal welding.
They have a 150l capacity and are able to store compressed gases with a
15°C charge pressure over 20Kg/cm2
 Cylinder bundles: cylinders grouped in bundles through a metal frame with a
common valve for charging/discharging. They usually contain 16 or 25
cylinders.
The cover cap screwed on each cylinder shoulder protects the valve against impacts
which may damage its performance and is kept open, in order to allow a gas bleeding in
case of valve leaks; it must be screwed just after using the cylinder. The base keeps the
cylinders in a vertical firm position and lifts the containers from the ground in order to
protect them against impacts, scrapings and humidity corrosion.

Pipework:
The pipework is the system part between the first stage decompression unit (to
which are connected the cylinders or bundles) and the points of use. The points of use
are the points where the gas is delivered to the user.

Decompression systems:
These special devices reduce the gas pressure in a steady and controlled way. They
are divided into first stage and second stage decompression groups. The first ones
reduce the cylinder/bundle pressure (200 bar) to the line pressure of each different
application, but always to a pressure value, which is higher than the one required for
that application. The second stage groups or points of use or line regulators reduce the
line pressure to the pressure value required by the application. If there is only one
application, the second group is not necessary.

1.2) Cylinder Boxes

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 Boxes for inflammable gases which are lighter than air

Reference standards and basic criteria

 Boxes containing inflammable gases which are lighter than air, with a maximum density of
0.8, are governed by the provisions about natural gases (DM - Ministerial Decree of 24
November 1984, Second Part, Section II). When using these gases, refer to the entire set of
rules.
 All boxes must be provided with bearing devices, also for bundles, preventing them from
falling, which vary according to the cylinder capacity: chains fastened to walls, frames such
as racks or handrails creating corridors for storing and fastening the cylinder bundles with
chains, etc.

Boxes for inflammable gases which are heavier than air

Reference standards and basic criteria

 Boxes containing inflammable gases which are heavier than air, are governed by the
provisions about LPG containers (circular no.74 of 20 September 1956); these standards can
be applied to all gases which are heavier than air (LPG density can vary according to the
composition: the relative density of air can reach minimum values around 1.5). When using
these gases, refer to the entire set of rules.

Boxes for inflammable gases with density similar to air

 For cases between 0.9 and 1.1 (end values not included), follow the provisions of the CEI
64-2 standards and further amendments about light and heavy gases.

Oxidizing gas boxes (comburent gases)

Boxes containing oxidizing gases (such as oxygen, air, nitrous oxide, etc) must be
kept away from containers for other gas types (inflammable, toxic gases).
They must not contain combustible substances or other products such as metal dusts
(aluminium, magnesium, etc).

Inert gas boxes

As inert gases (nitrogen, helium, argon, carbon dioxide, etc.) do not react with other
substances, their boxes can be stored with inflammable gas and oxidizing gas boxes.
However, for large quantities, taking into consideration:
 the possibility of producing small boxes,
 the need to separate different hazard sources,
for standardization reasons (allowing a certain flexibility), it would be worth, but not
strictly necessary, producing inert gas boxes according to the provisions described at
par. 2.1.1.2.

Boxes for operating cylinders/bundles

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 Besides stocking areas for empty or full cylinders, there are also areas where
operating cylinders are stored.
 Make sure the cylinders are grouped and placed in outdoor boxes, preferably
insulated and separated through reinforced concrete walls,
 The cylinders can be placed near an external wall of the building (secured through
suitable fastening devices, such as chains, clamps, etc.), as long as they are protected
against impacts and bad weather through non-combustible light small boxes,
allowing good air circulation (air is kept for toxic gases).
 Prevent cylinders from falling or moving, securing them through suitable fastening
devices, such as clamps, chains, bands, etc.
 As a general rule, except for particularly dangerous situations which will be
managed in accordance with control authorities, portable or trailer-mounted fire
extinguishers must always be placed near the boxes. The boxes containing more than
one cylinder, must be protected with a fire hydrant.
 Do not empty operating cylinders completely: a slight pressure must be left in order
to avoid that, due to different environment temperatures, when opening a cylinder
without reducer, the air flows in (for example when the supplier refills it).
 The user must check the cylinder test expiry date, in order to bring it back in time to
the owner company for a new test. Users forget this deadline quite often, when
working with gases which are not suddenly consumed.
 Cylinders must always be refilled by the owner and not by the user.

1.3) Reference standards

 DM – Ministerial Decree of 16.02.1982 – Amendments to the Ministerial Decree of

27 September 1965, about the definition of the activities subject to fire prevention
controls.
 DPR – Presidential Decree no. 547 of 27 April 1955 – Standards for work accident
prevention.
 DM – Ministerial Decree of 24 November 1984, Second part, Section II – safety
standards for fire prevention during transport, delivery, stocking and use of natural
gas with density under 0.8.
 DL – Law Decree no. 626 of 19 September 1994 – Implementation of the directives
no. 89/391/CEE, 89/654/CEE, 89/655/CEE, 89/656/CEE, 90/269/CEE,
90/270/CEE, 90/394/CEE, 90/679/CEE about the improvement of worker safety
and health in work environments – as specified and amended by the Law Decree no.
242/96 (art.33).
 DM – Ministerial Decree of 4 April 1997 – Implementation of art. 25, par. 1 and 2,
of the DL - Law Decree no. 52 of 3 February 1997, about packaging classification
and labelling of hazardous substances, according to the safety information sheet.

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 2) Gas distribution system for automatic cut systems

2.1) Block diagram and system structure

APPLICATION
Comburent

GAS INERT 1° stage 2° stage reduction Automatic

deposit gases reduction systems Cut

System
Combustible

Lasing gases

1° stage 2° stage reduction

GAS Comburent reduction systems
deposit Inert Interception systems

Cryogenic
gases

Cutting gases

2.2) Lasing gas distribution system

There are different types of lasing gases according to their different applications. Lasing gases
are usually CO2, He, N2 or helium based laser mixtures.
The centralization system consists of a primary decompression system located in the cylinder
box or in the gas tank stocking area. The tanks (cylinders or bundles) are connected to the
decompression system through special devices provided with modular extensions, able to deliver
alternatively or simultaneously (according to the user needs) their gas content.
These systems reduce pressure from 200 bar to an average line pressure of 8-10 bar.
The safety valve located on the line and after the first stage reducer is designed to protect the
distribution line and the second stage reducer.
For single applications, the delivery pressure can be directly adjusted to the level required and
connected to the primary pipework.
If there are more than one application, the line pressure must be higher than the highest
delivery pressure required. For each application there is a point of use or line regulator reducing
the pressure to the level required, making each application independent from the others.
The optimum performance of the system and the purity of the gas delivered are the result of
periodic maintenance, cleaning and check operations on each single device of the system.

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 It is therefore necessary to avoid any contact with any liquid, solvent, oil or grease, even
though compatible with the gases used and to follow carefully the use, maintenance and safety
instructions attached to the manual.
Before working on the first stage decompression panels and on the line regulators, please
read carefully the relevant instruction manuals.

2.3) Cutting gas distribution system

Cutting gases are usually Oxygen or Nitrogen.
The centralization system consists of a primary decompression system located in the cylinder
box or in the gas tank stocking area. Because of high consumption, the decompression system is
provided with two or more gas cylinder bundles, connected to an interception manifold through
flexible pigtail coils.
The decompression panel reduces the pressure from 200 bar to the line pressure which,
according to gas type and application, varies from 5 to 20 bar for oxygen and from 15 to 40 bar
for nitrogen.
The main decompression panel can be also connected to a second gas line, consisting of a line
coming from a cryogenic tank provided with evaporator, of an emergency reducer or a second
backup source.
For single applications, the delivery pressure can be directly adjusted to the level required and
connected to the primary pipework through an interception plug equipped with pressure gauge
and interception valve.
The safety valve located on the line and after the first stage reducer is designed to protect the
distribution line and the second stage reducer.
If there are more than one application, the line pressure must be higher than the highest
delivery pressure required. For each application there is a point of use or line regulator reducing
the pressure to the level required, making each application independent from the others.
The optimum performance of the system and the purity of the gas delivered are the result of
periodic maintenance, cleaning and check operations on each single device of the system.
It is therefore necessary to avoid any contact with any liquid, solvent, oil or grease, even
though compatible with the gases used and to follow carefully the use, maintenance and safety
instructions attached to the manual.
Before working on the first stage decompression panels and on the line regulators, please
read carefully the relevant instruction manuals.

2.4) Vaporizer cutting gas distribution system

In case of high consumption systems, the gas centralization system will be equipped with a
backup line, which will become then the main line for the delivery of the gas coming from the
liquid oxygen or nitrogen cryogenic tank.
The connection of this line to the existing system must be carried out with SIAD original and
approved materials and only by SIAD qualified staff.
No operation must be carried out by users on the vaporizer gas system. Any operation must
be carried out by authorized staff in compliance with the use and maintenance manual provided
with the cryogenic tanks.
In order to insulate the line coming from the evaporator and to work with gas bundles,
insulate the system coming from the evaporator by adjusting the interception valve located next
to the first stage decompression panel, at the connection between the line coming from the
evaporator and the centralization system.

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 While using the gas coming from the evaporator, insulate the first stage decompression
system and the cylinder bundles with the interception valve located on the first stage
decompression panel.
For any further information please refer to the first stage panel manual and to the relevant
decompression group manual.

3) Gas Distribution System for Industrial applications

2.2) Block diagram

APPLICATION
Comburent
Interception
GAS INERT 1° stage valves and/or Use
deposit gases reduction 2° stage reduction
systems
Combustible

2.2) Inert and Oxidizing gas distribution system

The centralization system consists of a primary decompression system located in the cylinder
box or in the gas tank stocking area. The tanks (cylinders or bundles) are connected to the
decompression system through special devices provided with modular extensions, able to deliver
alternatively or simultaneously (according to the user needs) their gas content.

There are two types of distribution panels:

- Low capacity: these systems reduce pressure from 200 bar to an average line pressure of
8-10 bar.
- High capacity: the decompression panel reduces the pressure from 200 bar to the line
pressure which, according to gas type and application, varies from 0 to 15 bar, from 0 to
30 bar and from 0 to 50 bar.
When using cryogenic tanks, the main decompression panel can be also connected to a
second gas line, which can be used as the line coming from the cryogenic tank or as backup line
consisting of an emergency reducer or a second source.

The safety valve located on the line and after the first stage reducer is designed to protect the
distribution line and the second stage reducer.
According to different applications it is necessary to reduce pressure a second time through a
second stage decompression system which adjusts pressure to the level required, making it
independent from the others.
For single applications, the delivery pressure can be directly adjusted to the level required and
connected to the primary pipework through an interception plug equipped with pressure gauge
and interception valve.
If there are more than one application, the line pressure must be higher than the highest
delivery pressure required. For each application there is a point of use or line regulator reducing
the pressure to the level required, making each application independent from the others.
The optimum performance of the system and the purity of the gas delivered are the result of
periodic maintenance, cleaning and check operations on each single device of the system.
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 It is therefore necessary to avoid any contact with any liquid, solvent, oil or grease, even
though compatible with the gases used and to follow carefully the use, maintenance and safety
instructions attached to the manual.
Before working on the first stage decompression panels and on the line regulators, please
read carefully the relevant instruction manuals.

2.3) Inflammable gas distribution system

As regards inflammable gas distribution systems follow the instructions described in par. 2.2,
according to the current standards about using and handling of inflammable gases on work
environments and gas tank stocking areas. Oxidizing and inflammable gases must be kept and
used in different boxes and mustn’t come into contact.
Further instructions and restrictions apply to the tank stocking areas governed by the CEI 64-
2 standards or by the CEI 31-35 1999-1 standards.

2.4) Vaporizer gas distribution system (if present)

OK

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 4) Pure Gas Distribution System for Laboratories

2.3) Block Diagram

GAS APPLICATION LABORATORY

deposit Comburent
interception
GAS INERT 1° stage valves and/ or Use
deposit gases reduction 2° stage reduction
systems
Combustible

2.2) Inert and Oxidizing gas distribution system

The centralization system consists of a primary decompression system located in the cylinder
box or in the gas tank stocking area. The tanks (cylinders or bundles) are connected to the
decompression system through special devices provided with modular extensions, able to deliver
alternatively or simultaneously (according to the user needs) their gas content.
These systems reduce pressure from 200 bar to an average line pressure of 8-10 bar.
The safety valve located on the line and after the first stage reducer is designed to protect the
distribution line and the second stage reducer.
According to different applications it is necessary to reduce pressure a second time through a
second stage decompression system which adjusts pressure to the level required, making it
independent from the others.
The optimum performance of the system and the purity of the gas delivered are the result of
periodic maintenance, cleaning and check operations on each single device of the system.
It is therefore necessary to avoid any contact with any liquid, solvent, oil or grease, even
though compatible with the gases used and to follow carefully the use, maintenance and safety
instructions attached to the manual.
Before working on the first stage decompression panels and on the line regulators, please
read carefully the relevant instruction manuals.

2.3) Inflammable gas distribution system

As regards inflammable gas distribution systems follow the instructions described in par. 2.2,
according to the current standards about using and handling of inflammable gases in laboratories
and gas tank stocking areas. Oxidizing and inflammable gases must be kept and used in different
boxes and mustn’t come into contact.
Further instructions and restrictions apply to the tank stocking areas governed by the CEI 64-
2 standards or by the CEI 31-35 1999-1 standards.

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 3) Use and Maintenance Instructions

3.1) Bleeding operation for the first starting

Before starting the system for the first time, bleeding operations must be carried out on all
lines by means of an inert gas (Nitrogen), in order to remove any trace of other gases and any
impurity which could affect the system future performance. The operation takes place by
blowing Nitrogen in all lines and is one of the main part of the testing phase.

3.2) Pipework fluxing

If the system hasn’t been used for a long time and is not under pressure, flux periodically all
pipeworks for comburent or combustible gases by means of inert gases such as Nitrogen.
For this operation contact a qualified professional in order not to damage or modify the
system and follow all instructions and safety procedures for inflammable gas handling.

3.3) Exhausted cylinder/bundle replacement

When the cylinder or bundle is exhausted, follow the instructions on the product sheets of the
first stage reduction system.
All operations must be carried out by qualified staff in compliance with all instructions and
safety procedures for gas handling.
The right instructions to be followed for cylinder/bundle replacement are included in the
product sheets of each decompression system.
Before carrying out any operation, you must:
 Check the system valve condition (line and purge valves) and, if necessary, adjust them
according to the product sheets for the 1° stage reduction system;
 Close the interception valve of the exhausted cylinder/bundle;
 Carry out any opening and closing operations with precise and slow movements;

3.4) Operation conditions

When the system is running, all system check, monitoring and service devices must work
properly. Before using the system, the following devices must be switched on:
- Cylinder exhaustion warning systems (if present),
- Any other SIAD system electric or pneumatic equipment operating during the gas delivery
process.

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 3.5) Periodical checks
Before working on any part of the system, even for very easy adjustments, read carefully all
flowcharts, material product sheets and documents attached to the manual.
Pleas check daily all information provided by the system measuring devices (pressure gauges
and control panel).
Before adjusting any device, refer to the relevant documentation to make sure you deeply
know the way it works.
Make sure you are following all instructions in order to guarantee the staff and system safety.
In case of breakdown, try to isolate (if possible) the faulty part by hanging a sign with the
fault details (fault type, date and time, name of the person who found out the fault), in order to
help in finding the reasons for the breakdown.
Any breakdown must be immediately reported to S.I.A.D.

Periodical checks must be carried out by qualified staff.

Daily checks:

- the delivery systems must have enough gas;

- no interception valve supplying unused or not working devices must be open;
- the gauge pressure value must be the one set at system starting without any pressure
increase;

Weekly checks:

- pipe fitting leak detection (through leak finder liquids);

- safety devices must not be tampered, as for example:
- bleeding devices;
- signal systems;
- labelling;

For any other check or maintenance operation, refer to the device product sheets and to the
relevant use and maintenance manuals.

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3.6) Routine Maintenance

Here attached a schedule of the main periodical maintenance operations:

KEYS EVERY 6 MONTHS YEARLY

YEARLY
SEAL

EXTRA STANDARDS
LABELLING

CALIBRATION

GROUNDING
EXTERNAL APPEAR.

OPERATION SIMUL.
OPERATION

VALVE CLOSING

OVERALL STATE
THREAD STATE

ADJUSTMENT

ELECTRIC CONNECT.
GASKET
S=REPLACEMENT

V=OVERHAUL

Racks V
Rack fastening chains V
Pigtail coils V V S* V S
Decompression panels V V V
Non-return valves V V S
Line valves V V S V V
Purge valves V V V V
1° stage reducer V V V V V
Safety valves V S V
Line joints V V S
Pressure switch joints V V S
Pressure switch V V S V V V V V V
Distribution network V V V V V
2° stage point of use VV V S V V V V V V
Interception valves VV V S V V V V
Line blocking valves VV V S V V V
Electric board & Alarms V V V V V V V V
* Manifold side gaskets / GRUPPO A-B-C-SA

The frequency of maintenance operations depends on how often the system is used and must
comply with the details of the material product sheets. However, maintenance operations must
be carried out at least every 3 years.
Clean the system with a clean cloth. The cloth must not be contaminated with oily or greasy
substances.
In case of leaks or reduction system wear, close the cylinder interception valve, stop the
working process and contact your supplier.

3.7) Extraordinary Maintenance

In case of anomalous operation or system wear, contact SIAD.

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 4) Cylinder Exhaustion Monitoring System

4.1) Control and warning panel

The system has been designed to report the gas exhaustion of the containers connected to the
decompression system.
This system consists of:
- A pressure switch or transducer, connected to the decompression system, detecting
whether the pressure level of the containers is under the threshold value. The
calibration range of the pressure switch may vary from 4 to 40 bar for high pressure
gases and from 0.5 to 2.5 bar for low pressure gases.
- A warning and alarm card, such as BS92/SM devices or similar, managing the alarms
displayed on the card display and signalled by audible alarms.

When the container is almost exhausted, the pressure switch detects the exceeding
(decreasing values) of the preset calibration threshold and sends an electric signal to the
detection card.
The card processes the signal and produces an audio-visible alarm to warn the users that the
system must be adjusted.
If the decompression system is not able to automatically select a new gas container, the
working process must be interrupted for cylinder replacement. Otherwise the replacement is
carried out with operating decompression panel.

For any further detail about container monitoring systems connected to decompression
groups through a pressure switch, refer to the use manual of the alarm control boxes.

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 Gas distribution system
for automatic cut systems

Gas Safety Sheets

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Gas Safety Sheets Sheet No. Ver. Date

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 Gas distribution system
for automatic cut systems

Product Sheets

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Product Sheet Sheet No. Revision Date

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 Gas distribution system
for automatic cut systems

Equipment manuals

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Use and maintenance manual Reference Revision Date

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 Gas distribution system
for automatic cut systems

Certifications

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Material Company Certificate Date

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 Gas distribution system
for automatic cut systems

Reports

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 REPORT No.
Test Notice

Test Report

Workmanlike Installation Report

Delivery Report

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 Gas distribution system
for automatic cut systems

Project Drawings and Bills of Materials

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 Drawing Description Drawing No.

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