Practice 000.653.

3103
Date 01Jan2010
Page i

PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

This page is provided for information only and is not part

of the practice. Review of this summary does not relieve
the reader of responsibility for the contents of the practice.

Revision Summary:

Included an explanation regarding Form 000.653.F0107:

Note: Forms used to document inspections (000.653.F0107 series) and performance

evaluations (000.653.F0218 series) are specific to the machine. Both forms have
a sub-letter designation for nearly each type of machine. For example,
.F0107“z” is used for air compressors.

For additional information, contact Dan Palmer at 509.376.4240.

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

PURPOSE

This practice defines the requirements for operating or using pressurized or compressed
air equipment.

SCOPE

This practice includes the following major sections:

 General Requirements
 Pressurized/Compressed Air Equipment
 Compressed Gas Cylinders
 Manifolds
APPLICATION

This practice applies to work activities and employees under the control of Fluor and its
contractors.

DEFINITIONS

Pressurized Equipment  Includes but is not limited to any equipment, such as line,
hose, vessel, or container, which is subjected to pressure above or below that of one
atmosphere.

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

1.0 GENERAL REQUIREMENTS

All connections on pressurized/compressed air hoses or lines must have a positive means
of coupling to prevent the connection from uncoupling.

All hoses will have a containment device fitted to prevent whipping should it become
detached.

1.1 Whip Check

If inadequately restrained or “whip-checked,” the resulting whipping effect may, and has
previously, caused equipment damage and significant injury to, or death of, employees.
Consequently, all pressurized equipment must be restrained, or whip-checked through the
use or combined use of the following:

 Single leg cable stocking

 Sling (such as 1 or 2 leg slings)
 Internal reinforcement
 Double or 2-leg cable stocking, or
 Proprietary fittings or fixtures

Particular attention must be given to the securing and whip checking of:

 Hydraulic lines and pressure units

 High-pressure water lines, pumps, and vessels
 Air compressors and lines
 Associated tools and accessories

2.0 PRESSURIZED/COMPRESSED AIR EQUIPMENT

Only certified pressure vessels are permitted.

Employees required to use pressurized equipment must be trained in the use of such
equipment and fully conversant with the hazards associated with pressurized equipment.

Most pressurized equipment fails through:

 Mistreatment
 Sharp edges
 Poor handling techniques
 Incorrect installation or fitting
 Incorrect fitting of whip-check system
 Incorrect flow rate

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

Before compressed air equipment is brought to the project/site, it must be inspected and
deemed fit for the intended purpose.

Certificates of inspection for air receivers must be provided before arriving on the
project/site. Bleed-/pressure-relief valves, as well as air diffusers, must be fitted to air-
powered equipment.

Air lines must be protected from being driven over by machinery and kept away from
walkways and supported by cable stands where practicable.

1.2 Inspections

Pressure vessels must be inspected/certified according to the manufacturer’s

recommendations, and applicable codes/standards (such as ASTM, ASME, and
in-country).

Air compressors and similar equipment will be inspected daily with results documented
on Form 000.653.F0107z, Inspection Report – General Line Equipment: Air Compressor;
and monthly with results documented on Form 000.653.F0108, Monthly Inspection
Report – Construction Equipment and Light Vehicles.

Note: Forms used to document inspections (000.653.F0107 series) and

performance evaluations (000.653.F0218 series) are specific to the machine.
Both forms have a sub-letter designation for nearly every type of machine.
For example, .F0107”b” and .F0218”b” are used for aerial lifts;
.F0107”c” and .F0218”c” are used for scissor lifts; .F0107”x” is used for a
welding machine; and .F0107z is used for an air compressor.

1.3 Cleaning

Compressed air must not be used for cleaning purposes unless the pressure is reduced to
less than 30 psi — and then only with effective chip guarding and adequate personal
protective equipment.

3.0 COMPRESSED GAS CYLINDERS

1.4 Procurement Specifications and Limits

Requisitions for cylinders and hardware will include the following specifications when
applicable:

 Portable cylinders used to store and ship compressed gas will be constructed and
maintained in accordance with U.S. Department of Transportation (DOT)

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 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

regulations, Title 49 Code of Federal Regulations, Parts 171-179, or applicable

in-country standards.

 Devices used on compressed gas cylinders must comply with applicable

Compressed Gas Association (CGA) Standards, or applicable in-country standards.

1.5 Transporting and Moving Cylinders

When compressed gas cylinders are hoisted, they must be secured on a cradle, cylinder
truck/dolly, slingboard, or pallet; cylinders must not be hoisted using slings choked
around the body nor with unapproved devices or attachments.

When cylinders are moved with powered vehicles, they will be secured in a vertical
position, regulators will be removed, and valve protection caps put in place.

When cylinders are manually handled, unless cylinders are firmly secured on a cylinder
truck, regulators will be removed and valve protection caps put in place before cylinders
are moved in any fashion or by any means.

Whenever cylinders are moved, the valve will be in a closed position.

Regulators must be removed and, when provided for, valve-protection caps put back in
place before moving cylinders.

Proper support racks will be provided in vehicles used to transport cylinders.

The driver/operator will ensure cylinders filled for transportation (bulk loads) comply
with DOT regulations or applicable in-country standards, on the following subjects:

 Ownership and authorization to fill

 Type of shipping cylinders for each gas
 Charging cylinders – amount of gas and conditions of filling
 Marking and labeling
 Placarding transport vehicles
 Type(s) of pressure relief devices, where required

Compressed gas cylinders must not be transported in automobiles or in closed-bodied

vehicles.

Shipping compartments will be adequately ventilated.

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

1.6 Placing Cylinders

Cylinders will be secured in an upright position, even when being hoisted or moved.

Cylinders will be placed where they cannot become part of an electrical circuit and will
be kept away from piping systems and layout tables that may be used for grounding
electrical circuits.

When cylinders are in use, they will be placed with the valve end up, and a steadying
device used to keep them from being knocked over. Cylinders will not be placed where
they will be exposed to open flames, hot metal, or other sources of heat.

Note: This requirement does not apply to cylinders as follows (as prescribed in CGA
and National Fire Protection Association (NFPA) standards:

 Cylinders designed to remain stable without being secured (for example, LPG
cylinders commonly used with gas grills and weed burners)

 Cylinders with a maximum water capacity < 2.7 pounds

 Compressed gas and oxygen cylinders must not be placed in confined/enclosed or

nonventilated areas.

1.7 Storing Cylinders

Compressed gas cylinders must be stored in areas that are safe, dry, well-ventilated, and
protected from direct sun and weather conditions; do not expose cylinders to
temperatures above 125 F (51 C).

Compressed gas cylinder storage areas will be clearly identified and posted with the
name(s) of the gas(es) stored in the area.

The quantity of gas in cylinders allowed in storage (inside or outside) will be in

accordance with NFPA Standards 51 and 55.

Cylinders will not be stored near elevators, gangways, stairwells, or any other place
where they are likely to be knocked down or interfere with traffic.

Empty cylinders will be segregated from other cylinders and labeled or tagged “Empty”
or “MT.”

Oxygen cylinders not in use must not be stored within 20 feet (6.1 meters) of cylinders
containing flammable gases unless separated by a fire wall at least 5 feet (1.5 meters) tall
and having a fire-resistance rating of at least 1/2 hour.

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

Cylinders containing oxidizing gases must be stored away from flammable substances
such as oil and volatile liquids.

Smoking is prohibited within 20 feet of flammable gas cylinder storage areas. NO

SMOKING signs must be posted in storage areas containing flammable gases.

Valves on empty cylinders will be closed and capped.

Storage areas will be constructed so that they are dry, well-ventilated, and made with
noncombustible materials; ensure shelves are able to support cylinders.

Dry vegetation and combustible materials must be cleared for a minimum distance of
15 feet (4.6 meters) from around the storage area.

Physical protection (barriers) will be provided to prevent damage from vehicles.

1.8 Using Cylinders

Gas welding and cutting equipment must be inspected by the user at the beginning of
each shift to identify any of the following defects:

 Leaking or damaged hose or hose couplings

 Leaking or damaged fuel-gas pressure regulators and gauges and related

connections

 Leaking or damaged torch heads or shutoff valves and related connections

 Clogged tip openings

Before connecting a regulator to the valve, the valve will be opened slowly to clear debris
from the valve nozzle and closed immediately. This action will be taken in an area where
there are no possible sources of ignition, and the employee will stand to one side when
taking this action.
Safety devices will not be tampered with.
Cylinders must be clearly identified as to their contents in accordance with local
hazardous substance legislation.
Do not strike an arc on a cylinder.
Hoses from compressed gas cylinders must be removed from confined spaces when not
in use and during breaks.
Flashback devices must be installed at both the regulator and torch end, on both lines, of
oxygen/fuel gas systems.

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

Regulators and hoses used with flammable compressed gas cylinders will be leak tested
immediately after they are connected to the cylinders.
Cylinders must be kept far enough away from the actual welding/cutting operation to
prevent sparks, hot slag, and flames from reaching them.
Acetylene cylinder valves will be opened 3/4 of a turn or less; do not open acetylene
cylinder valves more than 1-1/2 turns.
Acetylene regulators will be adjusted so the low-pressure gauge indicates a delivery
pressure of less than 100 kPa (15psig) to the hose and torch.
Cylinders will be considered full and must be handled accordingly.
Approved reducers and regulators must be used; do not use gas directly from cylinders
without pressure being reduced through specifically approved regulators; do not tamper
with safety devices on regulators or on cylinder valves.
Cylinders will be protected from damage; do not drag, drop, or strike; do not use
cylinders with signs of damage.
Cylinders will not be used as rollers or supports, or for any purpose other than to store
and dispense the original contents.
Oxygen cylinders and fittings must be kept away from oil, grease, and other
combustible/flammable materials; keep cylinders, cylinder caps and valves, couplings,
regulators, hoses, and apparatus free from oil and greasy substances, and do not handle
with oily hands or gloves; do not direct oxygen at oily surfaces or greasy clothes.
Gaseous hydrogen systems will be equipped with pressure-relief devices and protected
from tampering. Relief devices will be arranged so that if actuated, they have an
unobstructed upward vent path to open air.
Users will verify that compressed gas cylinders indicate the following:

 Date the last hydrostatic test was performed (stamp).

 Cylinder contents (label with either chemical or trade name).

Cylinder tags or markings will not be removed or altered.

Mixing gases, transferring them from one cylinder to another, or refilling cylinders is
prohibited.
Valve protective caps will be kept on the cylinder except when the cylinder is secured
and connected to dispensing equipment.
Cylinder valves must be opened slowly.
Users will ensure reverse-flow gas check valves and flashback arrestors are installed on
both lines of all oxygen and fuel-gas setups.

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 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

Special wrenches, when required, will be left in position on the stem of the valve while
the cylinder is in use; in the case of coupled cylinders or cylinders connected with
a manifold, at least one such wrench must be available for immediate use.
When the work is complete, or at the end of the shift, valves and regulators will be
closed; gas lines and regulators must be drained; and the adjusting screw “backed out.”
Note: This does not apply to cylinders connected with a manifold.

Regulators and pressure gauges will be used only for the gases that they are designed and
intended for. Repair, modification, or alteration on cylinders, valves, or attachments will
be performed only by the manufacturer/authorized service center.
Difficult connections must not be forced; threads on regulators must match to those on
the cylinder valve outlet.
Cylinders will not be dragged, dropped, rolled, or struck in horizontal position, or
allowed to strike each other or another surface violently.
When transporting cylinders, a suitable hand truck, forklift, or similar handling device
will be used with the cylinder properly secured to the device and the valve cap on.
Cylinders may be rolled only for short distances, using the curved bottom edge of the
cylinder.
Cylinders will not be lifted using the protective cap or with a magnet.
When disconnecting regulators and hose, the valve must be closed and the hoses purged
before removing the regulators, and storing.
Torches and hoses will be completely depressurized (bled) before storage, or at the end of
each shift.
Torch, hose, and regulators must be completely contained within any box for storage.
Storage of torches or hose with one end out of the box is strictly prohibited, regardless of
the regulators being connected to a compressed gas cylinder.

1.9 Refilling Gas Cylinders

Compressed gas cylinders may only be refilled by the owner or authorized employees in
compliance with applicable standards.

4.0 MANIFOLDS

Use manifolds and manifold parts only for the gas(es) they are designed for.
Cylinder manifolds are installed under the supervision of an employee who is familiar
with the uses of the gas at that facility. Installations comply with applicable standards for
construction and use.

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental
 Practice 000.653.3103
Date 01Jan2010
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PRESSURIZED/COMPRESSED AIR EQUIPMENT AND COMPRESSED GAS

CYLINDERS/OPERATIONS

Ensure compressed gas manifolds are designed to meet NFPA Standard 51.

Ground and bond flammable-gas piping systems in accordance with NFPA Standard 51.
When acetylene cylinders are connected by a manifold, approved flash arrestors are
installed between each cylinder and the coupler block. One flash arrestor installed
between the coupler block and regulator is acceptable only for outdoor use or if the
number of cylinders coupled does not exceed 3.

5.0 RESOURCES

Global Standards
Australian Government Safety and Compensation Council; List of National
Codes of Practice
Safety and Compensation Council; List of National
Standards
European Union European Agency for Safety and Health at Work
United Kingdom Construction Regulations 2007

6.0 REFERENCES

Document ID Document ID
Forms:
000.653.F0107z Inspection Report – General Line Equipment: Air
Compressor
000.653.F0108 Monthly Inspection Report – Construction Equipment
and Light Vehicles
Non-Fluor Documents
49 CFR Parts 171-179 Department of Transportation Regulations (Hazardous
Materials and Carriage)
NFPA Standard 51 Design and Installation of Oxygen and Fuel Gas
Systems for Welding, Cutting, and Allied Processes
NFPA Standard 55 Compressed and Liquefied Gases in Portable Cylinders

Copyright © 2010, Fluor Corporation. All Rights Reserved. Health, Safety, and Environmental