Gas Safety Level 1 (GSL1)

Introduction

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Why Are We Doing This?
 History of gas incidents at Western Port
 4 explosions and numerous near misses

 Prevent gas accidents

By recognising gas hazards
Understanding why we must
follow gas procedures

 Know what to do in an emergency

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What About Your Goals?
 What involvement with gases do you
have?
 What do you want to learn?
 What are you unsure of?
 Previous training?

3
Accidents Involving Gas
 Lack of knowledge
 Correct procedures not being followed
 Procedures incorrect or not existing
 Carelessness
 Faulty equipment

4
Hazards Associated With Gases
 Poisoning
 Asphyxiation
 Vapours from liquids or fires
 Explosions
 Fires

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Gas Safety Level 1
Gas Hazards

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What do you know already?
 Dangers from gases
 What do you do in an emergency?
 Can you smell / see / hear gas leaks?
 What gases are present in your area?
 Gas fires

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Gases around the plant
 Natural Gas / Premix
 Acetylene
 Liquefied Petroleum Gas
 Hydrogen
 Nitrogen
 HNX
 Oxygen
 Chlorine
 Carbon Monoxide (combustion by-product)
 Argon, Helium, Nitrous Oxide etc.
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Properties of Gases
 Smell
 Relative Density
 Asphyxiant
 Toxicity
 Flammability
 Taste
 Visibility

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Behaviour of gases in air

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 DATA ON WESTERN PORT PLANT GASES

GAS SMELL DENSITY HEATING DEGREE L.E.L. U.E.L. COMPOSITION

RELATIVE VALUE OF (Lower (Upper
Explosive Explosive
TO AIR MJ/m3 FLAMMABILITY Limit) Limit)
Gross % %

Natural Gas Strong* 0.62 38 High 5.3 14 90.6 % Methane

5.6 % Ethane
1.0 % Hydrocarbons
1.7 % CO2, 1.1 % N2

Hydrogen Nil 0.07 12.5 Very High 4.2 74 100% H2

Liquefied Strong* 1.6 97 High 2 10 88% Propane

Petroleum 10% Propylene
Gas 2% Butane

Acetylene Strong 0.90 58 Very High 2.5 100 100% C2H2

Nitrogen Nil 0.97 - Nil - - 100% N2

Oxygen Nil 1.11 - Intensifies fires - - 100% O2

Chlorine Strong 2.5 - Nil - - 100% Cl2

Argon Nil 1.38 - Nil - - 100% A2

Carbon Nil 0.968 12 Very High 12 75 CO Sources: Calibration

Monoxide gas cylinders and
Exhaust gases

*normally odour free (mercaptan added as a stenching agent) lighter than air heavier than air
Carbon Monoxide Poisoning
 No smell, tasteless, non-irritating
 Deprives body of oxygen
 Factors influencing severity of poisoning
 Symptoms
 Gas behaviour

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Gases containing CO
 Flue Gases from Furnaces and Stoves
 Exhaust Gases from Petrol or Diesel
Engines
 Oxy-acetylene and Arc Welding Fumes

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 CARBON MONOXIDE (CO)

8%
6%
Cigarette Car Exhaust
Smoke 3%
2%
10000ppm (1%) Death in minutes

5000ppm (0.5%) Collapse in minutes

1000ppm (0.1%) Headache &

Nausea in minutes
CO poster 400ppm Should Not Exceed

200ppm 15 minute maximum exposure

100ppm 30 minute maximum exposure

Busy street corner 60ppm 60 minute maximum exposure

30ppm Safe Working Limit

16ppm

Zero
Cigarette smoke
filled room
Treatment of victims
 DO NOT PUT YOURSELF AT RISK
 Remove victim to safe, warm, gas free
area
 Call 333
 Do not send patient to Medical Centre
on foot
 If breathing has stopped, commence
resuscitation (if confident in methods)

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Asphyxiation
 Air contains 21% oxygen
 Ways that O2 content is reduced
 Asphyxiant gases
 Symptoms
 Treatment

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Flammable gases can also asphyxiate

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 OXYGEN

Oxygen enrichment
causes increased
flammability
25%

23.5%
NORMAL AIR
Confined Space
safe working
limits 21%

19.5% No noticeable effect

Oxygen poster
A candle
will go out
18%
17% Increased pulse &
breathing, impaired
thinking & coordination
14%

Very faulty judgment &

coordination

EXPLAINING THE 10%

HAZARD
You may not Nausea, vomiting & collapse,
realise that you followed by death
are becoming
6%
effected by lack
of oxygen
because there is a
Death in minutes
gradual decline
of your clarity of
thinking.
0%
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Gas Fires and Explosions

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Combustion

FIRE OXYGEN
FUEL

IGNITION
SOURCE 20
Combustion Laws
 Fuels require a specific amount of
oxygen to burn
 Oxygen comes from the air
 Different fuels give off different amounts
of heat
 Principles of lighting burners

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Gas Fires and explosions
Causes
Precautions
Emergency situations
• Call 333
• Clear area
• Do not extinguish unless trained to deal
with gas fires

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Gas Fired Equipment Design
AIMS
 Prevent fire hazards and explosions
 Prevent injury to persons or property

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 FLAMMABILITY

100% (Gas in Air)

THE FIRE TRIANGLE These gases

Note: All three sides are needed must be mixed
for a fire or explosion to occur. with air in the
concentrations
IGNITION
SOURCE
shown for them
FUEL
to be flammable.
Liquid Spark 75%
Solid Flame
Gas Heat
Flammability poster
OXIDIZER
Oxygen, Air

HYDROGEN

19%
14%
NATURAL GAS 10%
5%
LPG 4%
2%
Zero (Gas in Air)

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 Oxygen
 Dangers of O2 > 21%
 Things will burn more intensely in
oxygen than in air
 Oils or greases will ignite
spontaneously
 Precautions

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Gas Leaks - Causes
Pinhole or crack in pipe (material
selection)
Leaking flanges
Open valve
Leaking gas cylinder
Coming from other area
Flame failure, if no burner management
system installed
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Gas Leaks - Effects
Toxic poisoning
Asphyxiation
Flash fires
Explosions
Jet fires
BLEVE

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Avoiding gas exposure
 Don’t discharge gas into enclosed areas
 Always use appropriate authorisation,
eg ATWP
 Use ventilation systems
 Use gas monitors
 Do not enter confined spaces unless
authorised
 Always stand upwind of leak / fumes

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Gas Detection
 NOT BY SMELL
 Fixed monitors
 Handheld monitors – single/triple head
 Drager hand pump with detector tube -
single check only
 If in doubt, ASK for gas check

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Gas Safety Level 1
Gas Safety Management
Systems

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Gas Systems
 What is a gas system?
Anything that is part of or is connected to
the interworks gas pipe network
 What is gas work?
Includes operating an
appliance that uses gas
Must have a procedure

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Company Regulations
 Gas Regulations
 Confined Space Entry
 ATWP
• Authorised by Plant Owner
• Needed for all jobs (unless exempt task)
• May need to consult Combustion
personnel to identify all hazards

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Gas Procedures
 What must gas procedures include?
 Who can carry out gas procedures?
 Lighting furnaces
 Isolation requirements
• Positive isolation
• Block valve isolation
• Isolate, depressurise and verify

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Confined Spaces
 What are confined spaces?
 Working in Vessels and Furnaces
 Cable Ducts and Drains
• Can be confined spaces
 How to Make Confined Spaces Safe
• Testing & Monitoring
• Permits

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Current Work on Gas Safety
 MCL and CPL Gas Audits
 Hazard Register
 Review Procedures/Training
 Gas equipment to comply with current
standards

 Western Port Gas Safety Case

 Office of Gas Safety

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Where to from here?
 Now know GSL1 theory
 Still need to be trained in gas
procedures
 Now equipped to work more safely
around gas
 Further training?
GSL1R to GSL5

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 GAS SAFETY TRAINING LEVELS

What They Can

Gas Competency Training Content Who Do We Do After
Level Train? Completion Of
Training
Basic knowledge of gas
- View Piper Alpha Video - All Personnel hazards in area.
GSL1 - GSL1 Gas Awareness This will assist with audits,
Training. hazard ID, incident reporting.

Basic knowledge of gas

- View Piper Alpha Video - Maintenance Team hazards in area.
GSL1 - GSL1 Gas Awareness Leaders. Understanding of risks &
Training. statutory requirements for gas
Regulations - Superintendents.
systems. This will assist
- Gas regulation training. - Managers. management of hazards.
- OH&S Reps.

Basic knowledge of gas fired

- Comb. Fundamentals - Appliance Operators equipment & how it works.
GSL2 - Comb. Systems - SPO’s Gives an understanding of the
equipment, what it does, risks
- Basic Local Appliance - TC’s
associated & how it effects
Knowledge - Shift Supervisors the product.

Perform block valve

- Block Valve Isolations - Shift Maintenance Trades isolations. Plan gas appliance
GSL3 Gas Safety & Regs. - Appliance Maintenance work. Maintain &
- Explosions troubleshoot gas systems.
Planners
This will give a clearer
- Advanced Local - Instrument Trades understanding on scope of
Appliance Knowledge work and at what point
- Comb. System Fault specialists should be
Finding involved.
- Basic Skills Assessment
Gas work pre planning.
- ‘Restricted’ Type B training - Department Specialists Approving gas isolation &
GSL4 - 12 months hands on work procedures.
(Assessed by Gas Committee) Commissioning & tuning gas
- Skills Assessment fired appliances. This enables
- Commissioning skills & all day to day gas issues to be
Knowledge managed within each
department.

Inspect/ Audit gas systems.

Type B training - Plant Specialists Modification approvals. Key
GSL5 3 years Plant Combustion Gas Committee members. Gas
experience Incident investigation
(Assessed by Gas Committee) resource.
Review
 Where are your procedures kept?
 Where are your main isolation valves?
 Who in your area do you ask about Gas
Safety?
 Who would you go to for more
information?

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What can you do?
 Use procedures for ALL gas work
 Check gas monitors
 Report gas leaks, faulty equipment and
incidents
 Seek approval for system mods
 Ask questions
 Make sure!

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