Gas Cylider Technical Regulation.pdf

QATAR GENERAL PETROLEUM CORPORATION STANDARDS PUBLICATION

GAS CYLINDER TECHNICAL REGULATION DOC. NO.: QGPC-REG-Q-002 REVISION 1

CONTROLLED COPY NO

FACILITIES QUALITY ASSURANCE DEPARTMENT

GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

Doc. File No.: REG.Q.002. R1

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Custodian Dept. : FQAD

QATAR GENERAL PETROLEUM CORPORATION STANDARDS PUBLICATION

GAS CYLINDER TECHNICAL REGULATION DOC. NO.: QGPC-REG-Q-002 REVISION 1

02.01.200 0 Date

1

Rev.

Issued as Corporate standard Regulation Description

Doc. File No.: REG.Q.002. R1

QAA/3 Prepared by

QA A Reviewed by

Page 1 of 35

SC QA Approved by

SQ DO DT Corporate Endorsement

Custodian Dept. : FQAD

GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

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TABLE OF CONTENTS FOREWORD............................................................................................................................................4 1.0

OBJECTIVE ..................................................................................................................................5

2.0

SCOPE ............................................................................................................................................5

3.0

APPLICATION..............................................................................................................................5

4.0

POLICY..........................................................................................................................................6

5.0

DEFINITIONS ...............................................................................................................................6

6.0

REFERENCE STANDARDS AND CODES ...............................................................................8

6.1 6.2 6.3 6.4

DESIGN .............................................................................................................................................8 INSPECTION ......................................................................................................................................9 PAINTING..........................................................................................................................................9 QATAR STANDARDS .......................................................................................................................10

7.0

REGULATION REQUIREMENTS ..........................................................................................10

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

RESPONSIBILITIES FOR IMPLEMENTATION ......................................................................................10 PURCHASING..............................................................................................................................12 IDENTIFICATION, MARKING AND TRACEABILITY ........................................................14 INSPECTION AND TESTING ..................................................................................................16 MAINTENANCE REQUIREMENTS .........................................................................................22 CALIBRATION REQUIREMENTS ...........................................................................................24 STORAGE & TRANSPORTATION............................................................................................24 TRAINING & QUALIFICATION NEEDS ..................................................................................25

8.0

QUALITY ASSURANCE ...........................................................................................................26

9.0

QUALITY RECORDS ................................................................................................................27

9.1 9.2

FILLING COMPANY RECORDS .........................................................................................................27 OWNER / USER RECORDS ........................................................................................................27

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

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10.0 GAS CYLINDERS FOR FIRE & SAFETY APPLICATIONS ..............................................28 10.1 10.2 10.3 10.4 10.5 10.6 10.7

GAS CYLINDERS C LASSIFICATION AND USE ...................................................................................28 RESPONSIBILITIES ...........................................................................................................................29 IDENTIFICATION & TRACEABILITY..................................................................................................29 INSPECTION & TESTING ..................................................................................................................29 MAINTENANCE ...............................................................................................................................30 CALIBRATION .................................................................................................................................30 RECORDS ........................................................................................................................................30

11.0 APPENDICES ..............................................................................................................................31 11.1 11.2 11.3 11.4 11.5

APPENDIX A ...............................................................................................................................31 APPENDIX B................................................................................................................................32 APPENDIX C................................................................................................................................33 APPENDIX D ...............................................................................................................................34 APPENDIX E................................................................................................................................35

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

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FOREWORD

This Document has been developed by Facilities Quality Assurance Department, in consultation with the QGPC Safety & Fire Dept., all operational departments (offshore, Dukhan, Mesaieed), Maintenance, Engineering, Material control, affiliates to achieve the principles set by QGPC strategy Plan for standardisation. It was reviewed by QGPC User departments, approved by Standards Committee and endorsed by the QGPC Management for use as Corporate Standard for Gas Cylinders. This Document is now published for QGPC Departments/affiliates/Contractors/Sub-contractors utilisation. It should be emphasized that the document is intended to be used for QGPC operations wherever applicable and appropriate. The document in its present form reflects as far as possible the current QGPC requirements taking into account the known available industry practices and the applicable latest national and international codes and standards. It will be revised periodically and/or when deemed necessary. It is the responsibility of the operations managers to ensure that the latest version of this document is available for reference and implementation, by the concerned Departments. The Custodian of this document is Facilities Quality Assurance Department. Therefore, all comments, suggestions, interpretation, application or queries regarding these regulations should be directed to: Manager (QA) Facilities Quality Assurance Department Building No: 5, Ras Abu Aboud, Doha Tel: 402786 In addition to above please deal with Senior Quality Assurance Engineer (QAA/3) Facilities Quality Assurance Department Building No: 5, Ras Abu Aboud, Doha Tel: 402495, Fax: 402207, Mobile: 5537805 In case of accidents all matters relating to the Gas Cylinder accidents or incidents shall be reported to: Manager Safety & Fire Safety Department Building No: 17 Ras Abu Aboud, Doha Tel: 402659, Facsimile: 402806, Bleep: 264920

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 1.0

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OBJECTIVE The objective of these regulations is to establish standard safe working practices in handling Gas Cylinders at all QGPC Operational areas.

2.0

SCOPE

2.1

This identifies and specifies QGPC minimum mandatory requirements for safe utilization of the gas cylinders. subcontractors are bound by these regulations.

2.2

This identifies the organizational and technical methods to be implemented to ensure that the gas cylinders for the transportation of compressed and liquefied gases are fit for purpose and safe for use. Therefore any gas cylinder in use at QGPC sites, or at the contractor / subcontractor working locations shall be maintained with proper inspection & testing and certified with clear identification and traceability system.

2.3

This covers actions related to three major groups of Gas cylinders, a) Gas cylinders owned by the QGPC or Contracting Company. b) Gas cylinders owned by a filling company and supplied to the QGPC or Contracting Company c) premises for QGPC Contracts.

2.4

Specific requirements for following Gas Cylinders are covered in the section 10. a) Gas Cylinders for Fire Extinguishing/ Fighting. b) Breathing Apparatus and Medical Oxygen Cylinders.

3.0

APPLICATION

3.1

Gas Cylinders used in the QGPC Operational areas by any one shall conform to the requirements of these regulations and reference Standards/Codes mentioned herein.

3.2

The Regulations shall be implemented within six months from the Date of its issue, the period within which QGPC & s and contractors shall be required to implement the necessary system to fully comply with the requirements. For new contractors, the regulations shall be enforced from the contract start date.

3.3

It is the mandatory requirement to have Test Date Disc around the neck of each Gas cylinder as per Table-2. (Ref. clause 7.4.5 of the Regulations).

3.4

The Regulation shall also apply to the use, purchase, maintenance and hiring of Gas cylinders, including dissolved acetylene cylinders, by owners, users and fillers of the gas cylinders at any

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3.5

These regulations shall be implemented by the buyers, vendors, receivers, users, contractors / subcontractors, safety and inspection departments, with clear identification of their responsibilities. To prevent the use of any outdated and uncertified Gas cylinders the recording of activities shall be on the forms provided within the Regulations. Gas Filling Companies shall establish Quality Management System to comply with these regulations.

4.0

POLICY

4.1

QGPC Policy is to maintain safe working environment at all operational areas with a view to contractors/sub contractors.

4.2

In order to achieve this Policy, QGPC nominates competent personnel at all operational areas. QGPC conducts periodic audits on all the operational areas including affiliates & contractors/subcontractors to ensure that all parties comply with these regulations and applicable standards.

4.3

The requirements specified in these regulations are mandatory and become enforceable upon issue of this Document.

4.4

All Inspection Release Notes issued by the filling company shall be submitted to QGPC - QA department for review and approval prior to mobilizing Gas cylinders to any QGPC operational area (see Appendix- A for Inspection Release Note).

4.5

No dispensations can be given against these regulations, by any party, except in an emergency, in which case the Party shall raise Request for Waiver and approval shall be granted by the relevant operations manager. The details of waivers including Gas Cylinder identification markings shall be recorded by concerned party and copy to QA department (see Appendix-B for Waiver form).

4.6

Use of Domestic Cooking Gas Cylinders for industrial applications is strictly prohibited on the

5.0

DEFINITIONS The purpose of this section is to define the terminology used as general, technical inspection and shall apply within the scope of this document.

5.1

Certifying Authority (Third Party) An internationally recognized organization appointed to witness Gas Cylinders testing and to perform examination and certification.

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 5.2

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Competent Person A person, who has undergone training, practical experience and understanding of the Equipment and System, is able to verify compliance with the specified Standard in the Regulations.

5.3

Contractor The Organization that provides a product or Service to the customer. In Contractual situation this organization is termed as Contractor. (Ref: ISO 8402)

5.4

Corrosion A deterioration of materials that results in the removal / loss of the surface material and leads to the structural integrity of the Gas Cylinders being adversely affected.

5.5

Inspection An activity such as measuring, examining, testing or gauging one or more characteristics of an entity (Product/ item) and comparing the results with specified requirements in order to establish whether conformity is achieved for each characteristic (ISO 8402).

5.6

Liquefiable Gas Any gas that liquefies under pressure at - 10 with 1013 mbar Pressure.

5.7

0

C., but which completely vaporises at 17.5

0

C.

Organization A Company, QGPC, firm, enterprise or institution, or part thereof, whether incorporated or not, public or private, that has its own functions and administration. (Ref: ISO 8402)

5.8

Record A document, which furnishes objective evidence of activities performed or results, achieved. (ISO8402)

5.9

Service The result generated by activities at the interface between the Contractor and the customer and the contractor internal activities, to meet the customer needs. (ISO 8402)

5.10 Sub Contractor The Organization that provides a Product or Service to the Contractor (ISO 8402)

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5.11 Testing Station Suitably equipped and Certified premises, staffed with competent persons, to undertake periodic inspections and testing of Gas Cylinder as per the provisions of referred standard. 5.12 Owners, Users, Fillers Owner Any entity which legally owns the Gas Cylinders. User Any entity, irrespective of Ownership, in control or possession and Usage of the Gas Cylinders, at the given time. Filler Suitably Equipped and staffed Organization which undertakes Gas Filling activity and which has the necessary support to undertake Inspection and Testing of the Gas Cylinders. 6.0

REFERENCE STANDARDS AND CODES

6.1

Design BS 341

Specification for valve fittings for compressed Gas Cylinder.

BS EN 1089-3 Specification for identification of the contents of Ind. Gas Cylinders. BS 5045

Transportable Gas Cylinders Part 1 Specification for seamless steel Gas Cylinders above 0.5-liter water capacity. Part 2 Specification for steel Gas Cylinders of 0.5 liter to 450 Liters water capacity with welded seams. Part 3

Specification for seamless aluminum alloy Gas Cylinder above 0.5-liter water capacity and up to 300 bars charged pressure at 150 C

Part 5

Specification for aluminum alloy Gas Cylinders above 0.5 liter up to 130 liters water capacity with welded seams.

Part 6

Specification for seamless steel Gas Cylinders of up to and including 0.5-liter water capacity.

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 BS 5396

REV.1

Specification for seamless steel CO2 Gas Cylinders for fixed fire-fighting installations on ships.

BS EN 1800: 1999 Transportable acetylene Gas Cylinders

6.2

DOT 4BA

Specification for cylinders, welded or brazed steel cylinders made of definitely prescribed steel

BS EN 1439

1997 Transportable refilled welded Steel Cylinders for LPG-Procedure for checking before, during and after filling (Q)

BS EN 1440

1997 Transportable Requalification.

refilled

welded

Steel

Cylinders

for

LPG-Periodic

Inspection BS 5430

Periodic inspection, testing and maintenance of transportable gas containers of (excluding dissolved acetylene Gas Cylinders). Part 1 Specification for seamless steel containers of water capacity 0.5 liters and above. Part 2 Specification for welded steel containers of water capacity of 0.5 to 150 liters Part 3 Specification for seamless aluminum alloy containers of water capacity 0.5. Liters and above. Part 6 Specification for seamless steel Gas Cylinders of up to and including 0.5liter water capacity.

6.3

BS 6071

Specification for periodic inspection and maintenance of transportable Gas containers for dissolved acetylene.

DOT 4BA

Specification for cylinders, welded or brazed steel cylinders made of definite prescribed steel.

BS 5306

Part 3 Specification for Portable Fire Extinguishers- Inspection & Testing

Painting BS EN 1319

Specification for medical gas cylinders, valves and yoke connections

BS 4001-1

Recommendations for the compressed air open circuit type.

BS 381C 1996 Specification for colours identification, coding and special purposes Doc. File No.: REG.Q.002. R1

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BS EN 1089 3 1997 Specification for identification of the contents of Ind. Gas Cylinder 6.4

Qatar Standards QS 55/1987

Part 1: Industrial Safety and Health Regulation - Hazardous Materials - Gases, General Requirements

QS 56/1987

Part 2: Industrial Safety and Health Regulation - Hazardous Materials - Gases, Acetylene

QS 58/1987

Part 4: Industrial Safety and Health Regulation - Hazardous Materials - Gases, Nitrous Oxide and Oxygen

QS 60/1987

Part 6: Industrial Safety and Health Regulation - Hazardous Materials - Gases Liquefied Petroleum Gases

QS 118/1989

Requirements for Filling, Transport, Handling and Liquefied Petroleum Gas Cylinders

QS 139/1991

Oxygen for Industrial Purposes.

7.0

REGULATION REQUIREMENTS

7.1

Responsibilities For Implementation

Storage Of

It is the responsibility of QGPC Line Managers to ensure that the requirements specified in this document are complied with, in their individual operational area, for the Gas Cylinders utilised by QGPC or affiliates or the Contractor/Sub contractor. The implementation of these regulations requires interpretation of responsibilities assigned to each activity as mentioned here after: 7.1.1 QGPC Representative (Focal Point) The QGPC Representative (designated by the Management) is the Person in charge of all the Gas Cylinders (incoming and outgoing). The concept is to have a Focal Point who will be assigned the responsibilities of coordinating with various Departments, Certifying authorities, Suppliers and contractors/subcontractors to monitor compliance with the Regulations. Some of his responsibilities are to ensure, a) Check-in inspection (Receiving inspection) of Gas Cylinders entering the area of his Control. During the check-in inspection it must be ensured that, • for delivery to QGPC. • Identification no. & test details are marked on the Cylinders. • Cylinders are fitted with Date discs around the neck to mark the dates of hydrotest. Doc. File No.: REG.Q.002. R1

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 •

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Different batches are divided into homogeneous groups based on type of Gas for the systematic identification and inspection.

b) tests certification for the Gas cylinders. c) Review of the certificates and inspection reports for all the Gas Cylinders, brought by contractors for their own use. Ensure that all Gas Cylinders are correctly marked, colour coded and tagged with Test Date Disc (Section 7.4.5). D) Update the portable Gas Cylinders Register and Master file upon receipt of new Gas Cylinders at the stores and upon periodic inspections. Issue a new identification number and details for the certification of the new gas cylinders (QGPC owned). 7.1.2

QA Department It is the responsibility of the QA Department verifies that the QGPC, its affiliates, contractors and sub-contractors, implements the regulation. This is to be ensured through the following, • • •

7.1.3

Act in advisory role to QGPC departments, its affiliates, contractors and sub-contractors for implementation of the regulations Monitor the performance of the contractors, suppliers, certifying authorities. Coordination between QGPC Departments and approved certifying authority for scheduling inspections and audits.

Safety Department Random checking of Gas cylinders on the QGPC sites for compliance with regulation requirements. This may be done in liaison with the QA Department.

7.1.4

End User Any party that utilises gases stored in portable or fixed Gas cylinders. (The QGPC, affiliates, contractors & sub-contractors) End user shall identify a person responsible for implementation of the regulation. He shall be responsible for all activities related to Gas cylinders such as • • •

7.1.5

Material Issue Vouchers specifying all the data, Verification of Cylinders, delivery notes and certificates received as per MIV, Random external inspection of the Cylinders received at site.

Certifying authorities Third party certifying authorities shall not issue any certificate where the Gas cylinders do not fully meet the requirements of the applicable standards and any specific requirements of these regulations. Certificates of inspection/test issued by the authority shall clearly indicate all the

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necessary details. Where Gas cylinders fail to meet the requirements of the regulation and the standard a defect report, clearly identifying the reasons of rejection, shall be issued. QGPC approves Six Certifying Authorities, as listed here, for the purpose of Inspection, Verification and Certification of the Gas Cylinders. American Bureau of Shipping (ABS) Bureau Veritas (BV) Det Norske Veritas (DNV) Germanischer Lloyds (GL) Lloyds Register (LR) Velosi TUV Bayem-NKK(TUV) 7.1.6

Gas Supplier The Gas Supplier company shall clearly define responsibilities and functions for the following: • Filling Station • Inspection Section • Cylinder handling section (transportation and Delivery), • Purchasing Section (for new cylinders), • Maintenance Section and • Personnel involved in operation of Contract. Maintaining Quality Records related to all these activities is one of the prime responsibilities of the Gas supplier.

7.1.6.1 Filling Station Filling Station has the responsibility to ensure compliance with the requirements of the regulation and applicable standards for inspection and testing prior to filling of Gas Cylinders. (Ref Clause 6) 7.1.6.2 Testing Station It is the responsibility of the Testing Station to verify compliance with the applicable standard and these regulations for the testing activities undertaken. 7.1.6.3 The Competent Person The Competent person appointed by the Gas Supplier shall be responsible for compliance with all the requirements of the standard and these Regulations. 7.2

PURCHASING Owners, Users and Fillers of Gas cylinders shall ensure that purchased Gas and Gas cylinders conform to the requirements specified in these regulations. Evaluation and control of Gas cylinder Suppliers, maintaining their quality records shall be the responsibility of the purchase department.

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 7.2.1

REV.1

Purchasing Data Purchase Department is responsible to ensure that Gas cylinders are purchased with inspection and test certificates in accordance to requirements set by the standards. Any requisition without inspection and certification requirements specified, shall not be accepted for processing. The minimum purchasing data shall be as per Clauses 7.2.2.1 and 7.2.2.2. The purchase data shall be communicated to the supplier on the Standard Purchase form.

7.2.2

Purchasing of Gas Cylinders

7.2.2.1 Information To Be Supplied By The Purchaser The Purchaser shall provide the following information to the Manufacturer or Supplier in the standard format a) Description , type and application of gas b) Applicable Standard c) Volumetric Capacity & the mass of gas or filling ratio ( for Liquefiable gases this shall be the minimum) d) The filling pressure at 15 0 C (For permanent gases) e) Material of construction f) Preferred dimensions g) Shape of base h) Internal and / or external neck screwing dimensions i) Fittings required j) External and internal surface finish required k) Any special or adverse conditions under which the Gas Cylinder will be required to operate, and any corrosion allowance required. l) Any other information required by the manufacturer. m) Type of Certification required. N) Markings on the cylinders such as identification no., applicable standard, date of inspection, stamp of the certifying authority etc. 7.2.2.2 Information To Be Supplied By The Manufacturer The manufacturer / supplier shall supply to the purchaser and the certifying authority the following information. a) Fully dimensioned sectional drawing and Material Safety Data Sheet (MSDS) of the Gas. b) Volumetric capacity(for liquefiable gases this shall be the minimum ), c) Filling Pressure at 15 0 C. for permanent gases, mass of liquefiable gas, d) The Material of construction, e) The Test pressure details, f) Minimum and Maximum masses of the Vessel, g) Statement that the Gas Cylinder will comply with the requirements of stated standard, h) Design approval details, i) Corrosion allowance tolerances, j) Methods of manufacture, k) The Fittings supplied, l) A Drawing showing layout of stamped markings, Doc. File No.: REG.Q.002. R1

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m) Certificate of tests of material and Gas Cylinder. 7.2.2.3 Purchasing Of Gas ( Re-Filling Of Cylinders ) The Purchase requisition shall specify the requirement for the following, a) Type and characteristics of the Gas required, b) Certificate of Acceptance and Inspection Release Note to be made available with the delivery of the filled cylinder. c) The data for filling the gas shall be as marked on the cylinder. 7.2.3

Approval Of Gas Cylinder Suppliers The Purchaser (Owner & Filler) shall observe the following: a) Evaluate and select Gas Cylinder suppliers based on their ability to meet order requirements including Quality system and quality assurance requirements. b) Define type and extent of control exercised over the suppliers. c) Maintain a list of approved suppliers and their quality evaluation records.

7.2.4

Hiring Of Gas Cylinders

7.2.4.1 Gas Cylinders hired (by the User and Filler) shall also be governed by these Regulations. The Hirer shall be responsible to ensure that the requirements of these Regulations are clearly communicated to the Supplier and verification done to ensure that the Hired Cylinders also meet the specified requirements. 7.2.4.2 The Owner or User depending on the contract agreement, to ensure proper control of such cylinders including maintenance, storage, inspection and certification shall maintain a separate Register of such Cylinders. 7.3

IDENTIFICATION, MARKING AND TRACEABILITY

7.3.1

Gas cylinder data shall be identifiable and traceable at any time and at any location. A Traceability Log shall be maintained to monitor the location and inspection status of all the available Gas Cylinders. The Non-conforming Cylinders, which are identified as unsuitable for further operation, shall be clearly indicated in the traceability log and removed from the site.

7.3.2

For clear identification of the ownership of the gas cylinders, the name of the Owner Company shall be permanently and clearly marked with hard stamps of minimum 10-mm size near the bottom ring of the cylinder. Additionally the company name may be stenciled on the cylinder using appropriate colour.

7.3.3

Marking (Tagging) information on the Cylinders Each Gas Cylinder that complies with the requirement of this standard shall be permanently and clearly marked with the following information. a) The manufacturer name & mark. Doc. File No.: REG.Q.002. R1

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 b) c) d) e) f) g) h)

REV.1

Gas Cylinder serial number. The test pressure and test date. The working pressure. The identification mark (Stamp) of the certifying authority. The applicable standard number. The design minimum water capacity. The tare weight of the Gas Cylinder.

Note: Additional markings required for dissolved Acetylene Cylinders, • • • 7.3.4

The maximum mass content of Acetylene inside the Cylinder, Any additional or replacement markings shall be stamped on the valve boss, base ring, shroud or label. They should preferably be 6 mm in height, but in any case not less than 3 mm. The marks shall be applied with low stress stamps, in such a manner that they do not weaken or damage the Gas Cylinders.

Markings Of The Contents Of Gas Cylinder Each cylinder will be clearly and permanently marked at the shoulder of the cylinder with the following, a) The mark of the manufacturer of the mass and the type of the mass in the Gas Cylinder for dissolved acetylene Cylinders, b) The chemical formula of the Gas, c) The symbol or the name of the gas it contains, For Cylinder containing more than one type of gas (mixtures of gases) the following shall be marked, a) Chemical formulae, b) Symbols or the names of the gases, c) Proportions of the Gases.

7.3.4.1 Colour Coding And Colour Bands a) For identification of the contents of industrial Gas Cylinders, appropriate colour bands shall be applied to the gas cylinders as per the requirements of BS EN 1089-3, 1997 (Refer to Tables 1&2 of the standard). b) The colour band shall be painted round the neck of the cylinder. c) The Colour band shall be wide enough to occupy half the hemispherical portion of the Cylinder. d) When the valve of Gas Cylinders is wholly protected by an extension of the Cylinder body, the colour band shall be painted on the extension. e) When two colour bands are required, the second band shall be painted immediately below the first band. For hazardous Gases, an appropriate colour band shall be applied to the Gas Cylinder according to the requirements of BS EN 1089-3 Doc. File No.: REG.Q.002. R1

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

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Other painted marks: a) The presence of siphon tubes fitted in cylinders shall be indicated with a white line, 25mm wide, painted down the full length of the Gas Cylinders, or by some other method. b) Any other bands painted or marked on the Gas Cylinders, shall be placed on the body of the Gas Cylinder (Excluding the neck and shoulder) Note: Paints that contain aluminum & that are a fire risk shall not be used for marking. Table-1: Ground colour of Gas Cylinders shall be painted as per the following Table& applicable Standard.

7.4

S. N o

Name of the Gas

Ground colour of the cylinder

S.No

Name of the Gas

Ground colour of the cylinder

S.No Name of the Gas

Ground colour of the cylinder

1.

Acetylene

Maroon

8.

Hydrogen

Signal Red

15.

Black

2.

Air

9.

Methane

Signal Red

3.

Ammonia

French Grey Black

10.

Neon

4.

Argon

11.

Nitrogen

5.

Chlorine

12.

Oxygen

Black

6.

Ethylene

13.

Phosgene

Black

7.

Helium

Peacock Blue Golden Yellow Dark Violet Middle Brown

Middle Brown French Grey

14.

Propane

Signal Red

Carbon dioxide 16. Carb.monoxi de 17. Ethyl Chloride 18. Hydrogen Cyanide 19. Methyl Bromide 20. Methyl Chloride 21. Sulpher Dioxide

Signal Red French Grey Peacock Blue Peacock Blue Light Green Light Green

INSPECTION AND TESTING Owners and Fillers of the Gas Cylinders shall establish and implement documented procedures (Refer to Clause. 8) for Inspection and testing activities as per the applicable standard. The required inspection records to be maintained shall be detailed in documented procedure and such records shall be maintained for verification.

7.4.1

Receiving Inspection Requirements

7.4.1.1 Owners & Users (QGPC, Contractors, affiliates, Filling Companies etc.) Owners & Users shall ensure that incoming Gas Cylinder are not issued or used until they have been inspected or otherwise verified as conforming to applicable standard and these regulations. Cylinders shall be suitably marked to indicate the result of such inspection and verification. It is recommended to use colour coding or tagging system for the purpose. a) Gas Cylinders found acceptable can be released for further use. Doc. File No.: REG.Q.002. R1

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

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b) Gas Cylinders found unacceptable shall be suitably identified and quarantined till the discrepancies noted are resolved. c) Gas Cylinders released for use, in Emergency cases, without inspection and verification shall be positively identified & recorded on Waiver Form(See Annex). This will enable recall and replacement of the Cylinders in case of any nonconformity observed at later stage. 7.4.1.2 Gas Supplier ( Filler ) The Filling Company shall ensure that each cylinder is thoroughly examined before filling. It is the responsibility of the testing station to verify compliance to these regulations and the applicable standard to ensure that gas cylinders have been inspected and tested prior to refilling. The filling station shall ensure the following: a) Receipt log, for all incoming cylinders is maintained. b) After receiving inspection, Gas Cylinders found unacceptable are quarantined till the discrepancies noted are resolved. c) Report for the non-conforming gas cylinders is issued to the owner for timely corrective action. d) Gas Cylinders due for periodic inspection and testing are identified at the receipt stage and the necessary actions initiated before filling. 7.4.2

Periodic Inspection Requirements Methods and the Equipment (Tools) used for periodic inspection and testing of the gas cylinders shall comply with the requirements of the applicable standard. It is emphasized that the inspection is a mandatory requirement, for the identification of the defects. Each Gas Cylinder shall be visually inspected externally and internally, for any sign of corrosion or other defects as detailed below.

7.4.2.1 External Surface Inspection Each Gas Cylinder shall be externally inspected for: a) Bulges, dents, cuts, gouges, lamination, cracks, b) Corrosion - general corrosion or pitting is characterized by reduction in wall thickness over an area of the Gas Cylinder surface. It occurs externally and / or internally. Line chain or channel corrosion is characterized by internal and / or external linear pitting and is generally of limited width. c) Localized areas of corrosion that may occur externally or internally characterize as isolated pits. d) Other defects, such as illegible or unauthorized markings, fire damage, electric arc or torch burns unauthorized additions or modifications. 7.4.2.2 Internal Surface Inspection Internal inspection is performed using an inspection lamp of sufficient intensity to identify any internal defects. Gas Cylinder with internal corrosion shall be cleaned internally by, Doc. File No.: REG.Q.002. R1

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REV.1

Water jet abrasive cleaning, Flailing, Steam or hot water jet, Chemical cleaning. Internal surface of the Cylinder shall not be damaged during cleaning. After cleaning, the cylinders shall be inspected again.

7.4.2.3 Checking Cylinder Weight Weighing is performed against the stamped tare weight of the Gas Cylinders, for checking weight loss occurred due to Corrosion, during usage. a) The tare weight of the cylinders used for permanent gases does not include the mass of the Gas Cylinder valve. b) The tare weight of cylinders used for liquefiable gases includes the mass of the Gas Cylinder valve(s) and all permanent fittings. Any Gas Cylinder having a tare weight less than 95% of the original tare weight, shall be deemed unfit for further service and be destroyed. When there is a disparity between the actual and stamped tare weight, unrelated to excessive corrosion, the correct tare weight shall be established in consultation with TPI authority. The established tare weight shall be marked on the cylinder and the originally marked tare weight obliterated. Where a new or reconditioned valve is fitted, a damaged shroud, base ring or other attachment is replaced, the Gas Cylinder tare shall be established. If this tare weight differs from the marked tare, the latter shall be obliterated and the correct tare marked permanently and legibly. 7.4.2.4 Inspection of Gas Cylinder Neck Threads During internal inspection the internal neck threads of each Gas Cylinder shall be inspected to ensure that they are of full form, clean and free from burrs and other imperfections. 7.4.2.5 Inspection Of Valves Each Valve shall be inspected, tested and maintained to ensure satisfactory performance. The Valve stem and outlet threads shall be checked to ensure that thread diameter, form, length and taper comply with appropriate Standard. Excessive thread damage or serious deformation of the Valve body, Hand-wheel, spindle or other components shall be the criteria for replacement of the components or the Valve assembly. 7.4.3

Pressure Test Requirements Each Gas Cylinder (except acetylene Cylinders) shall be periodically subjected to either a hydraulic proof pressure test or a hydraulic volumetric expansion test as per applicable standard. The test pressure to be applied shall be that stamped on the cylinder.

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Normally a pressure test shall be carried out. However in the following circumstances, volumetric expansion test may be carried out. a) For Gas Cylinders used in corrosive environment, b) In case of any doubt arising from the inspection of the Gas Cylinders. c) At the discretion of the Company that decides to use volumetric expansion test. 7.4.4

Control Of Non Conforming Gas Cylinders The owner, user and the gas supplier (filler) shall follow documented procedures for control of non-conforming Gas Cylinders as per the provisions of applicable standards. a) Each Organization shall ensure that all incoming and outgoing Gas Cylinders, found unacceptable, are prevented from further use. Such cylinders that have been identified as unacceptable shall be clearly marked and segregated to the Quarantine area awaiting necessary action. b) It is recommended to compare findings of the periodic inspection and testing with the Guidance on rejection limits set by the standards. Cylinders approaching the rejection limits shall be removed from the service and sent to Quarantine area awaiting necessary action. c) Any Gas Cylinder showing a weight loss due to corrosion, which is more than 5 % of the original tare weight of the cylinder, shall be deemed unfit for further service and sent to Quarantine area awaiting necessary action. d) Cylinders, which are in use/operation and due for the periodic Hydraulic Testing, shall be removed from the service, segregated and necessary testing shall be arranged for them. e) Cylinders, which are deemed unsuitable for further service, shall be destroyed as per the procedure laid down in the standard. (Refer Clause 13 BS 5430)

7.4.5

INSPECTION AND TESTING STATUS Inspection and test status of the gas cylinder shall be clearly indicated on the gas cylinders by suitable means to clearly distinguish accepted cylinders from the rejected ones.

7.4.5.1 Receiving inspection Cylinders shall be suitably marked to indicate the result of inspection and verification. It is recommended to use colour coding or tagging system for the purpose. 7.4.5.2 Periodic Inspection & Testing After satisfactory completion of periodic inspection and testing, Gas Cylinders shall be permanently and legibly marked adjacent to the previous inspection and test marks. The typical marking shall be as follows, a) the symbol of the Testing Station, Doc. File No.: REG.Q.002. R1

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b) the date of test (which may be indicated by the month and year or by the year followed by a number within a circle to denote the quarter of the year) c) 7.4.5.3 Re-filling (Inspection Release Note) The Filling Company shall prepare and issue Inspection Release Note along with the filled Gas cylinder to the QGPC or its contractors. One copy of Inspection Release Note shall be retained at filling company for records of each gas cylinder delivered. (See the Appendix-A) 7.4.5.4 Hydraulic Testing (Test Date Discs) It is a mandatory requirement to fit Test Date Discs of Typical Shape and Colour, around the Neck of each Cylinder, which has been Hydraulically Tested and inspected. This will enable withdrawal of the Cylinder from service in the Year in which it falls due for the statutory Testing and Inspection. (See the Table 2) It is the responsibility of the Filling Station to ensure that the Cylinders are fitted with the Date Discs, before the cylinders leave the premises of the filling company. Table-2: Recommended Test Date Discs for Containers

7.4.6

Year of withdrawal

Colour and shape of test date disc on containers to be tested during the year indicated in column-1 Shape Colour

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Circular Hexagonal Hexagonal Hexagonal Hexagonal Hexagonal Hexagonal Square Square Square Square Square Square Circular

Aluminium Red Blue Yellow Green Black Aluminium Red Blue Yellow Green Black Aluminium Red

Inspection And Testing Frequencies All Gas Cylinders shall subject to periodical inspection and testing by the company inspectors or by the QGPC approved certifying authority surveyors. The periodic inspection frequency is as per the relevant standard and these regulations. The Owner, User, Filler are responsible for ensuring that inspection and testing are carried out at specified intervals. Doc. File No.: REG.Q.002. R1

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The inspection frequencies depending upon the type of gases and cylinders are prescribed in Table 3. 7.4.6.1 Inspection Frequencies For Acetylene Cylinders Inspection and Testing of Dissolved Acetylene Cylinders shall be subject to the Provisions of BS EN 1800: 1999. All cylinders, before being charged with acetylene, shall be subjected to periodic inspection as per the following intervals: a) Those containing high-porosity lime silica porous substance, after Twelve months of issue into service and thereafter at intervals of Five years. b) Those containing other porous substances, at intervals of Twelve months. Gas Cylinders due for inspection/tests shall be primarily identified from the permanent records maintained by the owner/filler. Alternatively, this may be achieved by the use of colour ring or date disc, located between the valve and the neck of the cylinder or the dates stamped on the gas cylinder. 7.4.6.2 Inspection Frequencies For Seamless Aluminium Alloy Cylinders Inspection intervals and survey requirements for offshore and onshore seamless aluminum alloy cylinders shall be as per the provisions of BS 5045 Part 3.

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Table No.3: Inspection and Test Frequencies for Gas cylinders (excluding Fire & Safety appliances) S.No

Gas Type / Service

1

Permanent gases e.g. oxygen, argon, nitrogen, hydrogen, air, helium, xenon, krypton, neon, boron tri fluoride Corrosive low pressure liquefiable gases, e.g. boron trichloride, carbonyl chloride, chlorine, chlorine trifluoride, hydrogen fluoride, hydrogen sulfide, nitrogen tetroxide, nitrosyl chloride, sulphur dioxide Non-corrosive high-pressure liquefiable gases, e.g. Ethane, Ethylene, Nitrous oxide, Sulphur hexafluoride, Chlorotrifluoromethane, Bromotrifluoromethane. Non-corrosive low pressure liquefiable gases, e.g. Ammonia, Butadiene, Butane, Dimethylether, Ethyl-amine, Ethyl-chloride, Ethylene-oxide, Refrigerant gases, Methylamin, Dimethylamine, Trimethlamine, Methyl bromide, Methyl chloride, Propane, Cyclopropane, Propylene, Vinyl chloride. Carbon dioxide (excluding fire extinguishing purposes) Gas Mixtures

2

3

4

5 6

External Inspection, Internal Inspection & Hydraulic Pressure Test (years) 5

5

5

5

5 5

General Notes: a) There is no general requirement for user to return a gas cylinder for inspection if the contents have been not used and the inspection/test interval may have lapsed. However, user is responsible to ensure inspection and testing of the gas cylinder after the contents have been consumed. b) Gas Cylinder shall be subjected to external surface inspection & verification of pressure test requirements prior to every re-filling the gas. It is the filling company responsibility before re-filling the cylinders to verify the inspection and test marks on the cylinder and ensure that the statutory pressure test period has not lapsed. 7.5

MAINTENANCE REQUIREMENTS

7.5.1

Gas Cylinders The Users of Gas Cylinders shall set up a procedure for maintenance of Gas Cylinders. A preventive maintenance program shall be established in consultation with the respective inspection dept. A suitably qualified person shall be nominated for maintenance of Gas Doc. File No.: REG.Q.002. R1

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REV.1

cylinders. The cylinders, which require maintenance, shall be segregated, based on the inspection reports. The periodic preventive maintenance is recommended at least once a year to avoid failures and to ensure safety of operations. 7.5.2

Valves & Fittings Each valve shall be inspected and maintained so that it will perform satisfactorily during service. All threads shall be checked to ensure that the thread diameters, form, length and taper are satisfactory. If threads show signs of distortion, deformation or burring, these faults shall be rectified. Valves shall be replaced if there is excessive thread damage or deformation of the valve body, hand wheel, spindle or other components. Maintenance of the valve shall include general cleaning, and replacement of worn or damaged components and replacement of packing, where necessary. Where the use of lubricants is permitted, only those lubricants approved for specific gas service shall be used. Re-valving: Each Gas Cylinder shall be re-valved during the inspection of the valve using a suitable jointing material and applying torque appropriate to the service pressure. (Ref. Table 3, BS 5430, Part 2)

7.5.3

Painting and Coating Cylinder external surface requiring painting shall be cleaned by grit blasting to SA2 or SA3 (depending on type of paint) finish as appropriate. The painting shall be carried out as

Where necessary each Gas Cylinder shall be repainted in accordance with BS1089-3, BS EN1319 or BS 4001, Part 1 as applicable. Where the surface is protected by zinc coating, the application and thickness should be agreed between the customer (QGPC, affiliates) and the supplier (contractor). 7.5.4

Minor /Major Repairs Minor repairs such as reforming damaged shrouds, base rings and handles, which do not involve welding or heating of the pressure containing parts, can be carried out without subsequent heat treatment. Major Repairs Repairs involving welding or heating to the pressure containing parts shall be carried out only after the approval from competent engineer. A competent engineer who can ensure that the repairs will not significantly impair the integrity of the Gas cylinder shall approve repairs to be carried out as per relevant standard. a) Repairs including welding and de-denting shall be carried out by qualified person as per approved procedures. b) After hot work, the competent engineer shall make the decision for heat treatment. The heat treatment shall be carried out as per the approved procedure. Doc. File No.: REG.Q.002. R1

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c) After major repairs the gas cylinders shall be subjected to a hydraulic test at testing station and certified by one of the QGPC approved certifying authority. Records of any repairs (minor / major) and subsequent inspection/tests carried out for each gas cylinder shall be maintained for verification and review. 7.6

CALIBRATION REQUIREMENTS

7.6.1

General All the measuring instruments such as pressure gauges, weighing machines and thickness measuring gauges used for the gas cylinder inspection shall be periodically calibrated. A competent person shall carry the calibration as per established procedure and certificate issued by a recognised calibration agency and records shall be verified at the time of Audit. All Gauges shall carry calibration status with date of calibration and due date for next calibration.

7.6.2

Testing Stations Testing stations shall establish a procedure for periodical calibration of the instrumentation used for hydraulic testing and measuring weight of the gas cylinders. Records of such testing equipment and calibration shall be maintained. Each test equipment and instrumentation shall be clearly marked with date of calibration and next date of calibration (refer to General requirements Clause 7.6.1)

7.7

STORAGE & TRANSPORTATION

7.7.1

Handling & Storage

7.7.1.1 Handling, storage & delivery of gas cylinder are of critical concern to the QGPC, as majority of the damages and deterioration occur during these activities. Therefore Owners, Users & Fillers shall establish and implement a procedure for these activities. 7.7.1.2 Handling of the Gas cylinders should be as per the methods specified in the relevant standards

7.7.1.3 Storage of the Gas Cylinders shall only be done at the designated areas. Cylinders shall be vertically arranged with their valves in uppermost. Condition of the cylinders that are stored for longer duration without use, shall be checked at periodic intervals. The requirements for storage areas shall be as follows: a) Shall be away from general storage areas and only accessible to authorised personnel b) Shall be free from flammable material, heaters or source of direct heat. c) Shall be such that cylinders can be removed quickly in case of emergency and shall be easily accessible. d) Shall have designated places for separating Filled cylinders, empty cylinders and nonconforming cylinders. Doc. File No.: REG.Q.002. R1

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e) Shall have segregation of Cylinders as per the contents, which shall be stored in rows separated by passages for easy access. f) Shall have adequate fire extinguishing facilities and adequate ventilation. 7.7.1.4 The delivery (Receipt and Dispatch) from the storage area to the user as well as to the supplier shall be done through methods of authorisation (such as Delivery Notes or Manifest) and records of such activities shall be maintained. 7.7.2

Transportation The following minimum requirements shall be followed for transportation of gas cylinders at any location, a) Cylinders shall be handled with care and shall not be subject to rolling, dropping, dragging and shocks. b) Gas cylinders, whether empty or filled, should not be transported with any other material. Where required to be transported with other material, clear separation shall be ensured from other material. c) Transportation of Gas cylinder to offshore locations is permitted through certified Gas racks only. Cylinders shall be securely fastened in the racks and no ol ose Cylinders are allowed to be transported. d) Gas cylinders with differing contents shall not be transported together in a Gas rack.

7.7.2.1 Transportation by Road Vehicles, a) Cylinder shall be vertically and securely mounted during transport by road vehicles. Cylinders shall not project from the vehicle constraints. b) Vehicles for transportation of cylinders shall be clean and free from inflammable material. The vehicles shall meet national safety requirements as regards to accessories and performance. c) Each vehicle assigned for transportation of Gas cylinders shall be provided with at least two dry powder fire extinguishers of 12-Kg capacity each. d) Cylinders loaded on a vehicle shall not be subjected to direct effect of engine exhaust. Smoking in and around the vehicle is not permitted. e) The quantity of cylinders loaded on the vehicle shall not be more than the licensed capacity of the vehicle and the vehicle speed shall not exceed 60 km/hr. f) Vehicles loaded with filled Gas cylinders shall not be left unattended on any QGPC site. 7.8

TRAINING & QUALIFICATION NEEDS

7.8.1

General All the personnel involved in any activity related to the Gas cylinders shall be given the awareness training on the provisions of the regulations. The training should cover as a minimum, the usage, hazards, warning labels, storage, handling and transportation. Personnel performing activities that can affect the implementation of the regulations (such as, but not limited to, purchasing, maintenance & inspection) shall be trained adequately.

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REV.1

The personnel involved in the operation of gas cylinders shall be trained through internationally recognised Compressed Gas Safety Trainers (CGST). The training records shall be retained at personnel or administrative section. 7.8.2

Testing Stations Competent Person undertaking periodic inspection and testing of the gas cylinders shall be qualified through practical experience and training. A minimum qualification of secondary school diploma/certification or equivalent with a minimum of five years experience in the field is essential. A thorough understanding of the applicable Standards and Equipment is essential as a minimum prerequisite for the Competent Person. The Testing Station shall maintain records of the Training for Competent Personnel.

8.0 8.1

QUALITY ASSURANCE The Regulations identify the following activities pertaining to Gas Cylinders. A comprehensive procedure shall be established to cover following activities for effective implementation of the Regulations. a) b) c) d) e) f) g) h) i) j) k)

Implementation of the Regulations Purchasing Identification and Traceability Maintenance, Inspection and Testing Calibration Requirements Non conformities and Corrective & Preventive Measures Handling, Storage, Preservation and Delivery methods Quality Records Periodic Auditing Training and Qualification.

8.2

Internal Auditing

8.2.1

Owners, Users and Fillers of the Gas Cylinders shall establish a Procedure for Internal Audits of the area under their control (including contractors / subcontractors) to ensure that the requirements of the Regulations are being effectively implemented. Auditors independent of the area to be audited shall perform audit. Audit findings such as nonconformance/observations shall be recorded in Audit Reports and brought to the notice of the concerned personnel for initiating timely corrective and preventive actions. Implementation of the proposed corrective and preventive actions shall be verified through follow up audit at mutually agreed period. Records of the Audit findings shall be maintained for review at External Auditing.

8.2.2

QGPC QA Dept. shall arrange audits on the QGPC sites, contractors / subcontractors, suppliers, filling stations (termed as auditee) to verify effective implementation of the regulations. These audits shall be conducted with formal notification to the auditee. QGPC approved third party auditors shall carry out such audits.

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8.2.3

Auditee must cooperate with the auditor and provide any documents and assistance to execute such audits. Audit findings shall be recorded on corrective action requests and discussed with the concerned area representative for initiating timely Corrective and preventive measures. Follow up audits shall be conducted for verification of the corrective and preventive actions implemented by the auditee.

8.2.4

Audit findings, which are safety related, shall result in the Gas Cylinder being removed to Quarantine area until the necessary actions have been completed and the documents are available.

9.0

QUALITY RECORDS

9.1

Filling Company Records Filling Company (at Test Station) shall retain Inspection and test records of each Gas cylinder for not less than the interval between tests specified in Tables 1 and 2. The original records shall Appendix-A). For cylinders owned by a filling company the record shall include the following information as a minimum, a) b) c) d) e) f) g) h) i) j) k) l)

Owner Type of gas contained Serial Number Manufacturing standard/code Tare or empty mass as tested Inspection type Test pressure and method of test ( Volumetric or Proof ) Result of inspection / Test Test date and data as stamped Inspector / Supervisor Third Party company name (if applicable) Details of any modifications made to the Gas Cylinders

9.2

OWNER / USER RECORDS

9.2.1

Company Gas Cylinders Register Inspection Division shall maintain register of Portable and Fixed Gas Cylinder owned by the Company. The register shall be in the electronic data form and consists of two files as follows, I.) Gas Cylinders Data file shall have the following information (see clause11.3): a) b) c) d) e) f)

Type of gas Serial Number. Manufacturing standard/code Capacity. Tare weight as tested. Initial Test Data as stamped.

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g) Colour h) Allocation. i) WIN number (if applicable). II.) Gas Cylinder Inspection and Certification Data file should have the following information (see Appendix-D): a) b) c) d) e) f) g) h) i) j) k)

Serial number. Initial Pressure Test Certificate Number Initial Test pressure Next Inspection due date Next pressure test due date Inspection type Result of Inspection and/or test Date of survey Inspector Third party company name (if applicable) Details of any modification made on the Gas Cylinder

The registers shall be maintained and updated by Inspection Department and used for monitoring certification of Company owned Gas Cylinders. 9.2.2

Record The Compliance and Test Certificates in original shall be filed within Inspection Department and copies will be provided as required by the operational divisions. The record shall also have the Register of Portable and Fixed Gas Cylinder (computerized) at Inspection Division.

10.0

GAS CYLINDERS FOR FIRE & SAFETY APPLICATIONS

10.1

Gas Cylinders Classification and Use These Gas Cylinders are classified in two categories I.)

Portable & semi-portable Fire Extinguishers

The types of portable & semi-portable fire extinguishers in use on QGPC sites a) Water (Stored Pressure) b) Dry Powder (Cartridge type) c) Carbon dioxide The Use of Portable Halon fire extinguishers is prohibited on QGPC sites as per the Montreal Protocol. II.) Breathing Apparatus cylinders The following sizes are used in QGPC for Breathing Apparatus (BA) Doc. File No.: REG.Q.002. R1

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a) 2 Ltrs, 2.5 Ltrs, 3 Ltrs, 6 Ltrs, 9 Ltrs portable cylinders used in Breathing Apparatus Sets b) 50 Ltrs cylinders used in BA Cascade system. Note that Clauses 1 to 9 of the regulations apply to Breathing Apparatus Cylinders also. Clause10 deals with cylinders used for fire extinguishing purpose only. 10.2 Responsibilities Fire & Safety Department has the overall responsibility to monitor the implementation of these requirements on all QGPC sites as well as the contractors. The SF Dept. operation divisions ensure that gas cylinders in use in their operational areas comply with the requirements of these regulations. Contractors working for QGPC shall also comply with the same requirements. 10.3 Identification & traceability 10.3.1 Portable Fire Extinguishers Portable Fire Extinguishers shall be painted signal red as per ANSI/Euro Standard or as per British Standard BS 381C colour code specified as in the Table-4 below, Table 4. Colour Coding Extinguishing Media Water Foam Powder Carbon Dioxide 10.4

Colour Red Pale Cream Blue Black

BS 381C Ref 537 352 166 -

RAL Colour Ref. RAL 3000 RAL 9001 RAL 5002 RAL 9005

Inspection & testing

10.4.1 Periodic Inspection I.) Owners and users shall ensure that Fire Extinguishing Cylinders are inspected at least once a year as per the requirements of British Standard BS 5306 Part 3, Section 8 and any specific procedures recommended by the manufacturer. The inspection shall be performed by a competent person using recommended tools, material and equipment only. II.)

inspection and identifying mark of the competent person. It is recommended to colour code

and identifying mark of the competent person. It is recommended to colour code such elements with a green square mark.

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10.4.2 Periodic Testing &Discharge I.) All the Fire Extinguishing Cylinders shall be test discharged as per the requirements of British Standard BS 5306 PART 3, Section 9 as per the intervals given in Table 5. The test discharging shall be carried out at agencies approved by QGPC SF Department.

Table 5. Extinguishing Media Interval of Test Discharge Water (Stored Pressure) 4 Years Water (Gas Cartridge Type) 5 Years Powder (Stored Pressure) 5 Years Powder (Gas Cartridge Type) 5 Years Carbon Dioxide (All Types) 10 Years Note: These tests shall be carried out at the specified interval even if an additional test has been carried out intermittently due to replacement of some part. II.) The Fire Extinguishing Cylinders shall be re-examined and recharged after the Test discharging as per relevant clauses of section 8 and section 4 of British Standard BS 5306 Part3 respectively. Extinguishers that fail to operate satisfactorily shall be taken out of service. Date of recharging shall be marked on the fire Extinguishing Cylinders found satisfactory. 10.5

Maintenance Owners and users shall ensure that the Fire Extinguishing Cylinders are maintained as per the requirements of British Standard BS 5306 Part 3, section 8. The maintenance shall be carried out by a competent person using recommended tools, material and equipment.

10.6

Calibration Refer to clause 7.6 of the regulation

10.7

Records Owner/User (including the contractors) of Fire Extinguishing Cylinders shall computerised Database record of Portable and Fixed Fire Extinguishing Cylinders. The shall be in the electronic format consisting of two files i.e. Gas Cylinder Data and Gas Inspection and Certification Data. Records of any maintenance carried out on Extinguishing Cylinders shall also be maintained.

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maintain database Cylinder the Fire

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GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002 11.0

APPENDICES

11.1

APPENDIX A

REV.1

INSPECTION RELEASE NOTE NOTE: Header Shall Have Name & Full Address Of The Filling Company

INSPECTION RELEASE NOTE OWNER /USER :

IRN NO: DATE :

GAS CYLINDER (TYPE) : CYLINDER SERIAL NO:

MANUF. SPEC.

GAS CONTENTS

INSPECTION STATUS Physical Condition: (Internal & External Surface)

TARE WEIGHT (ACTUAL KGs.)

IN

CYLINDER CAPACITY (in Cubic Meters)

TEST DATE DISC DETAILS (AS PER TABLE-2, Section-7.4.5)

PRESSURE TEST DETAILS Working Pressure : Test Pressure : Date Of Test : Test Status : Passed/failed

EXPANSION TEST DETAILS :

LAST DATE OF INSPECTION: DUE DATE OF INSPECTION :

LAST DATE OF HYDRO TEST : DUE DATE OF HYDRO TEST :

COLOUR CODE DETAILS

REFERENCE STANDARD

REMARKS: FILLING COMPANY (INSPECTION DIVISION)

Third Party Signature &Seal (Only for Hydro test witness)

Name Of The Inspector: Signature:

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REV.1

APPENDIX B REQUEST FOR WAIVER

SPONSORING DEPT. REPRESENTATIVE

Telephone No.:

Name:

Fax No.:

Signature:

Designation:

FOR QGPC DEPARTMENTS AREA OF OPERATION (tick as appropriate & write section underneath)

OFFSHORE FIELDS PS1

PS2

PS3

FOR CONTRACTORS PROJECT / COMPANY CONTRACT NAME NO.

PS4

ONSHORE FIELDS HALUL

MESSAIEED

REPRESENTATIVE

DUKHAN

AREA OF OPERATION

ONSHORE

OFFSHORE

ID NO.

CERTIFICATE NO.

EQUIPMENT DESCRIPTION

PERIOD WAIVER REQUIRED: FROM: REASON FOR REQUESTING THIS WAIVER:

NODCO

OTHERS (specify)

TO:

APPLICABLE CLAUSE OF QGPC-REG-Q-002: RESTRICTION PARAMETER TO BE IDENTIFIED TO ENSURE SAFE OPERATION:

REVIEW BY SAFETY DEPARTMENT:

Agreed by:

Operation Dept. Representative

Agreed by:

QAA/3

Approved by:

Signature:

Signature:

Signature:

Date: Enclose: Inspection Release Note

Date:

Date:

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OM / DR Manager

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11.3

REV.1

APPENDIX C GAS CYLINDER DATA FILE (Computer Update periodically)

CYLINDER SERIAL NO:

MANUF. SPEC.

TYPE OF GAS CONTENTS

TARE WEIGHT ACTUAL-(KGs.)

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CYLINDER CAPACITY (Cubic Meters)

INITIALTEST DATA AS STAMPED

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COLOUR

ALLOCATION

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WIN NUMBER (If applicable)

GAS CYLINDER TECHNICAL REGULATIONS DOC. NO.: QGPC-REG-Q-002

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APPENDIX D GAS CYLINDER INSPECTION AND CERTIFICATION DATA FILE (Computer Update Periodically)

CYLINDER SERIAL NO.

INITIAL PRESSURE TEST CERTIFICA TE NO.

INSPECTION DUE DATE

PR. TEST DUE DATE

INSPECTION TYPE

TEST PRESSURE

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RESULT OF INSPECTION OR PR. TEST

DATE OF SURVEY

INSPECTOR IN HOUSE

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TPI

DETAILS OF MODIFICATION

GAS CYLINDER REGULATIONS DOC. NO.: QGPC-REG-Q-002

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APPENDIX E REVISION HISTORY LOG Revision Number:

Item Revised

Reason for Change: Changes Made:

Item Revised

Reason for Change: Changes Made:

Item Revised

Reason for Change: Changes Made:

Note: The revision history log shall be updated with each revision of the document. It shall contain a written audit trail of the reason why the changes have occurred, what the changes were, and the date at which the changes were made.

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Custodian Dept. : FQAD