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Oxy-Fuel Audit (Volume 6)

Company Name Date

Address Postcode

Tel

H&S Manager Tel

email

Auditor Name Signature

Company Tel

Address postcode

Asset Number

Asset Description

Asset Location

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e-learningon site open workshop

This audit is provided as a guide to risk assessment, it does not remove the need for technical management judgment in all situations

Interactive Audit Guidence

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Useful LinksKnow Your Acetylene pdfKnow Your Oxygen pdfFind A CP7 InspectorPGS Oxy-Fuel e-learningPGS Oxy-Fuel Open coursesPGS Oxy-Fuel Onsite courses

General Observations YES NO

System

CP7 inspection in date

Free from PTFE tape

Free from jointing compounds & sealants

Practices & Procedures

Hoses coiled or wrapped around cylinderswhen not in use Suitable working pressures known and correctly set

Pre light up checks

Procedure available & adhered to

Hoses purged prior to light up

Serviceable spark lighter available

Shut down procedure

Procedure available & adhered to

Leak checks Approved leak detector solution available & used NO soaps in use

Fire extinguisher

Dry Powder or CO2 extinguishers available

Operators trained in use

Material safety data sheets

Available

PPE available for use in welding & allied processes

Safety goggles (clear) to BS EN 166

Filters used in eye protection to BS EN 169

Protective clothing to BS EN 470-1

Equipment for eye & face protection to BS EN 175

Ultra violet filters to BS EN 170

Infra red filters to BS EN 171

Notes:

FR

FR FR

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General Observations YES NO

Unattended Cylinders

Key left in closed position

Regulator showing no pressure on any of the gauges

No gas flowing when torch switched on

OperatorsHave they had appropriate safety training

Are training records up to date

Cylinders YES NO

Cylinders

Correctly labelled

Correctly colour coded

Upright & secured

Valve outlets clean & uncontaminated

Regulators YES NO

Correct regulator attached for the gas in useIt is a legal requirement to only use equipment marked for use with acetylene

Pressure Adjustment Screw

Labelled

Maximum inlet pressure appropriate

Maximum outlet pressure appropriate

Manufacturers name/logo

Fixed to body

Operates freely

Body

Undamaged

Standard marked BS EN 2503

Date stamp under 5 yrs (or manufacturers recommendation)

Useful LinksCylinder Disposal Know Your Cylinder PDF

Notes:

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0.5

1.0

bar

1.5

psi ISO

5171

ACETYLE

NE5

10

15

20

510

15

20 bar 2530

35

40

psi

100

200300

500

400

ISO

2503

ACETYLENE

MAX. INLET:25 bar

DECREASE

INCR

EASE

2.5

ISO 5171ACETYLENE

Notes:

Useful LinksRegulator date codes Know Your Regulator poster

Regulators YES NO

Bullnose

Undamaged

Threads undamaged

Clean uncontaminated

90° to body

Tightening nut undamaged

No unauthorised modifications

Outlet Connection

Threads undamaged

Clean uncontaminated

No unauthorised modifications

Pressure Relief Valve

In place

No unauthorised modifications

Internal- outlet opening free from obstruction

Gauges

In place; correct type

Appropriate high pressure & low pressure gauges marked ISO 5171 or EN 562

Undamaged; No unauthorised modifications or PTFE

Needles start at zero; positioned at correct side of stop; unbent; scale backing plate undamaged & allows free movement of the needles

Backs in place & clear covers

Replacement Interval

Date stamp or code under 5 years or manufacturer's recommendation

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Flashback Arrestors and Non-Return Valves

Flashback Arrestors will always contain integral Flame Arrestors and may also contain Cut-Off Valves; individual Flame Arrestors, Non-Return Valves (or Hose Check Valves) may also be used where required

Oxygen and Flammable Gases YES NOIf oxygen and flammable gases are used, has the need for flashback arrestors and non-return valves been assessed?Inert gases do not require Flashback arrestors

Oxygen flammableused together with source of ignition present

Non return valves (NRV) present in the process equipment connection in the hose assembly.

FBA and NRV at regulator outlet connection prestent

When using acetylene a FBA shall always be in use.When using oxygen or other flammable gases individually with no source of ignition an FBA is optional.Inert gases do not require NRV. Refer BGA CP47

Flashback Arrestor Checks

Body Undamaged, standard marked ISO 5175(before 19.12.2017 EN 730-1)

Connections Clean; uncontaminated; no PTFE

Pressure Rating Legible; suitable for cylinder

Replacement interval

Date stamped under 5 years or manufacturer's recommendation

Reset Button (where applicable)

Not tied down, restricted, modified or damaged

Pressure Systems Safety Regulations (where applicable) YES NO

Are systems subject to the pressure systems safety regulations

Are systems designed, assembled and constructed in accordance with the current issue of those regulationsRefer to Pressure Systems Safety Regulations 2000 from the HSE

Useful LinksFlashback Arrestor Date CodesFlashback ISO UpdatePSSR 2000

Notes:

ISO

Before 19.12.2017EN 730-1

After 19.12.2017ISO 5175-1

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Flashback Arrestors Standard UpdateGas Welding Equipment Safety Devices incorporating a flame (flashback) arrestor BS EN 730-1:2002 has been replaced by BS EN ISO 5175-1:2017 Flashback arrestors purchased from 2018 may now be seen with the new number ISO 5175-1

Flashback Arrestors (FBA) These should be used where oxygen & fuel gas are in use supplying the same equipment or process. The fitting of a FBA is mandatory when acetylene is the fuel gas. 5 Year Life• Replace flashback arrestors every 5 years or according to manufacturer’s recommendations. • Check the manufacturer’s date stamp or coding. • As with regulators not all manufacturers may date the flashback arrestors.• If the code is not present ascertain from purchase records or management whether the FBA is under 5 years old. - If in doubt replace. Before Use Flashback Arrestor Checks• Appropriate for the gas in use.• The body is free from damage, contamination & correctly labelled.• Conforms to ISO 5175: *BS EN 730-1 *December 2017 updated to BS EN ISO 5175-1.• Connections free from oil, grease, PTFE tape & other contamination.• Appropriate Maximum Working Pressure of the FBA.• Reset button or lever check for gas flow in the operating position. If there is no gas flow, check for signs of damage caused by previous flashback on the FBA or any attached hoses & regulators.

FLASHBACK ARRESTORSSTANDARD UPDATE

Nationally Accredited safety training for the users or compressed & cryogenic gases

ISO

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Useful LinksBCGA CP7 BCGA CP4 Manifold

Hose Checks YES NO

Correct colour code for the gas type in useEntire length undamaged

Marked to the correct Standard

BS EN ISO 3821:2010 Rubber (for Welding & Cutting Applications)BS 3212-1 (Low Pressure) or 3212-2 (High Pressure) Propane (for single-gas applications; NOT suitable for mixed-gas applications such as welding and cutting) BS EN 1327 ThermoplasticBS EN ISO 14113 Rubber & Plastic Hose Assemblies (450 bar)

Protected from damage & entire length visible

Hose LengthNo longer than is necessary for the task in hand(If long lengths are often required consider permanent piping - see BCGA CP4)

Hose Connections

Marked to the correct

standard

BS EN 560 Hose ConnectionsBS EN 561 Quick Action CouplingsBS EN 1256 (the complete hose assembly standard but it is rarely marked on the hose)

Free from re-usable worm wheel-drive clips (‘Jubilee’ clips)Free from contamination, oils, greases etcFree from PTFE tape on connections/joints

NO PTFE taped joints should not be used on hoses

O’clips & PTFE tapeare bad practice as shown here

Non-Standard Hoses to Process Equipment

Manufactured and tested to BS EN 1256 or BS EN ISO 14113NOTE: Many different types of metal, rubber or plastic tubing, hose and pipe are employed in laboratory applications – it is not possible to list all possibilities here. It is the duty of the user to ensure that such tube/hose/pipe is suitable for the purpose for which it is used.Refer to BCGA CP47 & CP4 for further information

Repairing hoses is not recommended; if in doubt replace the entire hoseAnti-whip Cable

Attached to cylinder & fixed point where fitted

Notes:

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Torch YES NO

Blowpipe(Torch)

Designed for the gas and application

To BS EN5172, undamaged and fit for purpose

Nozzle

Correct size used for application

Undamaged

Fit for purpose

Suitable for application & torch

Contaminants YES NO

Is the systemfree from:

PTFE tape

Jointing compounds

Sealants

Oils and GreasesAny hydrocarbon-based contaminant poses a risk of ignition if it comes into contact with pressurised Oxygen

CP7 Inspection YES NO

CP7Inspection

Is the system marked with the expiry date of the last CP7 InspectionIs a record kept of these inspectionsIs the use of this equipment such that more frequent inspections should be considered

An CP7 Inspection is the minimum required by BCGA CP7. Contact Proactive Gas Safety Ltd if you require staff to be trained to undertake these inspections on behalf of your Company

Cylinder Security & Protection YES NO

Evacuation

Is an emergency evacuation plan available and understood by staffAre Assembly Areas known to employeesDo you have a procedure to inform neighbouring premises within a 200m radius of a potential gas cylinder incident

Note: For gas cylinders involved in fires the Emergency Services would consider 200m as the possible minimum distance for evacuation. The local Fire Service may be able to advise you on the area to consider and any procedure to adopt

Useful LinksKnow Your Welding- DownloadCP7 Inspection Course Find A CP7 Inspector

Notes:

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Frequently Asked QuestionsYESNOQ - What inspections must be made to our Mobile Oxy-Fuel gas systems?CP7 Inspection:Mobile Oxy-Fuel Gas systems should be checked at least annually by an operator deemed competent by local management and with the relevant experience.Written Record: A written record should be kept of these Inspections.Before Use Checks:All operators should check equipment before use.Q - We have no records of CP7 Inspections - what should I do?Solution:Contact Proactive Gas Safety Ltd Q - Before Use Check - how do I know if this is NOT being done?Some Warning Signs:Hoses wrapped around cylinders when in use.Unattended cylinders left with one or all the following:• Cylinder key in ‘open’ position• Regulator showing pressure on one or more gauges• Gas flows when the Torch valves are opened.No approved Leak Detecting Fluid in usePTFE tape being used on Regulator and/or hose fittingsWorm-wheel drive (‘Jubilee’) clips being used on hose fittingsRegulators:• In use when more than five years old or exceeding manufacturers

recommended life • Damaged or in poor condition• Cigarette lighters or other ignition sources being used in place of

proprietary spark lighters for lighting up torches • Free-standing or unsecured cylindersSolution:Refer operators to PGS Industrial Gas Users Handbook Pages 21-25 or PGS Before Use and Safe Light-Up/Shutdown Checklist

Useful LinksRegulator date codes Purchase TestkitPGS Inspection coursesBCGA CP7