Risk Assessment

A guide to the safe storage anduse of oxygen and dissolvedacetylene equipment

2Introduction

From the 1st October 2006 the Regulatory Reform (Fire Safety) Order 2005 (RRO) was brought into force, this revoked the FirePrecautions (Workplace) Regulations 1997. Whilst many of the new requirements are similar they now have a broaderapplication as they apply to virtually all premises, other than domestic premises, whether or not such premises are a place ofwork. In addition the Order contains specific provisions relating to the dangerous substances which are similar to thosecontained in the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSERA). This includes acetylene due toits flammability.

One of the key changes in the new requirements is the introduction of a general duty to minimise the risk of fire, as well as totake precautions to ensure the safety of persons should a fire occur. As was the case under the previous legal requirements,there is also a risk assessment duty. Critically, the RRO contains a specific duty on the “responsible person” to take general fireprecautions to ensure the safety of employees, so far as is reasonably practicable.

To view the Regulatory Reform (Fire Safety) Order 2005 please visit www.opsi.gov.uk/si/si2005/20051541.htm

To view the Dangerous Substances and Explosive Atmospheres Regulations 2002 please visitwww.opsi.gov.uk/si/si2002/20022776.htm

Every day thousands of gas cylinders are used in the workplace or transported by road without incident. However, if gascylinders are involved in a fire and one of these is suspected of being an acetylene cylinder, it can cause serious localdisruption due to the setting up of a cordon around the incident scene.

Most of the reported incidents would not have happened if users:

• Fully understood the properties of the gases and the associated hazards

• Were properly trained on how to use oxygen and dissolved acetylene equipment

• Followed guidance on the safe handling and storage of gas cylinders

Three separate model risk assessments have been produced in order to assist your business in managingthe hazards associated with the following activities:

1 Indoor oxygen and dissolved acetylene package storage

2 Outdoor oxygen and dissolved acetylene package storage

3 Oxygen and dissolved acetylene package use

The risk assessment can be copied if your business has a number of oxygen and dissolved acetylenepackages.

NOTE: The oxygen and dissolved acetylene package referred to in this document typically consists of anoxygen cylinder, acetylene cylinder, gas regulators for both gases, flashback arrestors fitted toboth regulator outlets, oxygen and dissolved acetylene hose assembly, gas torch and cylindertrolley.

INTRODUCTION

3How do you rate risk?

How to carry out the assessment

The risk assessment should be carried out by a competent person who has been trained in the use of the equipment.It shouldn’t take too long to complete.

1 Select the Risk Assessment form for the activity to be risk assessed from this guide.

2 Enter details in required fields at the top of the Risk Assessment form.

3For each Situation/Activity record the existing control measures in place beside each of the applicable recommendedcontrol measures.

4Based on a comparison of the existing control measures in place against the suggested control measures stated carryout risk rating for each situation/activity by entering a rating of Low, Medium or High for both the Severity and theLikelihood.

5

Using the Risk Rating Matrix above, determine the level of risk and enter the result in the Risk Rating column.Examples:1. If Likelihood is Low, and Severity is Medium, Risk rating is Low.2. If Likelihood is High, and Severity is Medium, Risk rating is High.

6

Decide the result for level of control and enter it onto the Risk Assessment form in the appropriate column (Result).There is a link between the Risk Rating and the Result as follows:Risk Rating = Insignificant, Result is likely to be Adequately Controlled.Risk Rating = Low Risk, Result is likely to be Adequately Controlled or Minor Residual Risk.Risk Rating = Medium Risk, Result is likely to be Minor Residual Risk or Not Adequately Controlled.Risk Rating = High Risk or Severe Risk, Result is likely to be Not Adequately Controlled.

7If the result is "Not Adequately Controlled" decide what action is required to reduce the risk to as low as reasonablypracticable (ALARP) and record the same in the Remedial Action column.

8 Do not continue with the activity until risk is reduced to as low as reasonably practicable (ALARP).

Risk is a combination of the likelihood of an incident occurring and the severity of the injury or loss due to the incident. TheLikelihood versus Severity Matrix below is a means for rating risk.

Likelihood Based on the precautions/controls in place to prevent an incidentoccurring.

High Where no precautions are put in place and the employee can only avoid anincident by following verbally communicated procedures - which typicallyare only short term.

Medium Where the employee can only avoid an incident by working carefully,following training, work instructions and safety procedures.

Low Engineering controls such as Flashback Arrestors and Non Return Valvesminimise the likelihood.

Severity The degree of injury to the employee or third party, or the cost of loss dueto property damage.

High Death or disabling injury.

Medium Serious injuries requiring medical treatment and time off from work.

Low Minor injuries.

Med

ium

Low

High

LIKEL

IHOOD

Low

SEVERITY

RISK RATING

Medium

Low

Insignificant

Medium

High

Medium

Low

High

Severe

High

Medium

HOW DO YOU RATE RISK?

4Model Risk Assessment for the Indoor Storage of an Oxygen and Dissolved Acetylene Package

Use page 5 to record your results

5Model Risk Assessment for the Indoor Storage of an Oxygen and Dissolved Acetylene Package

6Model Risk Assessment for the Outdoor Storage of an Oxygen and Dissolved Acetylene Package

Use page 7 to record your results

7Model Risk Assessment for the Outdoor Storage of an Oxygen and Dissolved Acetylene Package

8Model Risk Assessment for the Use of an Oxygen and Dissolved Acetylene Package

Use page 9 to record your results

9Model Risk Assessment for the Use of an Oxygen and Dissolved Acetylene Package

10Model Risk Assessment for the Use of an Oxygen and Dissolved Acetylene Package

Use page 11 to record your results

11Model Risk Assessment for the Use of an Oxygen and Dissolved Acetylene Package

The stripe symbol and the letters BOC are registered trade marks of The BOC Group plc. Both BOC Limited and The BOC Group plc are members of The Linde Group, the parent company of which is Linde AG.Reproduction without permission is strictly prohibited. © BOC Limited 2007 206165/0907

For product and safety enquiries please phone

In the United Kingdom

0800 111 333In the Republic of Ireland

Dublin (01) 409 1800

Email us at: custserv@boc.com

BOC, Customer Service Centre, Priestley Road, WorsleyManchester M28 2UT, Fax: 0800 111 555

BOC Ireland, P.O. Box 201, Bluebell, Dublin12, Fax: (01) 409 1801

www.bocindustrial.co.uk

Further reference

British Compressed Gases Associationwww.bcga.co.uk

GN2 Guidance for the Storage of Transportable Gas Cylinders for Industrial Use. Revision 3: 2005.

CP31 Safe Storage and Use of Cylinders in Mobile Workshops and Service Vehicles.

CP7 The Safe Use of Oxy-Fuel Gas Equipment (Individual Portable or Mobile Cylinder Supply). Revision 4: 2004

Health and Safety Executivewww.hse.gov.uk

INDG 163 Five steps to a risk assessment

INDG 308 The safe use of gas cylinders

INDG 327 Take care with acetylene

HSE 8 (rev2) Take care with oxygen

HSG 139 The safe use of compressed gases in welding, flame cutting and allied processes

BSI Groupwww.bsi-global.com

BS EN ISO 2503:1998 Gas welding equipment. Pressure regulators for gas cylinders used in welding, cutting and allied processes up to 300 bar.

BS EN 559: 2003 Gas welding equipment. Rubber hoses for welding, cutting and allied processes.