Published on August 18, 2010
Slide 1: 1 WELCOME To TECHNICAL “KNOWLEDGE SHARING SESSION 1” Slide 2: 18-Aug-10 2 KPCL SUBJECT : HANDLING OF OXYGEN GAS AND OXYGEN MEDIA RELATED COMPONENTS AND SERVICE EQUIPMENT Special Instructions : Special Instructions For oxygen handling services Oxygen is not combustible, but supports combustion. Hence combustible matter is not to be stored in close vicinity of pressurized oxygen. Hydrocarbon deposits, oil contamination on oxygen handling pipes / surfaces can cause fire. Avoid handling of oxygen components by bare hands. Normal hands also have oil deposits and can lead to fire / explosion hazards. Wear gloves while handling oxygen components. 18-Aug-10 3 KPCL To Be Continued…. : Wear head shower caps while working on oxygen components. Even hair oil contamination can lead to dangerous situation. Always wear full body cover aprons / personal wear while handling oxygen tubing / components. Cleaning of tubes is must for oxygen services. Use prescribed solvent / cleaning agent for cleaning. Always check cleanliness level with UV light source before assembly. Do not open packing of oxygen service pre-cleaned components in a room other than clean room. 18-Aug-10 4 KPCL To Be Continued…. Slide 5: Always cap the open ends of valves and fittings with clean plastic caps. If in doubt clean the component once again before assembly. Use clean / oil free / compressed air for blowing cleaning. Use of cotton waste/ cotton rags is prohibited. Instead use lint free cloth. Wear UV protection goggle when checking cleanliness level of components by UV source. Use tools / tackles those have been cleaned with solvent. Use of lubricant oil / grease is prohibited. . 18-Aug-10 5 KPCL To Be Continued…. To Be Continued…. : Use CRATOX or equivalent grease for sliding (tools) e.g. adjustable spanners. Clean all tools before assembly and after assembly. As far as possible avoid using adjustable spanner, instead use side / ring spanners of exact size. For tubing purpose after cutting and bending operation deburr the tubing and clean the tube piece in solvent before assembly. If in doubt, ask an expert before arriving at any decision. Refer to material safety data sheet (MSDS) for handling and other safety instructions 18-Aug-10 6 KPCL To Be Continued…. Slide 7: 18-Aug-10 7 KPCL CLEANING OF ITEMS Special instructions (for operation of unit) Handling of Oxygen demands special training. Only trained person should be allowed to operate the unit. The bottle should not be filled with any gas other than Oxygen. The oxygen cylinders fitted on the unit are to hydro-tested after an interval of 5 years. Smoking is strictly prohibited while working on this unit. Also No naked flame is allowed in vicinity 10 m from of the unit. When the unit is charged to full pressure with medical grade oxygen, do not carry out any repair activities such as welding, grinding (in which case there are chances of sparks). Release the oxygen gas slowly and then prepare the unit for repairs. To Be Continued…. : 18-Aug-10 8 KPCL While opening and closing valves for oxygen service, great care needs to be exercised. Too rapid closing / opening of oxygen valve cause sudden expansion / compression and may lead to fire. Do not release the pressure inside piping and tubing suddenly. Never open any valve, fitting or tubing for maintenance / troubleshooting unless it is ensured that the pressure inside has been relieved totally. Also Never tighten up threaded joints of the Oxygen system under pressure If any hissing sound is heard form components, tubing or fitting. It is indicative of leakage. Check the leakage with a soap solution and arrest the leakage. In case of triggering of Fire detection / fighting system, the inside volume of the unit will be flooded with CO2 gas. Do not operate the unit or stand in close vicinity of the unit. The expelled CO2 gas can cause suffocation / asphyxia. To Be Continued…. To Be Continued…. : 18-Aug-10 9 KPCL After a fire / explosion incident, the unit will need a major inspection, a leakage test and an operational test. Do not attempt to start the unit unless these tasks are completed. When attending the unit, please wash your hand with soap and plenty of water before touching any oxygen gas service item. Wearing of gloves is suggested. During the boosting operation, over-pressurization may occur. The unit is provided with safety relief valves. If the relief valve pops up during the operation, abort the boosting operation. Close Oxygen cylinder valves on Units as well as cascade and relieve excess pressure through set of drain valves. Also electrical safety in terms of pressure switches is provided, This will stop the booster immediately. Whenever any item is removed for inspection / cleaning, cap the open ends of valves and fittings with clean plastic caps. Before refitting any component, clean the component, blow with clean and dry nitrogen and then re-fit onto the unit. To Be Continued…. To Be Continued…. : 18-Aug-10 10 KPCL Check the condition of High pressure hoses daily. Any damage to the external sheath, should be reported immediately. The hoses used for connecting the unit to end application as well as external oxygen source are to be flushed for 3-5 minutes just before use. This will remove contaminants from inside of hose. If in doubt, ask an expert before arriving at any decision. To Be Continued…. Slide 11: 18-Aug-10 11 KPCL INTRODUCTION TO DESIGN OF CLEANROOM What is cleanroom? According to Federal Standard 209E: “A room in which the concentration of airborne particles is controlled and which contains one or more clean zones.” According to ISO 14644-1: “A room in which the concentration of airborne particles is controlled, and which is constructed and used in a manner to minimise the introduction, generation, and retention of particles inside the room and in which other relevent parameters, e.g. temperature, humidity, pressure, are controlled as necessary.” CLASSIFICATION OF CLEANROOM : 18-Aug-10 12 KPCL CLASSIFICATION OF CLEANROOM According to Federal Standard 209D: Federal Standard 209 Classification 1 10 100 1000 10000 100000 No. of particles/ft^3 0.5 µm 1 10 100 1000 10000 100000 Slide 13: 18-Aug-10 13 KPCL CLASS OF ROOMS REQUIRED BY DIFFERENT INDUSTRIES Class 1 These rooms are used by integrated circuit manufactures manufacturing sub-micron geometries. Class 10 These rooms are used by semiconductor manufacturers producing integrated circuit with line widths below 2µm. Class 100 Used when bacteria-free or particulate-free environment is required in the manufacture of aseptically-produced injectable medicines. Required for implant or transplant surgical operations. Isolation of immunosuppressed patients, e.g. after bone marrow transplant operations. Slide 14: 18-Aug-10 14 KPCL To Be Continued…. Class 1000 Manufacture of high quality optical equipment. Assembly and testing of precision gyroscopes. Assembly of miniaturised bearings. Class 10 000 Assembly of precision hydraulic or pneumatic equipment, servo-control valves, precision timing devices, high grade gearing. Class 100 000 General optical work, assembly of electronic components, hydraulic and pneumatic assembly. Slide 15: 18-Aug-10 15 KPCL TUBE CLEANING PROCEDURE Schematic Description of cleaning procedure: Powered by compressed air, the rubber foam projectile travels through the tube or hose that needs to be cleaned, expanding against the inside wall. The combination of compressed air and expansion causes the unique cleaning effect. Slide 16: 18-Aug-10 16 KPCL To Be Continued…. Slide 17: 18-Aug-10 17 KPCL COMPONENTS OF CLEANING SYSTEMS ptc-launcher unit ptc-nozzles ptc-cleanig plugs Slide 18: 18-Aug-10 18 KPCL TAKE CARE WITH OXYGEN RISK ASSESSMENT BEWARE OF OXYGEN ENRICHMENT NEVER USE MATERIALS INCOMPATIBLE WITH OXYGEN NEVER USE OXYGEN IN EQUIPMENT NOT DESIGNED FOR IT Slide 19: 18-Aug-10 19 KPCL Employers are legally required to assess the risk in the workplace, and take all reasonably practicable precautions to ensure the safety of workers and members of the public. RISK ASSESSMENT Slide 20: 18-Aug-10 20 KPCL 2. BEWARE OF OXYGEN ENRICHMENT Oxygen enrichment is often the result of: Leaks from damaged or poorly maintained hoses, pipes and valves. Leak from poor connections. Opening valves deliberately or accidentally. not closing valves properly after use. Using an excess of oxygen in welding, flame cutting or a similar process. Poor ventilation where oxygen is being used. Slide 21: 18-Aug-10 21 KPCL Oxygen enrichment can also result from the misuse of oxygen. Never use oxygen for: Cooling or refreshing the air in confined spaces. Dusting benches, machinery or clothing. Slide 22: 18-Aug-10 22 KPCL 3. NEVER USE MATERIALS INCOMPATIBLE WITH OXYGEN It is needed to take care when replacing: O-rings and gaskets Metal components Pressure regulators Oxygen hoses Lubricants Tape components approved by manufacturer should be used when maintaining oxygen equipment Slide 23: 18-Aug-10 23 KPCL 4. TAKE CARE WITH OXYGEN CYLINDERS AND EQUIPMENT Oxygen cylinders Handle oxygen cylinders carefully. Use a purpose-built trolley to move them Keep cylinders chained or clamped to prevent them from falling over. Store oxygen cylinders when not in use in a well-ventilated area or compound, away from combustible materials and separated from combustible materials and separated from cylinders of flammable gas. Slide 24: 18-Aug-10 24 KPCL Oxygen equipment Open the valve slowly. Rapid opening, particularly of cylinder valves, can result in momentarily high oxygen velocities. Any particles will be pushed through the system very quickly, causing frictional heat. Alternatively, if the system has a dead end such as where a pressure regulator is connected to an oxygen cylinder, heat can be generated through compression of the oxygen. Both cases can result in a fire. Ensure that pressure adjusting screws of the pressure regulator is fully unwound, so that the regulator outlet valve is closed before opening the the oxygen cylinder valve, particularly when opening the cylinder valve for the first time after changing cylinders. Slide 25: 18-Aug-10 25 KPCL Ensure that cylinder valves are closed and piped supplies isolated whenever work is stopped. Do not try to cut off the supply of oxygen by nipping or kinking flexible hose when changing equipment, eg blowpipes. Maintain hoses and other equipment in good condition. Cleanliness of the equipment is to be maintained. General precautions: - Ensure that ventilation is adequate. - Check fire extinguishers are in good condition and ready for use. - Check that escape routes are clear. To Be Continued…. Slide 26: 18-Aug-10 26 KPCL Cleaning procedure for safety relief valve Slide 27: 18-Aug-10 27 KPCL Slide 28: 18-Aug-10 28 KPCL Slide 29: 18-Aug-10 29 KPCL Special Cleaning and Packaging (SC-11) Specification SCS-00011 Revision— (March 2002) Scope This document specifies guidelines used by Swagelok and its suppliers to ensure compliance with product cleanliness requirements as stated in ASTM G93 Level C. Application of the document is limited to wetted system components. This document must be used in conjunction with product catalogs, technical bulletins, and reports. Slide 30: 18-Aug-10 30 KPCL Specification Requirements Components shall be assembled, lubricated, tested, and packaged according to the practices described in this document. All components shall meet the requirements of the Standard Cleaning and Packaging (SC-10), prior to processing products to this specification. ASTM G93 Level C specifies that nonvolatile residues must be removed to a level of 6 mg/ft2 (66mg/m2) or less. Assembled products shall be lubricated with nonhydrocarbon lubricants, such as Krytox® 240AC, as described in the product catalog. Special lubricants can be provided on request. Slide 31: 18-Aug-10 31 KPCL Finished products shall be packaged individually in a sealed plastic bag. The package shall be labeled. Swagelok Special Cleaning and Packaging (SC-11) ASTM G93 Standard Practice for Cleaning Methods and Cleanliness Levels for Material and Equipment Used in Oxygen-Enriched Environments, Level C. Do not open bag until ready for use. Bagged products shall be boxed for protection from contamination and damage during shipment and storage. Slide 32: 18-Aug-10 32 KPCL Process Verification and Control The special cleaning process shall be monitored and controlled by direct oxidation carbon coulometric detection of carbon residues based on ASTM G144, using test coupons prepared and cleaned by techniques based on ASTM G121 and ASTM G122. This practice ensures that thecleaning process meets the requirements of ASTM G93 Level C. Cleaning, Drying, and Inspection Components are cleaned in multi-step processes that ensure thorough cleaning, rinsing, draining, and drying. These processes combine: Slide 33: 18-Aug-10 33 KPCL Heated aqueous cleaning with cleaning agents selected in accordance with ASTM G127 Ultrasonic agitation techniques based on ASTM G131 Multistage de-ionized water rinsing for complete removal of cleaning agent. Non-combustive drying for the removal of rinse waters from components without depositing residues. Visual inspection performed with the aid of bright illumination or ultraviolet light. Slide 34: 18-Aug-10 34 KPCL Assembly and Testing Cleaned components are protected from damage and contamination. Cleaned components are assembled in a clean, welllighted work area. Assembly work areas, equipment, and methods are designed and maintained to protect cleaned components from contamination. As described in the product catalog, non-hydrocarbon lubricant is applied to threads, mating surfaces, O-rings, and seals to prevent galling, reduce friction, and promote proper sealing. Production tests of assembled products, as described in the product catalog, are done with clean, dry nitrogen or helium. Slide 35: 18-Aug-10 35 KPCL Packaging and Identification End connections are covered with clean caps and plugs, as needed, to protect threads and other critical surfaces, and to maintain cleanliness. Finished products are packaged to protect them from contamination and damage. Each product is packaged individually in a sealed plastic bag. Bagged products are packed in boxes with suitable protective material. Boxes are identified with the part number, quantity, and packaging date code. Slide 36: 18-Aug-10 36 KPCL INSIDE VIEW OF CLEAN ROOM Slide 37: 18-Aug-10 37 KPCL ATTIRE ROOM: ATTIRE FOR CLEANING ROOM ARE PLACED IN THE RACK SHOWN. IT IS MANDOTARY TO WEAR ATTIRE TO ENTER INTO THE CLEANING ROOM. Slide 38: 18-Aug-10 38 KPCL PASS BOX: MATERIAL WHICH IS USED IN THE CLEAN ROOM IS TO BE PASSED THROUGH PASS BOX, ENSURING NO CONTACT WITH THE EXTERNAL ENVIRONMENT. Slide 39: 18-Aug-10 39 KPCL PRESSURE GAUGE AND TEMPERATURE INDICATOR Slide 40: 18-Aug-10 40 KPCL “ Do not open bag untill ready to use.” Slide 41: 18-Aug-10 41 KPCL CLEAN ROOM WITH TROLLY INSIDE. Slide 42: 18-Aug-10 42 KPCL THANK YOU!