Scott Compressed Gas Design And Safety Handbook
Hall is a registered trademark of Thermo Electron Corporation.Kalrez and Viton are registered trademarks of DuPont Dow Elastomers LLC.Kynar is a registered trademark of Atofina Chemicals Incorporated.Monel is a registered trademark of Special Metals Corporation.Snoop is a registered trademark of Swagelok Company.Teflon and Tefzel are registered trademarks of E.I. du Pont de Nemours and Company.
DESIGN SAFETY HANDBOOKIntroductionContentsCompressed Gas: Safety .2Cylinder: Storage and Use .4Industrial processes must move at everfaster speeds in order to remain competitive in today’s global economy. It isincreasingly more important to improvequality and reduce the cost of the endproduct. At the same time, many industries are faced with meeting tougher regulations governing process emissions. Toprosper in such an environment, reliabletesting methods are essential, both to ensure regulation compliance and to result ina quality end product that is cost-effectiveto produce. Modern analytical instrumentation is certainly up to this challenge —yet today’s instruments are only as reliableas the specialty gases used to calibratethem and the equipment used to deliverthose gases.Pressure Regulators:Selection / Operation .6Gas Compatibility .9Maintenance . 12Accessories . 14Delivery Systems:Safety . 16Sizing Lines . 18Design . 20Semiconductor . 24Quality and performance of specialty gasdelivery equipment are essential. This handbook will aid in the design and safe operation of custom specialty gas delivery systems. Our goal is to help you acquire (ordesign) an efficient, safe and reliablesystem that will provide the correct gas tothe point where it is needed—at the specified purity level, pressure and flow rate.Accessories . 26Manifold Specification Worksheet . 28Application Connections . 29Cylinder Valve Outlets and Connections . 37Definitions and Terminology . 42Table IndexGas Compatibility Guide .As one of the world’s largest suppliers ofspecialty gas products and technology,Scott has a long history of working withagencies such as the U.S. EnvironmentalProtection Agency (EPA), the NationalInstitute for Standards and Technology(NIST) and the Netherlands MeasurementInstitute (NMi), helping to develop manyprotocols and certified reference materials.Our products include high-purity gasesand gas mixtures for industrial, scientific,laboratory, electronic, medical, environmental, chemical and petrochemical applications, as well as high-performance gashandling equipment. Scott provides expertdesign and construction services of customgas delivery systems for any application aswell as individual components for existingsystems.9Maximum Service Pressure Ratings . 18Specific Gravity of Gases . 18Capacity Correction for Gases Other than Air . 18Capacity of Distribution Lines in SCFH (NL/min) @ 60 F (16 C) . 19Characteristics of Specialty Gases . 34Physical Properties of Gases . 36Cylinder Specifications . 40This handbook is a compendium of the knowledge and experience gathered overmany years by Scott’s Research and Development Department, production staff,equipment specialists, field representatives and customers. We gratefully acknowledgetheir contributions.SCOTT SPECIALTY GASES 1 800 21 SCOTT1SCOTTGAS.com
DESIGN SAFETY HANDBOOKCompressed Gas: SafetyCompressed Gas: SafetyAll cylinders containing gases must belabeled, packaged and shipped accordingto local and national requirements, as wellas industry standards. Transportation labeldiamonds, regardless of color, indicatehazardous materials. Personnel handlingany compressed gas should be familiarwith the potential hazards before usingthe gas. In addition to the chemical hazardsof compressed gases, hazards accompanying high pressure or low temperature mayalso be present due to the physical state ofthe gas (i.e. liquefied or nonliquefied).Gas CategoriesCorrosive – Gases that corrode material or tissue with which they come in contact, or doso in the presence of water, are classified as corrosive. They can also be reactive and toxicand/or flammable or an oxidizer. Most are hazardous in low concentrations over longperiods of time. It is essential that equipment used for handling corrosive gases be constructed of proper materials. Use check valves and traps in a system where there is a possibility that water or other inorganic materials can be sucked back into the cylinder. Dueto the probability of irritation and damage to the lungs, mucus membranes and eye tissues from contact, the threshold limit values of the gas should be rigidly observed. Properprotective clothing and equipment must be used to minimize exposure to corrosive materials. A full body shower and eye wash station should be in the area. Personnel must befamiliar with the work area. Aisles should always be clear and unobstructed in the eventthat the gas makes contact with the eyes and vision is disrupted.It is also recommended that personnelwho handle compressed gases engage inpre-job discussion with their supervisor oranother knowledgeable coworker beforebeginning any task. Outline the job stepby step. Address potential emergenciesand the safe and proper measures necessary to avoid these emergencies. Identifyseveral scenarios that could result in gasleaks or other emergencies to be totallyprepared to respond adequately. If there isdoubt regarding proper safety procedures,consult your Scott Representative. Furtherinformation concerning the safe handling,storage and use of compressed gases, inaddition to the information presented inthis handbook, is available from ScottSpecialty Gases and at scottgas.com.Flammable – Gases that, when mixed with air at atmospheric temperature and pressure,form a flammable mixture at 13% or less by volume, or have a flammable range in air ofgreater than 12% by volume regardless of the lower flammable limit, are classified asflammable. They can be high-pressure, toxic, reactive and displace oxygen in air. Achange in temperature, pressure or oxidant concentration may vary the flammabilityrange considerably. All possible sources of ignition must be eliminated through properdesign of facilities and the restriction of smoking and open flames. Use a vent line madeof stainless steel, purge with an inert gas and use a flash arrester. It is important to have(and know how to use) a fire extinguisher in the area where flammable gases are usedand stored, as well as a hand-held flammable gas detector to determine if flammablegases are building up. This gas detector can also be used as a leak detector on the linesof the equipment being used. Always remember that the source of flammable gas mustbe closed or shut-off before attempting to put out a fire involving flammable gases.Inert – Gases that do not react with other materials at ordinary temperature and pressureare classified as inert. They are colorless and odorless, as well as nonflammable and nontoxic.The primary hazard of these gases is pressure. These gases are often stored at pressuresexceeding 2,000 psi (138 bar). Also, they can displace the amount of oxygen necessary tosupport life when released in a confined place. Use of adequate ventilation and monitoringof the oxygen content in confined places will minimize the danger of asphyxiation. Alwayswear safety glasses and safety gloves when working with the lines to avoid absorption ofthe gas through the skin.Oxidant – Gases that do not burn but will support combustion are classified as oxidants.They can be high-pressure, toxic and reactive, and can displace breathing oxygen from air(except O2 itself). All possible sources of ignition must be eliminated when handling oxygen and other oxidants as they react rapidly and violently. Do not store combustiblematerials with oxidants. Do not allow oil, grease or other readily combustible materials tocome in contact with the cylinder or equipment used for oxidant services. Use only equipment that is intended for this type of service. Use only a regulator that has been clearlyprepared for use with this type of service—this regulator should be labeled “Cleaned forO2 Services.”2
DESIGN SAFETY HANDBOOKCompressed Gas: SafetyCryogenic – Gases with a boiling point below -130 F (-90 C) at atmospheric temperatureare considered cryogenic gases. They are extremely cold and can produce intense burns(similar to heat burns) and tissue necrosis may be even more severe. They can be nonflammable, flammable or oxidizing. Cryogenic liquids can build up intense pressures. Atcryogenic temperatures, system components may become brittle and crack. Never blocka line filled with cryogenic liquid as a slight increase in temperature can cause tremendous and dangerous buildup of pressure and cause the line to burst. The system shouldalso be designed with a safety relief valve and, depending upon the gas, a vent line. Toprotect from injury, always wear gauntlet gloves to cover hands and arms, and a cryogenicapron to protect the front of the body. Wear pants over the shoes to prevent liquids fromgetting trapped inside your shoes. Wear safety glasses and a face shield as cryogenic liquidstend to bounce upward when spilled.Toxic or Poison – Gases that may produce lethal or other harmful effects on humans areclassified as toxic or poison. They can be high pressure, reactive, nonflammable or flammable, and/or oxidizing in addition to their toxicity. The degree of toxicity and the effectswill vary depending on the gas; however, death will occur when breathed in sufficientquantities. The permissible exposure levels must be strictly adhered to (please refer to thePELs listed in the Scott Specialty Gases’ Reference Guide or at scottgas.com). Read yourMSDS thoroughly before use and consult with your Scott Representative or a moreknowledgeable coworker who has handled the gas before. Never work alone with toxicgases — a backup safety person is essential! Inspect the entire assembly or system thatwill contain the gas and thoroughly test it for leaks with an inert gas before use. Purge alllines with an inert gas before opening the cylinder valve or breaking connections. Contactyour Scott Representative for proper purge procedures.Use toxic gases in a well-ventilated area. For safety purposes and to minimize exposure, it isimportant to have gas detectors. It is preferable that the breathing apparatus be stored ina safe area immediately adjacent to the work area, so that in the event of an emergency,a person can go directly into the area and close the door and safely put on the apparatus.Full body showers, eye washes, fire alarms and firefighting equipment should be in thearea of use and readily accessible. Refer to your local building code for storage and userequirements for toxic gases. Keep your inventory of toxic or poison gases to a minimum.When a project is completed, return leftover cylinders to Scott. They should never bestored for possible future use. This might result in accidental removal of cylinder labeling,making it an unnecessary hazard and greatly increasing the cost of proper disposal.DefinitionsU.S. D.O.T. LabelsCompressed – Nonflammable material or mixture having in the container pressureexceeding 41 psia (3 bar) at 70 F (21 C) or any flammable or poisonous material that is agas at 70 F (21 C) and 14.7 psia (1 bar) or greater. Most compressed gases will not exceed2,000 to 2,640 psig (138 to 182 bar) though some do go up to 6,000 psig (414 bar).Nonliquefied Compressed – Chemical or material other than gas in solution that underthe charged pressure is entirely gaseous at a temperature of 70 F (21 C).Liquefied Compressed – Chemical or material that under the charged pressure is partiallyliquid at a temperature of 70 F (21 C).Compressed Gas in Solution – Nonliquefied compressed gas that is dissolved in a solvent.SCOTT SPECIALTY GASES 1 800 21 SCOTT3SCOTTGAS.com
DESIGN SAFETY HANDBOOKCylinder: Storage and UseCylinder: Storage and UseStorageStorage Area – Store gas cylinders in a ventilated and well-lit area away from combustiblematerials. Separate gases by type and store in assigned locations that can be readily identified. Store cylinders containing flammable gases separated from oxygen cylinders andother oxidants, by a fire-resistant wall (having a fire-resistance rating of at least a halfhour) or locate them at least 20 feet (6.1 meters) apart from each other. Poison, cryogenicand inert gases should be stored separately. Labels, decals or other cylinder content identification should not be obscured or removed from the gas cylinder. Cylinders should also bestored where they can be protected from tampering by unauthorized personnel.Storage Area Conditions – Storage areas should be located away from sources ofexcess heat, open flame or ignition, and not located in closed or subsurface areas. Thearea should be dry, cool and well-ventilated. Use of a vent hood does not provide for asafe storage area except for when a cylinder is actually in use. Outdoor storage should beabove grade, dry and protected from the weather.Securing Cylinders in Storage – The risk of a cylinder falling over and possibly shearingoff its valve demands that a cylinder always be held in place with a chain or another typeof fastener such as a bench or wall clamp. While in storage, cylinder valve protection capsMUST be firmly in place.Cylinder Rack – Model 55-84CSstores cylinders safelyCylinder Temperature Exposure – Cylinder temperature should not be permitted toexceed 125 F (52 C). Steel cylinders are typically used for more corrosive products.Though they are more durable than aluminum cylinders, they should not be stored nearsteam pipelines or exposed to direct sunlight. Aluminum cylinders are used for increasedstability of mixtures containing certain components and they can be damaged by exposure to temperatures in excess of 350 F (177 C). These extremes weaken the cylinderwalls and may result in a rupture. Do not apply any heating device that will heat any partof the cylinder above 125 F (52 C).Safety glasses, gloves and shoes shouldbe worn at all times when handlingcylinders.Appropriate firefighting, personnel safetyand first aid equipment should be availablein case of emergencies. Ensure adequatepersonnel are trained in the use of thisequipment.Empty Cylinders – Arrange the cylinder storage area so that old stock is used first.Empty cylinders should be stored separately and clearly identified. Return empty cylinderspromptly. Some pressure should be left in a depleted cylinder to prevent air backflow thatwould allow moisture and contaminants to enter the cylinder.Follow all federal, state and local regulations concerning the storage of compressed gas cylinders. Refer to the Compressed Gas Association (CGA) PamphletP-1 in the U.S. for further information orconsult EIGA (European Industrial GasAssociation), CPR-15 or CIMAH in Europe.UsageLabeling – If a cylinder’s content is not clearly identified by proper labels, it should not beaccepted for use.Securing Cylinders Before Use – When a cylinder is in use, it must be secured with afastener. Floor or wall brackets are ideal when a cylinder will not be moved. Portablebench brackets are recommended when a cylinder must be moved around. Stands areavailable for small cylinders as well as for lecture bottles. Your Scott Representative canassist you in determining which type of cylinder fastener best meets your needs.Initiating Service of Cylinder – Secure the cylinder before removing the valve protection cap. Inspect the cylinder valve for damaged threads, dirt, oil or grease. Remove anydust or dirt with a clean cloth. If oil or grease is present on the valve of a cylinder thatcontains oxygen or another oxidant, do NOT attempt to use it. Such combustible substances in contact with an oxidant are explosive. Notify the nearest Scott facility of thiscondition and identify the cylinder to prevent usage.4
DESIGN SAFETY HANDBOOKCylinder: Storage and UseValve Outlet Connections and Fittings – Be sure all fittings and connection threadsmeet properly – never force. Dedicate your regulator to a single valve connection even if itis designed for different gases. NEVER cross-thread or use adapters between nonmatingequipment and cylinders. Most cylinder valve outlet connections are designed with metalto-metal seals; use washers only where indicated. Do not use Teflon tape on the valvethreads to help prevent leaking, it may become powdered and get caught on the regulatorpoppet causing full pressure downstream. Never use pipe dope on pipe threads. Also,never turn the threads the wrong way. This could produce brass particles that might getcaught in the poppet.Know your connections and fittings! If youare using a CGA and its middle digit is aneven number, then it is right-handed andthe threads should be turned clockwise totighten the fitting. If the middle digit is anodd number, it is left-handed and thethreads should be turned counterclockwise to tighten the fitting.Gas Cabinets – When hazardous specialty gases are used in an enclosed location, it iswise to provide an extra degree of protection for personnel. A gas cabinet can contain andvent leaking gas. A gas cabinet also accommodates manifolds and gas handling systems,providing an efficient and cost-effective means to safely organize specialty gas distributionequipment.Contain hazardous gas in the event of leakageProperlyDesignedGas SystemsMaintain gas integrityAutomatic shutoff of gas in the event of catastrophic failureEffective control of residual gas during cylinder changeoutCylinder storage problems are simplified because the cabinet/manifold system conceptencourages separation of gases according to their classification. For example, corrosives,oxidizers, flammables and toxics can be separated and grouped into separate cabinets.This satisfies both national and local fire and building codes.In order to provide containment of potentially dangerous gases, cabinet exhaust systemsshould be designed with the capability to allow 150 to 200 linear feet (45.7 to 61 linearmeters) per minute of air to pass through the cabinet with the access window open. Thisis equivalent to 13 air changes per minute. As an extra measure of fire protection, gascabinets used to store flammables should be equipped with an integral sprinkler system.While exact requirements may vary with the specific application, a typical sprinkler wouldhave a fuse rated at about 135 F (57 C) and a flow capability of approximately 40 GPM(2.524 L/s).Gas Cabinet withModel 8404 ChangeOverConsideration should be given to materials of construction when selecting a gas cabinet.For example, use of 11-gauge steel or better for the cabinet and door will ensure sturdiness and also provide a half-hour or more of fire protection. Horizontally and verticallyadjustable cylinder brackets should also be specified to ensure that cylinders are properlysecured. If poisonous gases are to be kept in the cabinet, an access window should beprovided so the cylinder valves can be closed and leaks detected without opening thecabinet door and compromising the exhaust system. For cabinets used to store inert gases,a fixed window to allow visual inspection is an acceptable and economical alternative.Terminating Service of Cylinder – Disconnect equipment from the cylinder when notin use for long periods and return the cylinder valve protection cap to the cylinder.Transporting Cylinders – Always move cylinders by hand trucks or carts that are designedfor this purpose. During transportation, cylinders should be properly secured to preventthem from falling or striking each other. Always use a cylinder cart equipped with achain restraint. Do not move a cylinder with a regulator connected to it. Never transporta gas cylinder without its valve protection cap firmly in place. Keep both hands on thecylinder cart during transport. A cylinder cart or hand truck is not a suitable place forstorage of a cylinder.SCOTT SPECIALTY GASES 1 800 21 SCOTT5SCOTTGAS.com
DESIGN SAFETY HANDBOOKPressure Regulators: Selection/OperationPressure Regulators: Selection/OperationThe safest means to reduce cylinder pressure to a workable level for operatingequipment and instruments is through apressure reduction regulator. Applicationdetermines which regulator to use.Single-Stage vs Two-Stage – There are two basic types of regulators. Duration of gasusage helps to identify whether a single-stage or two-stage regulator provides the bestservice. A single-stage regulator is a good performer for short duration gas usage. Itreduces the cylinder pressure to the delivery or outlet pressure in one step. This type ofregulator is recommended when precise control of the delivery pressure is not requiredbecause delivery pressure variations will occur with decreasing cylinder pressure.Scott offers over 40 regulator series withmore than 120 different pressure ranges.All are intended for specific applications.Information for gases listed in the ScottSpecialty Gases reference guide includesrecommended pressure regulators for bestservice.A two-stage regulator provides better performance for long duration gas usage. It reducesthe cylinder pressure to a working level in two steps. The cylinder pressure is reduced bythe first stage to a preset intermediate level, which is then fed to the inlet of the secondstage. Since the inlet pressure to the second stage is so regulated, the delivery pressure(manually set by means of the adjusting handle) is unaffected by changes in the cylinderpressure. Thus, the two-stage pressure regulators provide precise control of the gas beingconsumed. A two-stage regulator performs best when it is attached to the cylinder andadjusted to the desired reduced pressure, and then remains in service until the cylinder isready for changeout.Materials of Construction – A regulator must be constructed with materials compatiblewith the intended gas service and application. When selecting your regulator, you shouldfirst consider the wetted materials (those that will come in contact with the gas). Typicalmaterials used for regulator construction are:Noncorrosive: Aluminum, Brass, Stainless Steel, Buna-N, PCTFE,Neoprene, Teflon , Viton , Nylon.Corrosive:Aluminum, Stainless Steel, Monel , Nickel, PCTFE, TeflonThe ideal construction for high-purity gas service is a regulator that has a stainless steeldiaphragm. They are noncontaminating and assure satisfactory use for all applications ofnoncorrosive and mildly corrosive gases.Single-Stage RegulatorTwo-Stage RegulatorPressure Adjusting ugeBonnet(Spring Housing)Needle Valve(Flow Control)Bonnet(Spring Housing)InletPressureGaugeNeedle Valve(Flow Control)PressureAdjusting Handle(Poppet Valve Actuator)2nd Stage Diaphragm2nd StagePoppet AssemblyInletPressureGauge1st StagePoppet AssemblyPoppetAssembly1st Stage DiaphragmBonnet1st Stage is Preset6
DESIGN SAFETY HANDBOOKPressure Regulators: Selection/OperationFor general use, brass regulators with Buna-N or Neoprene diaphragms will give goodservice in noncorrosive applications where slight contamination or diffusion from an elastomeric diaphragm is not important. Both Buna-N or Neoprene are permeable to oxygen.Therefore, regulators with these types of diaphragms are not suitable for GC analysis thatcan be affected by the diffusion of atmospheric oxygen through the elastomerdiaphragm, or the outgassing of monomers and dimers from the elastomer. In fact, labsthat perform temperature programmed analysis are faced with excessive baseline driftand large unresolved peaks due to this diffusion and outgassing.Brass regulators with stainless steel diaphragms have several advantages over the elastomeric type. Firstly, they prevent air diffusion and adsorption of gases on the diaphragm.This is important with low concentration mixtures of hydrocarbons where the trace components may be adsorbed on the elastomeric diaphragm. Secondly, these regulators donot outgas organic materials and prevent the diffusion of atmospheric oxygen in the carrier gas. The chemical potential of oxygen between the carrier gas and the atmosphereprovides sufficient driving force for oxygen to intrude the carrier gas through a permeablediaphragm. Stainless steel diaphragms prevent this scenario from happening.Two-Stage Stainless Steel RegulatorModel 215 – Corrosive gas usePerformance CharacteristicsDroopRegulator performance is characterized by droop; the changein delivery pressure as flow is initiated and increased throughthe regulator.Supply PressureEffectSupply pressure effect is the change in delivery pressureas the inlet pressure changes. For most regulators, a decreasein inlet pressure causes the delivery pressure to increase.RepeatabilityDeliveryPressure CreepRepeatability refers to the change in delivery pressure afterpressure has been set by turning gas flow on and off usingan external valve.Single-Stage Brass RegulatorModel 202 – Noncorrosive gas useThere are two types of creep. The first type is normal as a resultof internal spring forces equalizing when the flow stops. Thesecond type of creep is a result of contamination that, when leftunchecked, can lead to regulator and/or supply line failure.Droop – The two most important parameters to consider during regulator selection andoperation are droop and supply pressure effect. Droop is the difference in delivery pressurebetween zero flow conditions and the regulator’s maximum flow capacity. Supply pressureeffect is the variation in delivery pressure as supply pressure decreases while the cylinderempties. Single-stage and two-stage regulators have different droop characteristics andrespond differently to changing supply pressure. The single-stage regulator shows littledroop with varying flow rates but a relatively large supply pressure effect. Conversely, thetwo-stage regulator shows a steeper slope in droop but only small supply pressure effects.The effect of these differences on performance can be illustrated with some examples. Forinstance, when a centralized gas delivery system is supplying a number of different chromatographs, flow rates are apt to be fairly constant. Supply pressure variations, however,may be abrupt, especially when automatic changeover manifolds are used. In this scenario, a two-stage regulator with a narrow accuracy envelope (supply pressure effect) anda relatively steep droop should be used to avoid a baseline shift on the chromatographs.On the other hand, if gas is being used for a short-duration instrument calibration, a singlestage regulator with a wide accuracy envelope (supply pressure effect) but a comparativelyflat droop should be chosen. This will eliminate the need to allow the gas to flow at aconstant rate before the calibration can be done.SCOTT SPECIALTY GASES 1 800 21 SCOTT7SCOTTGAS.com
DESIGN SAFETY HANDBOOKPressure Regulators: Selection/OperationSelection/Operation continuedDelivery Pressure Range – Determining an appropriate delivery pressure range for aregulator can be confusing but can be accomplished by following these steps:Single-Stage RegulatorDelivery Pressure1001. Determine the gas pressure that is needed.902. Determine the maximum pressure the system might require(this pressure and the gas pressure are often the same).500 PSIG803. Select a delivery pressure range so that the required pressuresare in the 25% to 90% range of the regulator’s delivery pressure(a regulator’s performance is at its best within this range).70602000 PSIG50100150200Relieving/Non-Relieving – A relieving regulator has a hole in the center of the diaphragm.As long as the diaphragm is in contact with the poppet, the regulator does not relieve.When the pressure under the diaphragm increases as a result of back pressure from downstream, the diaphragm will rise, allowing the pressure to relieve through the opening inthe diaphragm. While the internal gas is relieving through this opening, the surroundingat
Liquefied Compressed– Chemical or material that under the charged pressure is partially liquid at a temperature of 70 F (21 C). Compressed Gas in Solution– Nonliquefied compressed gas that is dissolved in a solvent. DESIGN SAFETY HANDBOOK Compressed Gas: Safety SCOTT SPEC
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Compressed gas cylinders must be properly stored to prevent injury in the case of a container breech. The following precautions must be taken during the storage of compressed gas cylinders. 1. Signage is required at compressed gas cylinder storage locations including: 2. Cylinders must be stored in a cool, dry, well ventilated area. 3.
Compressed gas - A material that is shipped in a compressed gas cylinder and acts as a gas upon release at normal temperature and pressure or is used or handled as a gas. Hazardous gas - A gas that is included in one or more of the following hazard categories: corrosive, flammable, health hazard, oxidizer, pyrophoric, reactive, or toxic.
Ordering and Receiving Compressed gas Cylinders Before ordering compressed gas cylinders, Review the Safety Data Sheet for physical and health hazards. Ensure the storage location has the required ventilation for safe use of the gas Ensure piping, regulator etc. are compatible with the gas If the gas is listed on the United .
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