Control Measures (Existing Or Planned) s1
Work Activity:
Charging or opening up a CO2 system /
Thornliebank Industrial Estate Glasgow G46 8JW
Tel: 0141 638 7916 Fax: 0141 638 8111
Site/Location:
Various site locations
Those at Risk / Y/N / Comments - enter names or general groups
Star Employees:
Other workers:
General Public: / Y
Y
N / Star Engineers and their assistants
Subcontractors and other trades working in the area
Comments: Accompaniment is required during charging and when opening up a part of the plant that may contain liquid CO2
Hazards
1. Explosion
2. Asphyxiation
3. Freeze burns
4. Manual handling injury when moving cylinders or plant
Control Measures (existing or planned)
Control / DetailsPPE: / 1. Safety boots with a heel, good grip and steel toe cap (200 joule)
2. Overalls/protective clothing.
3. Safety goggles to BS EN 166-349B
4. Hide gloves with a fleece lining to provide some Thermal insulation
Equipment: / 1 Personal CO2 gas detector
2 Suitable charging lines rated at 90 Bar (g) minimum.
3 Log sheet or logbook for recording amount charged or decanted.
4 Cylinder Electric Heating Jacket (if Required)
Information, Instruction, and Training / 1. Accompaniment is required when charging CO2 or opening up parts of a system that may have contained liquid CO2.
2. Wear impervious gloves to prevent refrigerant contacting the hands.
3. Eye protection must be worn. As a minimum goggles are required.
4. Only engineers that are experienced or have received CO2 training may charge or open up plant. They may have an apprentice or assistant helping them or observing the operation
5. A personal CO2 gas detector (checked for correct operation before use) must be worn during charging and opening up operations.
6. Secure cylinders from toppling over
7. Do not trap gas or liquid refrigerant between valves
8. Use mechanical handling equipment or follow good manual handling techniques when moving cylinders.
9. If the cylinder must be heated to facilitate charging a thermostatically controlled heater belt or partial immersion in warm water is to be used but on no account must it ever be heated above 40oC.
10. If charging after evacuation, the vacuum should be broken with vapour to a pressure corresponding to a saturation pressure above –20oC (18.7 Bar g) or 0oC (33.8 Bar g) if the system is water cooled to prevent freezing.
11. If venting CO2 then to prevent it turning solid any liquid should first be transferred to another part of the system that is above 4.2 Bar g, then the vapour can be vented to atmosphere.
12. Venting of large quantities (greater than 5 kg) of CO2 must always be to outdoors.
Control Measures Continued
Control / DetailsSupervision: / Managers and Supervisors must;
1. Ensure that engineers are experienced or appropriately trained in handling CO2.
2. Ensure engineers are trained in the use of the personal gas detectors.
3. Ensure personal gas detectors receive 6 monthly recorded maintenance.
4. Write site specific risk assessments for unusual or difficult operations
Environment; / 1. CO2 is an asphyxiant and can accumulate, particularly in low lying areas such as pits, below ground plant rooms, sealed stairwells, beer cellars, etc, therefore, ensure adequate levels of ventilation particularly at low lying areas.
2. Check emergency exits.
Procedures, documents etc / 1. When charging liquid refrigerant, disconnect hoses slowly in case liquid remains in the hose (frost on the hose may indicate that liquid is still present).
2. Keep an accurate record of the amount of refrigerant charged.
COSHH: / 1. COSHH or product data sheets for CO2 (and for the system oil) should be read before beginning the operation.
Communication / 1. Comply with site rules. Permits may be required
2. Familiarise yourself with the site emergency plan
Emergency action/procedures / In case of a leak.
1. Isolate leak (if possible)
2. If isolation is not possible, evacuate area and follow site emergency plan
3. Treatment of injuries should be in accordance with the COSHH or material safety data sheet
Access: / 1. The engineer should strictly control access to the area.
2. Store cylinders safely - away from traffic routes and heat sources
Waste / 1. The recovery of CO2 to cylinders is prohibited.
Risk Evaluation of Identified Hazards
Likelihood / Highly unlikely = 1 / Unlikely = 2 / Likely = 3Severity / Slightly harmful = 1 / Harmful = 2 / Extremely harmful = 3
(Likelihood x Severity = Risk level) 1 = Trivial, 2 = Tolerable, 3-4 = Moderate, 6 = Substantial, 9 = Intolerable
Identified Hazards (base scores on existing or planned control measures) / Triv' / Tol' / Mod' / Sub' / Int'
1. Explosion 1x3
2. Asphyxiation 1x3
3. Freeze burns 1x2
4. Manual handling injury when moving cylinders or plant 1x2 / 2
2 / 3
3
Note: Moderate scores; Thought should be given to reducing risk, but the cost and time requirements of prevention
should be carefully considered and limited.
Substantial: Work should not be started until the risk has been reduced, for work in progress, urgent
action is required. Considerable resources may have to be allocated.
Intolerable: If unlimited resources cannot reduce risk, work will be prohibited.
Is risk adequately controlled using the above control measures Y/N / YES / If "NO" State further action requiredState further action required: None
Note : This risk assessment is only valid when all control measures are in place before the work or activity commences and will be reviewed 10/08/14 or earlier if the nature of the work changes or there is a dangerous occurrence.
Assessor: / Chris Haslam / (Sign) / Date 10/08/09References:
BSEN 378 2007
Institute of Refrigeration – Safety Code for Refrigerating Systems Utilizing Carbon Dioxide.