Oil & Gas Safety Alert

Safety Alert
OIL AND GAS SAFETY ALERTS
1. A crushing incident involving drill collars and selection of lifting elevators 2. Broken leg from coal seam gas sampling incident involving high pressure 3. Crushing fatality – pipe racks load shift 4. Drill Rig Walkway -Toe amputated when securing walkway 5. All portable gas refrigerator users 6. Forklift truck / loader - crushing injury 7. Mis-matched threads on surface casing and lifting nubbins 8. Working near power tongs and sub-sections 9. Inappropriate modification and use of wrenches and stilsons 10. Storage of used automotive tanks inside workshops 11. Use of hand tools 12. Screw plugs in cylinder outlets 13. Location of air conditioners 14. Portable gas refrigerators 15. LP Gas Cylinder Alert 16. Two-Stage Gas Regulator Failure 17. Underground LP gas storage tank fire 18. Unsafe LPG dispenser operation 19. FLAMMABLE REFRIGERANT ALERT 20. USE OF NON-METALLIC FITTINGS 21. TWO-STAGE GAS REGULATOR FAILURE 22. CONTAINER MARKING 23. 190 kg Cylinder Alert

24. Patio Heater Safety 25. Filling of gas cylinders 26. Fuel Gas For Camper Vans 27. CARAVAN COMMISSIONING 28. USING CHEATER BARS ON HANDTOOLS 29. Vehicle Fire Involving Gas Cylinders 30. COAL SEAM GAS RIG FATALITY 31. FLAMMABLE REFIGERANT ALERT 32. PIPE RACK STOPPERS 33. PORTABLE LP GAS HEATERS 34. CARE OF LP GAS CYLINDERS 35. LP GAS IN MOTOR VEHICLES 36. USE OF WINCHES 37. Oxygen Safety 38. UNLICENSED GASFITTING - LAMB ISLAND 39. Unguarded Machinery 40. Oxygen Regulator Fire

Broken leg from coal seam gas sampling incident involving high pressure
What happened? A gas sampling contractor was struck by a flying fragment from an exploded gas filter. The filter had been exposed to a pressure that exceeded its design specifications (1,600kPa). The filter was being used as part of a gas sampling kit on the high pressure (9,000kPa) product end of a coal seam gas processing plant. One of the contractor technicians undertaking the work sustained a broken leg and

related soft tissue damage. While the exact causes of the incident are still to be determined, this safety alert is a reminder to all operators, staff, their employees and contractors to take particular care when selecting components to be used on high pressure gas systems.

 Safety issues identified • Incorrect selection of filter type for the application. • Contractors had no formal training in high pressure sampling and had not directly undertaken work before. • Lack of risk assessment, identification of hazards and use of standard operating procedures when taking gas samples. • Poor implementation and adherence to existing: o permit to work systems o company policies and procedures o contractor supervision Recommendations • Gas sampling connection and disconnection procedures to include requirements for correct sequence of events and specify the type and rating of components that form the sampling kit. • Dedicated sampling point to be provided if regular sampling is a standard requirement at the facility. • Organisations to immediately review their: o Hazard registers o Risk assessments o Standard operating procedures (SOPs) o Job safety analyses (JSAs) o Contractor training and supervision requirements.

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Crushing fatality – pipe racks load shift
What happened? A 24-year-old man was struck and crushed by pipe racks which came off a truck that was being unloaded at a drill site. The rig worker did not survive his injuries. Petroleum and Gas Inspectors are currently investigating the incident and will prepare a report for the coroner. While the exact causes of the incident are still to be determined, this safety alert is a reminder to all operators, staff, their employees and contractors to take particular care when loading and unloading large heavy equipment from vehicles.

 Safety issues identified • Load restraint bollards only in place on one side of the truck. • It appears pipe rack groups were separately tied down (i.e. upper and lower layers separately restrained) but the upper layer was not removed before restraints were removed from lower layer of pipe racks. • People standing in high risk area adjacent to vehicle. • Lack of risk assessment and use of standard operating procedures when unloading. Recommendations • Restraint bollards to be used wherever practical for transport of pipe racks and other long loads. • Appropriate exclusion zones to be put in place when loading and unloading. • Loading and unloading procedures to include requirements for correct sequence of events and/or use of primary and secondary restraints. • Organisations to immediately review their: o detailed risk assessments o standard operating procedures (SOPs) o job safety analyses (JSAs) o training and supervision requirements to ensure that this type of task and associated risks are adequately covered. • Refer to Australian Load Restraint guide for transport.

Drill Rig Walkway -Toe amputated when securing walkway
What happened?

A person climbed part way onto a truck-mounted rig carrier vehicle to secure the fold down walkway on the side of the vehicle into the travel position. A second person was standing on the ground beside the vehicle supporting the weight of the platform.

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 The person on the vehicle lost his balance, and fell backwards whilst holding the walkway. His right foot was trapped between the walkway rail and edge of the tray on the vehicle. As the platform hinged downwards, the end of the steel capped boot was severed by the guillotine action of the falling gate and fixed side rail on the vehicle. The person sustained two partially amputated toes due to this incident.

 Safety issues identified • The company did not identify the pinch point during the hazard identification process. • The safe work procedure did not specifically include this piece of equipment. Normal lifting/manual handling safe work practices were not followed. Recommendations • Drilling companies must ensure that all hazards are identified in relation to their work activities, and appropriate controls are identified and implemented to reduce risk to as low as reasonably practicable. • Hazards of this nature should be addressed by engineering controls and not rely on PPE (personal protective equipment) or administrative controls such as a job safety analysis to prevent injury.

All portable gas refrigerator users
What happened? A male person died inside his Hi-Ace vehicle which was set up as a ‘campervan’. An outdoor gas appliance (portable refrigerator) was found still operating inside the campervan. The cause of death was identified as carbon monoxide poisoning. This is the second of this type of incident in Queensland in the last two years. Safety issues identified • Carbon monoxide (CO) is a colourless, odourless gas undetectable by humans and can result in fatal consequences. • Portable gas appliances should not be operated in enclosed vehicles or poorly ventilated areas (small sheds, tents, etc).

• These types of gas appliances are specifically approved for outdoor use only. • The lack of ventilation leads to an accumulation of dangerous concentration levels of carbon monoxide gas produced by the gas burning process. • Portable refrigerators and all outdoor gas appliances come with appropriate safety warning signs. • The Petroleum and Gas Inspectorate instructed importers and suppliers of these types of refrigerators that from 1 January 2008 they must fit larger warning labels on gas-operated refrigerators. • Note: These appliances can only be safely used inside when operated on electricity (12 or 240 volts), if that option is available.

 Recommendations • Users of these products should read the warning labels and follow the operational instructions for the product. • These outdoor gas appliances must not be used indoors or in enclosed spaces. • This warning applies to all other gas appliances specifically designed to be used outdoors such as barbeques and/or patio heaters.

Forklift truck / loader - crushing injury
What happened? A drill rig worker sustained injuries to his back after the jib of a loader was accidentally lowered while he was working under the jib. The incident involved the routine operation of lifting and suspending a slung load while workers connected up BOP (blow out prevention) components used in drilling operations.

Safety issues identified • Work was undertaken under a suspended load. • The loader operator left the machine’s cabin while the machine was operational. • No adequate company policy/procedure was in place relating to the machine operations. • The operator appeared to be distracted while conducting unscheduled cleaning/maintenance of the machine. • Operators were unfamiliar with this machine and its control functions. Employing licensed operators does not guarantee operator competence. • No operating manual was available within the cabin. • Lockout safety devices were not activated because operators were unaware they existed. • Importance of conducting job safety analysis (JSA) for unplanned or non-routine tasks. Recommendations • Operators must be at the controls at all times while the machine is running. • Policies and procedures should detail when lockout devices are to be activated if operations are suspended, or the machine is required to be stationary for extended periods of time. • A manufacturer’s operating manual must be within the operator’s cabin for reference. For operators to be assessed as competent they must be fully conversant with every aspect of the specific machine’s controls. • No person should stand, walk or work under elevated forks/loads, even when a load is not being moved.

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Mis-matched threads on surface casing and lifting nubbins
What’s happening? The Department of Mines and Energy is currently investigating an incident involving the routine procedure of lifting threaded surface casing from the catwalk into the hole. The casing came free from the lifting nubbin, injuring a worker. Safety issues identified • Redesigned lifting nubbin used • Mis-matched casing and nubbin threads • Crew forced connection together • Incomplete training • Detailed standard operating procedures (SOPs) not available for task • Importance of conducting job safety analysis (JSA) • Crew unfamiliar with rig’s equipment • No casing inventory controls • No industry standardisation of casing threads from manufacturer

 • Failure to quarantine surplus casing from drill site Failure to conduct a JSA when departing from the SOP • No mechanism for easy identification of nubbins to correct casing

 Recommendations • Experienced personnel should directly supervise inexperienced / unskilled workers • Companies should inventory all existing casing stock and sort accordingly • Only one type of threaded casing should be sent to site • All threaded connections should be capable of being started by hand and not forced • All lifting connections should be checked by two crew members • A visual system of identification for matching nubbins to casing (e.g. colour and / or number codes) should be developed

Working near power tongs and sub-sections
What’s happening? The Department of Mines and Energy is currently investigating an accident involving the routine procedure of clamping sub-sections (Kelly cocks) into power tongs. Safety issues identified • Lack of experience within drill crews • Problems with floor communications equipment/methodology • Crushing hazards not properly identified • Selection of short sub-section (Kelly cock) • Lack of detailed standard operating procedures (SOPs) for all tasks • Lack of understanding of all existing SOPs • Lack of enforcement of SOPS by staff and management • Step back and other take five initiatives not used at all times • Inadequate supervision by experienced personnel • Inadequate review and / or investigation of previous related issues. Key issues • Length of sub-section must protrude through power tong jaws • Crew’s hands must be clear from tongs when power tongs are energised • Clear verbal communication must take place between driller and floor crew during all operations • Driller must have a clear line of sight at all times during the operation. Recommendations • Companies should review the length of subsections to ensure the lifting nubbin protrudes above the power tong jaws • Written procedures should be reviewed to ensure they clearly state hands are not to be placed in the working area of the power tongs • Companies should implement a penalty system for non-compliance with the written SOP.

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Inappropriate modification and use of wrenches and stilsons
What happened? Incidents continue to occur in which hand tools, particularly ‘stilsons’ and other types of wrenches, are being used inappropriately.Hand tools are just that, designed to be used as hand tools. They are not designed to have attachments such as crowbars, pipe-lengths or other items welded to or bolted to them. Petroleum and Gas Inspectors continue to find modified use of hand tools, particularly in the drilling industry, but are yet to see any manufacturer endorse its products being cut, welded or otherwise attached to a device. Unauthorised modifications of hand tools are a serious safety breach. Unauthorised modifications can stress the hand tool beyond its design limits. In some cases, the modified hand tools have ruptured violently, posing serious hazards and

injuring people. There have been serious hand, arm and facial injuries (including a broken jaw). Key issues • Hand tools are designed and manufactured to specific conditions by the manufacturer. • Hand tools are designed to be operated by hand only with no additional devices. • Modifications seriously compromise the hand tool’s integrity. • Risk analyses need to be undertaken for any change or planned change to a hand tool. The manufacturer must be consulted and should authorise any changes. Recommendations • Organisations should review their operational procedures and change management procedures in their safety management plans (SMP) to ensure there is no inappropriate use of hand tools • Changes to equipment require an engineering design and assessment and “formal safety assessment consisting of the systematic assessment of risk”. • Use of modified tools must be documented in the SMP and available for inspection by the Inspectorate upon request.

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Storage of used automotive tanks inside workshops
What’s happening? Inspectors are continuing to find workshops that are storing used automotive tanks illegally. All automotive tanks must be stored in accordance with AS/NZS1596:2008 ‘The storage and handling of LP Gas’. Tanks are not to be stored indoors with LP Gas remaining in them. They must be stored

outdoors in a well ventilated area.

 Key issues • Increased potential for and escalation of a fire • Higher risk to emergency services personnel in a fire situation • Liquid in contact with the safety relief valve • Leakage from valves outlets • Tank corrosion due to contact with wet surfaces Recommendations All authorised workshops are to carry out a workshop survey of their automotive tank storage arrangements for compliance with the standard. If non-compliances are found, implement changes that conform to the requirements of the Standard. Failure to rectify non-compliances may result in suspension or cancellation of the workshop authorisation. Indoors storages must • be purged with an inert gas, and be liquid free • be stacked and racked off the workshop floor • be stacked individually, not stacked on top of each other • be stored in their correct orientation • have all their outlets capped or plugged Outdoors storages must • be stored in their correct orientation to ensure the SRV is in contact with the vapour space of the tank • be stacked / racked off the ground • have outlets capped or plugged

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Use of hand tools
What happened? There have been a number of cases where hand tools, particularly stillsons, have been used in drilling operations in a manner not intended by the manufacturer. This includes the use of “cheater bars” and unauthorised modifications of the tools themselves. Tools with unauthorised modifications which are stressed beyond their design limits have ruptured violently, in every case posing a hazard and, in some instances, causing injury to operators or bystanders. Key issues Tools are designed and manufactured to be used within stated or implied conditions. In particular, hand tools are designed to be operated by hand only with no additional devices to increase torque. Should a modified tool be required, its construction and tolerances would need to be subject to rigorous engineering assessment and risk analysis, allowing for a safety margin. Recommendations Section 675(1)(e) of the Petroleum and Gas (Production and Safety) Act 2004 requires that all safety management plans (SMPs)have a “formal safety assessment consisting of the

systematic assessment of risk…..”. As the unauthorised modification and use of hand tools has been shown to pose a significant risk, any proposal to use modified tools must be documented in the SMP.

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Screw plugs in cylinder outlets
What happened? There have been a number of cases of LPG gas cylinders leaking in vehicles, where the valve was

either accidentally opened, or where it had not been closed fully. Legislative changes will make it mandatory for all cylinders offered for sale to have a screw plug to be fitted in the outlet valve of the cylinder. The term “plug” includes a cap on male thread outlets where applicable. This will substantially decrease the risk of leakage from the cylinder. Key issues The current requirement in the Petroleum and Gas (Production and Safety) Regulation 2004 is for screw plugs to be made available to customers who purchase gas in cylinders. Amendments effective from 1 April 2008 will mandate that LPG suppliers provide a screw plug in the outlet of the cylinder. Schedule 7 (Safety requirements for transporting cylinders in vehicles) will read: Part 3 7. Cylinders for supply of LPG must have screw plugs: A person who supplies LPG to consumers in cylinders with a capacity of 9kg or less must ensure each cylinder is fitted with a screw plug that— (a) is inserted into the cylinder outlet; and (b) allows for its easy removal by a consumer. LPG suppliers should also be aware of the other related requirements which include: 8. Cylinders not to be overfilled: A person who supplies LPG to consumers must, if filling a cylinder with LPG, fill the cylinder in a way that prevents it being overfilled. 9. Signage required at places where cylinders are filled or exchanged: A person who supplies LPG to consumers must ensure a notice stating the requirements under Part 2 is displayed at each place where the person fills or exchanges cylinders. The above obligations are safety requirements, and s708A of the Petroleum and Gas (Production and Safety) Act makes it an offence not to comply with a safety requirement, carrying a maximum penalty of $37,500. Recommendations LPG suppliers must ensure that by 1 April 2008 all cylinders they supply with LPG to consumers have suitable screw plugs fitted, including both exchange cylinders and cylinders filled by decanting on-site. It is recommended that the consumer be provided with clear instructions for the plug’s use including

how to remove it easily and that it should be used whenever the cylinder is not in use. 

Location of air conditioners
What happened? There have been a number of cases where electrical devices, particularly the external components of split system air conditioners, have been installed in close proximity to LPG cylinders. These units are defined as ignition sources and are not suitable for the hazardous

areas surrounding a cylinder. This alert gives guidance regarding the legally required distances to ensure safety. Key issues There are two types of gas cylinder which can be identified by looking at the valve. The pictures show an exchange cylinder valve and an in-situ fill cylinder valve. Note that the in-situ valve has a fitting (with a yellow cap) which allows connection by a tanker. Safety distances for this type of cylinder are larger than for exchange cylinders. The drawing shows the hazardous areas for each type of cylinder. Recommendations Air conditioner installers should pay particular attention to the drawing and ensure that air conditioner compressors are located outside the hazardous zone. They may be required to relocate incorrectly positioned units at their cost. Gas installers should likewise avoid placing cylinders closer than the required distance to air conditioners and other sources of ignition.

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 Distance from valve

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Portable gas refrigerators
What happened? A fatality has occurred in north Queensland where the cause of death has been identified as poisoning by carbon monoxide generated from a portable refrigerator operating on gas in an enclosed vehicle. Key issues These appliances must not be used in unventilated areas when operated on gas.

Use of these appliances when operated on gas in confined spaces such as in a house, shed, car, caravan or tent can lead to the generation of high concentrations of carbon monoxide gas. Carbon monoxide is colourless, odourless and thus not detectable by humans, and can result in death when inhaled in small concentrations. While all these appliances are approved for safe use in ventilated areas, they come with warning labels about their use in unventilated enclosed spaces. However this warning may not be immediately obvious. Note: These appliances may be safely used inside when operated on electricity (12 or 240 volts) if that option is available. Recommendations Consumers and users of these products need to ensure that they read the warning and operation details on the product, and do not operate in enclosed unventilated spaces. This warning also applies to other appliances designed to be used outdoors such as barbeques or patio heaters. Importers and suppliers of these refrigerators are being instructed that from 1 January 2008 they must fit larger warning labels with respect to the fridge’s operation on gas.

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LP Gas Cylinder Alert
What happened? Some 9kg LPG cylinders manufactured in China have been found to have a faulty valve. There have been a number of reported cases in Australia of the securing gland nut on these valves not being correctly tightened and allowing the contents of the cylinder to escape. In some cases this has resulted in a serious fire and/or injury. Key Issues The pictures show the nut which, having a left-hand thread, can be undone during the process of manually turning off the cylinder valve. This may cause the valve assembly to loosen and separate, allowing the immediate release of the cylinder contents under pressure with no real way of stopping the flow once started. Recommendations All persons refilling these cylinders are requested to pay particular attention to the tightness of the gland nut. Remember that this is a left-hand thread and is tightened in an anticlockwise manner. All valves on Chinese manufactured cylinders should be checked as a matter of course and any loose nuts found reported to this office. Tightening should ensure that the valve gland nut is well-secured in place. IF IN ANY DOUBT, DO NOT FILL THE CYLINDER.

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A crushing incident involving drill collars and selection of lifting elevators What happened? A rig worker sustained serious injuries to his back after being struck by a falling length of drill collar while drilling a coal seam gas well.

The incident resulted in the worker being knocked to the rig floor. The drill collar was being raised onto the rig floor in readiness for connection onto a drill bit sub and the drill bit itself. Almost in the vertical position, the drill collar slipped through the incorrectly selected set of 5½” casing elevators,bounced off the pipe handler and struck the worker, coming to rest on the hand railing. Safety issues identified • The risk of storing and transporting identical looking

sets of locating and

elevators in the same
transport bin was not identified. • The safe work procedure did not specifically include

verifying of code
stampings on the individual elevators. • Inexperience and lack of training.

 Recommendations • Drilling companies must ensure that all hazards are identified in relation to their work. • Activities and appropriate controls are identified and implemented to reduce risk to as low as reasonably practicable. • Design/engineering controls should always be considered as a first possible control mechanism.

• Standard Operating Procedures (SOP) of this nature require more than one verification process. • In this case the company involved has subsequently implemented a three level verification process prior to the elevators being attached onto the bail arms, including a simple colour coding system that allows visual identification of different sized elevators.

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Two-Stage Gas Regulator Failure
What happened? There have been a number of failures of 2-stage gas pressure regulators on LPG installations throughout Queensland. Most regulator failures have led to blocking, stopping the flow of gas. In a few cases a diaphragm has ruptured leading to serious leakage. This problem has occurred in a variety of regulator types and on most brands of gas. Key issues Experiments by LPG Australia and the Department of Mines and Energy SIMTARS laboratory have demonstrated that some residue can be formed when LPG liquid is deposited in flexible hoses. They have demonstrated that some hoses can produce unacceptable amounts of residue which can then affect regulator performance if allowed to drain into the regulator. However, similar effects have been found with regulators connected to copper pigtails.

Almost all regulators found to exhibit these failures are the smallest available (around 200 MJ/hr) Recommendations Use regulators of capacity at least 300MJ/hr. Use copper pigtails for fixed installations and low-loss flexible hose for mobile applications such as caravans (check with your hose supplier). Mount regulators above the level of the cylinder valve. Fit an elbow or “T” to the inlet and ensure that any residue which deposits in pigtails will flow back into the cylinder

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Underground LP gas storage tank fire
What happened? A service station attendant was conducting an early morning routine check of the underground LP gas storage tank. The attendant stated that he was attempting to view the tank contents gauge (located in an access pit at ground level) using his mobile phone light. He also stated that he was carrying a cigarette lighter which fell out of his pocket onto the ground. When he picked it up, a flash fire erupted in his face. He was treated in hospital for burns. Key issues  There have been a number of these types of incidents in Queensland.  Carrying of unsafe devices into hazardous areas.  Leaks associated with fittings on gas storage equipment without ventilation.  Inadequate staff training or competency. Recommendations It is recommended that service station managers review their obligations under the Petroleum and Gas (Production and Safety) Act 2004 and in particular–  Ensure their Safety Management Plan (SMP) addresses the risks associated with LP gas  Take all necessary measures to provide an “acceptable level of risk” which may include:  Installation of telemetry to provide remote reading of gauges  Ventilation of enclosed areas  Requirement that staff must not carry any ignition devices that are likely to ignite gas (eg matches, lighters), into hazardous areas  Revision of operating procedures.

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Unsafe LPG dispenser operation
What happened During refuelling at a Gold Coast service station a taxi driver ‘latched’ the nozzle of the LPG dispenser while attending to other tasks. He then drove off with the gas dispenser nozzle/hose still attached to his vehicle. The dispenser was pulled off its mounts and struck an adjacent taxi driver attending his vehicle. The second taxi driver was seriously injured and LPG liquid was released, creating a further dangerous situation. A petroleum fuel tanker was delivering fuel to the site at the time of the incident. Key issues • Driver did not attend the nozzle when refuelling (the nozzle was fixed in the ‘on’ position). • Vehicle drove off with LP gas nozzle/hose still connected. • Due to angle of nozzle stretch, the breakaway coupling failed to operate in time. • Damage to service station LPG dispensers can lead to significant gas leaks. • Additional hazards exist during tanker deliveries

 Recommendations • Drivers are required to remain at the dispenser whilst refuelling their vehicle. Australian Standards require a person to positively activate the flow of LPG at all times. • Where drivers are observed to be not attending the dispenser during refuelling, the gas supply should be shut off. • All latching devices should be removed from standard dispenser nozzles. Refer to AS/NZS 1596: Storage and handling of LP gas (Section 9.3.4, Dispensing nozzles).

• Review tanker delivery procedures, i.e. timing, location and exclusion zones. • Review emergency procedures with respect to site shutdown and vehicle entry/exit. • Ensure Safety Management Plans conforming to the Petroleum & Gas (Production and Safety) Gas Act 2004 are in place and implemented.

FLAMMABLE REFRIGERANT ALERT
What Happened: The Petroleum and Gas Inspectorate has been advised that attempts may be made to sell refined LPG for use in automotive air-conditioning in Queensland. These refrigerants are normally sold in aerosol type cans and may contain the words “hydrocarbon refrigerant”, “propane” or “butane”. Some vehicles from interstate may be fitted with these refrigerants Key Issues: • The use of flammable hydrocarbon refrigerants in automotive applications is currently not permitted in Queensland. • LP gas is a highly flammable product and can lead to fire or explosion when as little as 2% is mixed with air. • Repairers of air-conditioning systems from other States must take care to ensure their personal safety. Recommendations: • Do not use these refrigerants in any vehicles repaired or serviced in Queensland. Note that no new vehicles are fitted with these refrigerants. • If servicing an interstate vehicle, shut down all sources of ignition in a 3 metre radius around the vehicle. Under no circumstances use a flame unless the system is emptied and purged. Replace with non-flammable refrigerant. • Report any instances of this product being sold/used to a

USE OF NON-METALLIC FITTINGS
What Happened: There appears to be some confusion about the use of non-metallic fittings in above ground gas installations, particularly with respect to their use with composite gas pipe. There are

now many suppliers of this composite pipe throughout Australia for use with both gas and water and some supply both metallic and non-metallic fittings. Key Issues:  The approval of the pipe (a typical type is shown here) falls under Australian Standard AS4176 which is called up in AS5601 Table 3.1.  Table 3.1 also requires fittings to comply with AS4176.  It is understood that some non-metallic fittings have been approved under AS4176 (see picture).  However Clause 3.2.2 (e)(i) of AS5601 specifically provides that non-metallic fittings shall not be used above ground.

 Recommendations:  It is understood that some legal argument is being conducted at the moment about the exact interpretation of the Code, but a number of Australian States have already advised that these fittings will be banned above-ground in their jurisdictions. Accordingly it is recommended that, until the issues have been resolved, you should not install nonmetallic fittings above ground in Queensland gas installations. Any installer who has already completed such an installation should contact a Petroleum and Gas Inspector for advice.

TWO-STAGE GAS REGULATOR FAILURE

What Happened: There have been a number of failures of 2-stage gas pressure regulators on LPG installations throughout Queensland. Laboratory experiments have shown that under certain circumstances liquid LPG can enter regulators and may damage non-metallic components including the regulator diaphragm. Most regulator failures have led to the regulator ceasing to pass gas, but in a few cases a diaphragm has ruptured leading to serious leakage of gas. This problem has occurred in many types of regulator and on most brands of gas. Key Issues:  Under some conditions LPG liquid can condense in the high-pressure flexible hose or copper pigtail joining the cylinder to the regulator.  If the regulator is placed below the level of the cylinder outlet or a significant portion of the pigtail is above the regulator inlet, this liquid can drain into the regulator and may affect non-metallic components.  Continual exposure of non-metallic components to liquid LPG can result in deterioration and failure.  Excessive use of thread sealant can lead to contamination of LPG liquid. Recommendations: 1. Mount regulators above the level of the cylinder valve. 2. Fit an elbow to the inlet to keep pigtails below the regulator as far as possible. 3. Use Teflon© tape rather than thread sealant on high-press

CONTAINER MARKING
Key Issues: Containers shall be clearly marked with the type of gas contained, e.g. PROPANE. A colour patch shall be applied to highlight the current re-test date stamp. The colour patch shall be of a contrasting colour to that of the cylinder and shall indicate, by colour, the year of test. The following colour code is preferred: Year of test: 2005 2006 2007 2008 2009 2010 Patch Colour: Cream Red Lilac Yellow Green White Year of test: 2011 2012 2013 2014 2015 2016 Patch Colour: Purple Pink Brown Orange Black Cream Note: A colour patch is not required on new containers. Recommendations:

Cylinder test stations and gas suppliers must ensure that this important safety feature is maintained.

190 kg Cylinder Alert
What Happened: Following a series of inspections of installations supplied by 190 Kg cylinders it has been found there is a safety issue with the direction of the safety relief valve discharge openings on cylinders fitted with multivalve fittings, impinging on cylinder lids and cowl rings. Key Issues: ▪ Cylinders re-fitted with multi-valves may breach the requirement that the safety relief valve discharge must be unimpeded. ▪ This occurs when the relief valve opening and the opening in the cylinder lid fail to coincide. ▪ AS2030.1-1999 Section 5.4.2 (b) states that “The form of protection shall permit unimpeded escape of discharge from the safety relief valve.” ▪ Where this does not occur, cylinder lids will need to be modified to bring the installation into line with the Standard. Recommendations: Cylinder test stations and gas suppliers must ensure that this important safety feature is maintained.

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Patio Heater Safety
What Happened: Patio Heaters are now widely used throughout Queensland, particularly in outdoor situations. There are serious safety issues with using these units indoors or improperly storing the gas cylinders used to supply them. A recent fire in a restaurant was the direct result of storing LP gas cylinders near the kitchen. Key Issues: • Patio heaters are not designed for indoor use and must not be used inside under any circumstances. • They may be used in temporarily screened-off outdoor areas provided that there is significant ventilation to allow the products of combustion to escape. • Gas cylinders used for these devices (usually 9 kg capacity or more) are not permitted to be stored inside. • Any improper use or storage is a breach of the Queensland Gas (Residual Provisions) Regulation 1989 and has the potential to cause fire or serious injury. Recommendations: Restaurant and café owners should ensure that the use of these heaters is in accordance with regulations.

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Filling of gas cylinders

What Happened: Reports have been received that there are some individuals filling non-automotive gas cylinders at service stations. Key Lessons: • Automotive LP gas used as an engine fuel is not suitable for general gas appliance use. • The LP gas used in engine applications can contain up to 50% butane which can alter the combustion characteristics of appliances and could result in dangerous emissions. • The filling of small cylinders from dispensers often results in over-filling which can cause safety relief valves to discharge at a later time. • The filling of a non-automotive gas cylinder from an automotive dispenser is a breach of the Queensland Gas (Residual Provisions) Regulation 1989. Recommendations: • Companies who supply automotive LP gas are asked to make this alert known to every relevant outlet and advise them of their responsibilities and potential liabilities. • Any person found illegally filling a cylinder on a forecourt should be reported to the Petroleum and Gas Inspectorate.

Fuel Gas For Camper Vans
What Happened: A number of reports have been received of gas installers being requested to connect the gas appliances in a campervan to the LP Gas engine fuel supply. Key Lessons: • LP Gas used as an engine fuel is not suitable for general gas appliance use. • The LP gas used in appliance applications can contain up to 50% Butane which can alter the combustion characteristics of appliances and could result in dangerous emissions. • Installers, campervan manufacturers and owners are advised that regular inspections will be made and any breaches of this important safety requirement will be treated seriously. Recommendations: • Gas Installers are instructed to report any instances of appliances being supplied from a vehicle fuel tank to their regional gas inspectorate office. • All certifiers of campervans should take particular care to check the source of gas appliance supply.

CARAVAN COMMISSIONING
What Happened: A camper trailer used as a display model at a caravan show was subsequently sold to a customer. The trailer contained a slide out gas cooktop designed for connection to the gas supply by a hose and bayonet fitting. The rear of the bayonet fitting had not been connected to the appliance and when gas was turned on a serious leak occurred through the open end. The customer had turned on the gas believing the appliance was fit for use. Key Issues: • The unit was sold to the dealer without indication that it had not been appropriately finished • There was no function checking of gas equipment prior to delivery to the customer. • This type of oversight is a breach of the Gas Regulations and has the potential to cause explosion and serious injury. Recommendations: Caravan dealers should check the gas installation is complete and conduct a test of appliances before a van or trailer is delivered to a customer.

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USING CHEATER BARS ON HANDTOOLS
What Happened: Recently, an incident occurred on a drilling site where a stillson wrench broke off at the handle after a six foot long “cheater bar” was attached to dislodge a drill bit from

a drill string. The incident resulted in a driller receiving injuries to his face as a result of a piece of metal from the handle of the stillsons flying up and hitting him. Key Issues: • The use of cheater bars on handtools, especially stillsons, appears to be a regular practice on some drilling sites. • This overloads the tool and can result in breakage with attendant risks to safety. Recommendations: The practice of using cheater bars on handtools should be stopped immediately. There is always an alternate way of doing the job safely. Managers and supervisors should lead the way in outlawing this practice.

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Vehicle Fire Involving Gas Cylinders
What Happened: A utility carrying two 9 kg gas cylinders was destroyed by fire after the webbing strap restraining the cylinders failed, allowing them to roll around in the back of the vehicle. The webbing strap had been placed through the openings in the cylinder neck ring and wrapped around the cylinder valve. The valves on both cylinders opened slightly allowing liquid gas to escape. The driver stopped the vehicle and attempted to turn off the cylinder valves. As he reached into the back of the vehicle a source of ignition, most probably static discharge, caused to gas to ignite. The driver suffered second and third degree burns to his face, head, arms and chest. Key Lessons:

Ensure all webbing straps used are of a suitable quality to restrain the cylinders under all conditions. Make sure the strap is not placed over sharp edges. The strap was placed around the cylinder valves, which may have contributed to the opening of the valves. If the cylinders had been adequately restrained the incident may not have occurred. Recommendations: • Everyone who transports gas cylinders must take particular care to ensure the cylinders are adequately secured. • A copy of this alert be circulated to all gas agents, distributors and portable cylinder exchange locations to make the public aware of the problem.

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COAL SEAM GAS RIG FATALITY
What Happened: A drill rig operator suffered fatal injuries when he was crushed between a length of drill collar and an adjacent “mousehole” during stacking pipe on an unstable foundation. It appears that the ground gave way between the position where the pipe was being stacked and the hole excavated to locate the “mousehole”. Key Lessons: • Great care needs to be taken when working with or near heavy objects. • Storage of heavy objects requires a known stable foundation. • Water or drilling mud can adversely affect ground stability • Be alert to possible entrapment situations • Do not use mats as load-bearing devices • Consider ground conditions carefully before locating temporary stacking facilities Recommendations:

All workers on drill rigs and similar installations need to take particular care when working in confined spaces with large, heavy objects. You should always have an “escape route”. Check the ground conditions below any temporary surfaces to ensure stability, particularly when soil conditions change.

FLAMMABLE REFRIGERANT ALERT
What Happened: The Petroleum and Gas Inspectorate has been advised that attempts may be made to sell refined LPG for use in automotive air-conditioning in Queensland. These refrigerants are normally sold in aerosol type cans and may contain the words “hydrocarbon refrigerant”, “propane” or “butane”. Some vehicles from interstate may be fitted with these refrigerants Key Issues: • The use of flammable hydrocarbon refrigerants in automotive applications is currently not permitted in Queensland. • LP gas is a highly flammable product and can lead to fire or explosion when as little as 2% is mixed with air. • Repairers of air-conditioning systems from other States must take care to ensure their personal safety. Recommendations: • Do not use these refrigerants in any vehicles repaired or serviced in Queensland. Note that no new vehicles are fitted with these refrigerants. • If servicing an interstate vehicle, shut down all sources of ignition in a 3 metre radius around the vehicle. Under no circumstances use a flame unless the system is emptied and purged. Replace with non-flammable refrigerant. • Report any instances of this product being sold/used to a Petroleum and Gas Inspector.

PIPE RACK STOPPERS
What Happened: A floorman was removing the covers from casing when two stands fell on him resulting in a broken leg and evacuation by the Royal Flying Doctor. Stoppers were not in place and the activity was being carried out in poor light conditions. The injured person was working alone at the time of the accident.

Key Lessons: Stoppers in place would have prevented this accident Poor lighting can add to a hazardous situation Supervisors and workers should be made aware of the hazards of their workplace Unsupervised work should only be carried out by suitably skilled personnel Recommendations: • Personnel must be made aware of the importance of installing stoppers on racks and other hazards at their workplace. • Ensure no cross-stacking of pipe occurs on racks or on the ground • Ensure all stoppers and racks are maintained in a serviceable condition • Only work in conditions of adequate lighting

PORTABLE LP GAS HEATERS
What Happened: There has been a disturbing increase in the use of portable gas heaters connected directly to 4.5 kg cylinders inside. There is some evidence to suggest that gas retailers are promoting the sale of combination gas heater/hose/regulator and cylinder as a consumer package. Key Lessons: There are many dangers associated with this type of set-up including • possible toppling of the cylinder with liquid release into the appliance; • heating of the cylinder from the appliance itself followed by release from the safety relief valve; • leakage from couplings or regulator vents causing fires. The consequences of a fire which ruptures the cylinder could involve loss of life, serious injury and extreme property damage. Recommendations: The Australian Gas Association is planning steps to outlaw the practice but, in the meantime, retailers should discourage consumers from using such a set-up to ensure their safety.

CARE OF LP GAS CYLINDERS
What Happened:

The domed base of a 45 kg exchange LP gas cylinder had apparently been on contact with the ground for some time. The base corroded, eventually resulted in a severe gas leak which caught on fire. Fortunately the damage caused was minimal, but could have threatened the house and its occupants. The cylinder was in test and otherwise appeared in good condition. Key Lessons: • Corrosion of gas cylinders may occur in areas not readily visible. • Once corrosion starts, it will continue and the eventual leakage may occur at a place far removed from the site of the original corrosion. • Any signs of corrosion should be treated seriously. Recommendations: All cylinder owners and re-fillers are required to examine cylinders thoroughly, particularly at the time of re-filling. If there is any doubt about the integrity of the cylinder, it must be taken out of use.

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USE OF WINCHES
What Happened: Improper lifting technique at an oil-rig caused part of a Rotating Head being lifted by winch to jam. Extra tension was applied and, when the unit still refused to move, the operator in charge climbed up onto the Blow-Out Preventer (BOP) Stack to take a look. As he did so, the unit suddenly released striking him on the head. He fell to the ground, did not regain consciousness and was pronounced dead some hours later. Key Lessons:

· Check equipment for correct method of attaching hooks prior to commencing winch operations. · Plan work and prepare for the unexpected. · Protection against falls is essential, even for short-term work at height. · If things go wrong during a procedure, stop and re-think. Don’t forge ahead and hope it will come out right. · Never place any part of your body near mechanical equipment under tension or compression where sudden release could cause injury. · Remember there is ALWAYS a safe way to do a job, so why not do it that way? Recommendations: Rig owners and operators please bring this Alert to the attention of all operational staff. The general circumstances of this tragedy, that is equipment with stored energy, is repeated every day at every site, so training, vigilance and continued reminders of the dangers must be part of daily working life.

Oxygen Safety
What Happened: A number of recent accidents in Queensland have highlighted the hazards of improperly using oxygen. This gas, known as the “gas of life” can kill if used wrongly. In particular, pressurised oxygen should be treated with great respect and should NEVER be allowed to come into contact with oil or any hydrocarbon as a spontaneous fiery explosion can result. The force of such an explosion can result in serious injury, terrible burns and death. Key Lessons: · Never use oxygen to leak test pipework. The slightest trace of oil or grease could set off an explosion. Oxygen is not a substitute for compressed air. · Turn oxygen valves on SLOWLY. Rapid pressurisation of pipework can lead to “adiabatic compression” where the oxygen heats rapidly and can then ignite metal particles or dust in an explosive manner. · Never oil or grease any components which will be used with oxygen and avoid oxygen contamination of clothes. · Never, ever fool around with oxygen. It could cost your life. Remember that in pure oxygen practically anything (including metals) will burn. Recommendations: With care, oxygen can be used safely, but users must never forget that this gas is hazardous and needs to be treated with great respect.

UNLICENSED GASFITTING - LAMB ISLAND
What Happened: We are aware of unlicensed gas installation work being carried out in the Lamb Island community. This Department has no record of any person on Lamb Island being licensed to undertake gasfitting work. Please be aware that a plumber is not necessarily licensed to install or repair gas appliances. Key Lessons: Residents should be aware that it is illegal and potentially dangerous to have gas installations or gas servicing work carried out by any person that does not hold a current Gas Installers Licence. Any licensed gas installer must produce his/her licence on request. Recommendations: If you have had a gas installation or service work carried out by a person who is not licensed, or who refuses to show you a licence, you should contact your gas supplier to have the installation inspected. The gas agent on the Island will be able to supply you with a contact number.

Unguarded Machinery
What Happened: Repairs to a rig at night involved electric welding and the rig was shut down while work was carried out. The electric welder cables were coiled on the deck and draped across an exposed drive shaft. When the clutch was engaged to test the repair, cables which were thought to have been removed were caught up in the drive shaft. The cables wrapped up the leg of an operator standing on the coil and dragged him into the shaft. The young operator suffered serious injuries to his leg.. Key Lessons: · Never assume that an action has been taken, particularly by inexperienced operators. Check yourself. · All rotating machinery needs to be guarded, even if it seems unlikely to ever cause a problem. · Never stand on coils of rope or wire. Recommendations:

All operators to immediately check rigs to ensure that rotating machinery is guarded. Safety rules should be reinforced at safety meetings. Regular audit schedules should include checking machinery guards.

Oxygen Regulator Fire
What Happened: A faulty Oxygen Regulator was placed into service, having been connected to an Oxygen cylinder which appears to have had dust or other contaminant in the valve. Upon opening the cylinder valve, the high pressure oxygen ignited the contaminant. The combustion then accelerated rapidly causing an extremely hazardous situation to develop. Fortunately the valves on both the Oxygen & Acetylene cylinders were able to be shut off and prevent any further problems. Key Lessons: Equipment must always be checked so as to ensure correct functioning and serviceability Cylinders should always be stored with dust caps or plugs fitted Whilst in use, cylinders and associated equipment should regularly be monitored to ensure correct functioning of this equipment. We must all avoid the tendency to become complacent about our workplace, as this is when accidents WILL occur Recommendations: If not already in place, a STANDARD OPERATIONAL PROCEDURE involving regular checks as mentioned above, should be enlisted by all who use the various gases available. At the start of “Shift” all gas equipment should be checked for soundness and safety.