CGA’s May & June 2020 Safety Publications (New Releases & Revisions)

July 22, 2020

During May and June 2020, the Compressed Gas Association (CGA) issued the following new and revised safety standards and guidelines:

CGA G-4.8, Safe Use of Aluminum-Structured Packing for Oxygen Distillation

Released: June 9, 2020 (5th Edition)
Special Attribute: Harmonized publication

Many air separation plants use aluminum sieve trays in their distillation columns. Most plants built after 1990 have used structured packing in place of trays. The low pressure drop and good mass transfer effectiveness of packing make it attractive for some air separation applications, particularly for columns operating at near-atmospheric pressure.

This publication addresses the use of aluminum-structured packing in oxygen distillation. Other materials that can be used in this service such as brass, copper, or stainless steel are not addressed.

A summary of current knowledge and industrial practices used in the safe application of aluminum-structured packing in columns for the distillation of oxygen is included.

This publication is not intended to be a mandatory standard. It is based upon the combined experimental work, operating experience, and design practices of major producers and operators of air separation plants.

CGA H-11, Safe Startup and Shutdown Practices for Steam Reformers

Released: May 20, 2020 (2nd Edition)

This publication applies to steam reformers that are operated with natural gas, refinery off gas, naphtha, and other light hydrocarbon streams. It specifically applies to large volume hydrogen production plants, defined for this publication as a production capacity of 380 000 scfh (10 000 Nm3h) (9 MMSCFD or 240 000 Nm3D) or greater. This publication may be applied to smaller reformers depending on the technology used.

This publication covers operational safety of steam reformer startup and shutdown. Emphasis is placed on operational guidance and features that provide safeguards against the hazards associated with the transition and infrequent nature of startups and shutdowns. The publication is not intended to address the details of design, installation, construction, and initial startup (commissioning) of steam reformers.

CGA M-12, Guideline for Investigating Out-of-Specification Test Results for Food and Medical Gas Manufacturing

Released: June 30, 2020 (3rd Edition)

This publication provides guidance on how a food or medical gas manufacturer shall evaluate OOS test results. Although this publication is based on the U.S. Food and Drug Administration’s October 2006 Guidance for Industry Investigating Out-of-Specification (OOS) Test Results for Pharmaceutical Production, CGA M-12 also applies to device and food gas OOS test results obtained during testing of these products.

OOS test results include all test results that fall outside the specifications or acceptance criteria of the official compendia or that do not satisfy the manufacturer’s definition of acceptance. An OOS condition within a food or medical gas production facility is generally considered any failure of a batch, a lot, or finished product. Provided the plant’s automated or manual systems are qualified, operated as designed, and do not allow out-of-specification product to be produced into product storage, OOS investigations are not required for process plant upsets.

This publication applies to traditional batch test release and not to Process Analytical Technology models, since they use process controls and in-process data as the release mechanism. It also applies to chemistry-based laboratory testing of food and medical gases as well as contract firms that perform testing of food or medical gases.

CGA M-13, Guideline for Qualifying Third-Party Testing Laboratories

Released: June 30, 2020 (3rd Edition)

This publication describes a method that can be used to qualify third-party testing laboratories for compliance with current good manufacturing practices (CGMP/GMP) and good laboratory practice standards.

This publication describes the minimum criteria for qualifying third-party testing laboratories that provide analytical testing services for medical gases.

CGA P-8, Guideline for Safe Practices for Cryogenic Air Separation Plants

Released: June 9, 2020 (6th Edition)
Special Attribute: Harmonized publication

This publication provides guidance on the safe operation of cryogenic air separation plants. It is based on the experience of CGA member companies that operate cryogenic air separation units (ASUs).

This publication serves the interest of those associated or concerned with air separation plant operations and applies to safety in the design, location, construction, installation, operation, and maintenance of cryogenic air separation plants.

Emphasis is placed on equipment and operational and maintenance features that are specific to cryogenic air separation processes. Limited coverage is given to plant equipment such as air compressors, which are used in other industrial applications and for which safe practices in design, installation, and use have already been established elsewhere.

CGA P-8.4, Safe Operation of Reboilers/Condensers in Air Separation Units

Released: June 16, 2020 (4th Edition)
Special Attribute: Harmonized publication

Industrial cryogenic air separation technology used to produce oxygen, nitrogen, argon, and rare gases has an extremely good safety record. However, as with many present-day production processes, it has inherent potential hazards that shall be recognized and addressed by design and operating practice.

This publication addresses the operation of the reboilers of air separation plants. It contains a summary of current knowledge and industrial practices used in their safe application. It specifically applies to the main reboiler and oxygen product reboilers in which the oxygen concentration is greater than 75% in the liquid phase. Its guiding principles may be used for other reboilers within air separation plants, including auxiliary vaporizers, guard adsorber vaporizers, argon condensers, and the main reboilers in nitrogen generators.

CGA P-86, Guideline for Process Safety Management

Released: May 27, 2020 (1st Edition)
Special Attribute: Harmonized publication

For the purpose of this publication, process safety management refers to providing guidance to improve process safety in industrial gas facilities. It is not meant to refer to the OSHA Process Safety Management regulations.

The process safety management framework may be applied to all processes within the industrial and medical gases industry. It is designed to address process safety hazards.

The process safety management framework is intended to provide a design basis for the development of a process safety management system where an organization does not have one. It also may be used as a common basis for benchmarking existing process safety management systems.

In some countries, there can be existing regulatory requirements for process safety management systems. This framework is not intended to replace these requirements but may be used to supplement them for all industry regardless of regulatory requirements.

CGA V-12, Leak Detection Fluids Use with Gas Cylinder Packages

Released: June 16, 2020 (3rd Edition)
Special Attribute: Harmonized publication

Over the years leak detection techniques have varied from the use of simple household soap-based solutions to specialized leak detection fluids (LDFs). These specialized LDFs are far superior to household soap-based solutions, which can contain contaminants or other detrimental constituents. As such, household soap-based solutions should not be used.

There are various national regulations and international guidelines to ensure that cylinders and valves are checked for leak tightness. Though such a postfill check is an essential part of a quality control procedure to ensure that customers receive a nonleaking package, the choice of the LDF needs to be carefully considered because of potential hazards from LDFs. These potential hazards include inducing stress corrosion cracking (SCC) and incompatibility with materials and cylinder contents such as oxygen.

This publication applies to gas cylinder packages. It covers the selection and use of specialized LDFs that are suitable for industrial gases including medical and food gases that have particular compatibility requirements.

CGA V-22, Guidelines to Address Potential Hazards of Quick Release Cylinder Valves Used in Firefighting Systems (Formerly SB-39)

Released: June 16, 2020 (1st Edition)
Special Attribute: Harmonized publication

Several incidents with quick release cylinder valves that are used on some firefighting system gas cylinders have been reported. In one incident, a worker died and in other cases workers suffered bone fractures (shinbone, hand).

In all cases, the cause of the incidents was either the unexpected or intentional opening of the valve fitted to the gas cylinder during handling, filling, or venting of the cylinder. The consequences were that the cylinders went out of control after the valve opened.

This publication provides guidelines for the handling of gas cylinders during filling, storage, discharge, maintenance, periodic inspection, and transport equipped with quick release cylinder valves used in firefighting systems.

Quick release cylinder valves are used on cylinders typically containing carbon dioxide, nitrogen, or gas mixtures in firefighting systems.

CGA V-23, Standard for Cylinder Connections on Portable Cryogenic Liquid Cylinders (Formerly SB-26)

Released: June 30, 2020 (1st Edition)

Significant amounts of medical and industrial gases are being delivered in portable cryogenic liquid cylinders or dewars, most commonly the DOT-4L/TC-4LM series cylinders. This publication was developed to prevent tampering of outlet connections on portable liquid cryogenic cylinders.

This publication is intended for cylinder owners of DOT-4L/TC-4LM cylinders and provides requirements for the attachment of cylinder outlet connections and labeling of these cylinders.

Users of cryogenic liquid cylinders and related equipment should be familiar with the characteristics and safe handling of gases as outlined in CGA P-1, Standard for Safe Handling of Compressed Gases in Containers and CGA P-2, Guideline for Characteristics and Safe Handling of Medical Gases.