SF.812 METHOD STATEMENT
MS004A Issue: AProject/Job No: Generic Name: Dermot Cotter
Brief Description: Liquid CO2 transfer from cylinders
/ Thornliebank Ind Estate, Glasgow G46 8JW
Tel: 0141 638 7916 Fax: 0141 638 8111
e-mail:
Issue
1.0 / Scope of Work1.1 / General Description of Works, Location & Boundaries
Liquid CO2 transfer by heating a portable CO2 cylinder
1.2 / Equipment to be Installed or Removed
N/A
2.0 / Dates and Times
3.0 / Monitoring and Witnessing
Sections 6 to 12 should be used before completing Sections 4 and 5
4.0 / Resources4.1 / Supervision, Labour, Qualifications and Training
A CO2 trained person.
4.2 / Tools and Equipment to be used, Certification and Notes
1. CO2 cylinders.
2. Star Factory CO2 multi cylinder charging manifold with non-return valves
3. Charging lines allowable types:
Ermeto 6mmo/d x 1.0mm wall 316 STST tube (416 Bar (G))
Hydrasun DN6 ¼” UFBX1 STST corrugated and braided hose (167 Bar(G)) BOC CO2 10 mm diameter, 90 Bar(G).
4. Fittings Ermeto 6-PL type (MWP 315 Bar)
5. Thermostatic controlled cylinder electric heater jackets.
6. 110V Transformer with RCD protection and a multi-way extension lead suitable for the environment.
7 Cylinder weighing scales
8. Hand tools.
4.3 / Personal Protective Equipment
The following PPE will be worn at all times:
Safety boots with a heel, good grip and steel toe cap (200 joule)
Overalls – Star Standard issue.
Goggles to BSEN 166-349B.
Gloves – Impervious gloves.
5.0 / Detailed Sequence/Method of Working
5.1 / Before CO2 liquid charging takes place, the system will previously have been charged with CO2 gas to 5.0 Bar (G).
5.2 / A system check will take place to check all valves are open or set as required for the operation of the plant.
5.3 / The CO2 liquid cylinder(s) will stand vertically adjacent to the charging point and be secured upright in a well-ventilated area. All cylinders will be weighed.
5.4 / From this point the charging area shall be cleared of all personnel not involved with the charging process.
5.5 / A suitably rated charging hose (refer to section 4.2) will be connected between the liquid CO2 cylinder(s) and charging manifold. There will be non-return valves on the manifold to ensure liquid does not back fill into the cylinders. A hose will connect between the manifold and the charging point on the high-pressure receiver. The high pressure receiver charging point is to be above the liquid level in the high pressure receiver
5.6 / The heater jackets are to be fitted to the CO2 liquid cylinders but left electrically isolated.
5.7 / Wearing the above PPE:
The charging valve on the high-pressure receiver will be “momentarily” cracked open and then immediately shut off to test the hose and its connections for leaks to the CO2 manifold. The lines between each cylinder should be loosened retighten to check for gas. If there is gas in the lines, the non-return valves on the manifold need to be replaced.
5.8 / Connect the CO2 liquid cylinder(s) and test the lines by “momentarily” cracking open and then immediately shutting off to test the hose and its connections for leaks to each CO2 liquid cylinder.
5.9 / Once satisfied that the charging lines are leak free the charging valve on the high-pressure receiver will be opened fully.
5.10 / At any point that CO2 is found leaking the charging operation will stop and detailed leak searches will be carried out using soapy bubble or CO2 specific electronic detector. Once a leak is found the necessary remedial works will be carried out with the assembly at atmospheric pressure or at the very least with system valve and cylinder valves closed before the charging process is resumed.
5.11 / The valves on the CO2 cylinder(s) will be opened to one cylinder at a time.
5.12 / As CO2 liquid is introduced and the pressure rises leak checks will be carried out using soapy bubble or CO2 specific electronic detector.
5.13 / The heater jacket on the open CO2 liquid cylinders can be switched on after 2 minutes of charging. The heater jackets must have temperature thermostats fitted to limit the temperature to 500C.
5.14 / Once the cylinders have emptied, the cylinder heaters will be switched off prior to closing the valve on the cylinders and then the charging valve on the system.
5.15 / The charging line will be slowly bled of any pressure on the high-pressure receiver side of the manifold (to reduce the pressure behind the non-return valve to each cylinder), which might remain in it and then disconnected from the empty CO2 cylinder(s).
5.16 / The empty cylinders will be replaced by new liquid CO2 cylinder(s) and will then be connected repeating procedure items 5.5 to 5.15 inclusive.
5.17 / If applicable the compressor shall be run for short, infrequent “Bursts” until there is sufficient charge in the system to prolong compressor-running conditions
5.18 / Visual checks will take place using the gauges and the sight glass on the high-pressure receiver during running to ascertain the correct charge in the system.
5.19 / On completion of charging the charging hoses will be completely disconnected from the charging point, which will be mechanically capped with a blanking plug, cap or gas plug.
5.20 / Safety cut-out checks will be carried out on the system and documented at this point.
5.21 / All empty CO2 cylinders will be weighed and removed from the area to a safe secure place ready for collection.
5.22 / A final leak check of the system will be carried out again once normal running conditions are achieved to allow for temperature and pressure changes in the system.
Revision
Issue / Revision Notes* / Name (print) / Signature / DateDistribution
I confirm that I have read and understood this Method Statement and the associated Risk Assessment(s) RA022 and COSHH Safety Data Sheet(s) COSHH 015 REFRIGERANT - CARBON DIOXIDE R744.
Should circumstances change which invalidate this Method Statement or prevent the Control Measures being implemented, work shall be suspended until the Method Statement has been reviewed by the author or other suitable, competent, person and, if necessary, revised.
MS Issue / Name (print) / Signature / Company / DatePage 1 of 4
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