DIVING SAFETY

Title: INSPECTION MANUAL

MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 1 of 13

DIVING SAFETY MANAGEMENT SYSTEM

INSPECTION MANUAL

INS –IPR-043
GAS CYLINDER AND SAFE HANDLING

Prepared
Norshahira Bahari
By

Signature Date

Reviewed
Muhd Charles Mok (Diving Advisor)
By

Signature Date

Approved By Ahmad Kamarul Anwar bin Nasir (Project Manager)

Signature Date

Approved
A Ghani (Managing Director)
By

Signature Date

PIONEER PEGASUS
 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

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DOCUMENT CONTROL
Published electronic versions of documents are the only valid versions.
Paper printouts serve as information only.
Where there is a need to use controlled paper copies, this shall be defined and controlled
by Document Controller.

REVISION HISTORY
REV. ISSUE DATE DESCRIPTION REASON FOR CHANGE
0 1 Oct 2018 Issued for Implementation New Manual

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

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Contents

1 SAFE OPERATIONS PROCEDURE – COMPONENTS…………………………………………………4

2 INTRODUCTION…………………………………………………………………………………………………4

3 CLIENTS, GOVERNMENT AGENCIES, SUB CONTRACTORS………………………………………4

4 ABBREVIATIONS…………………………………………………………………………………………………5

5 REFERENCES ……………………………………………………………………………………………………..5

6 CYLINDER HANDLING………………………………………………………………………………………….5

6.1 GAS QUAD & CYLINDER MARKING………………………………………………………………………..5

6.2 COLOUR CODING FOR PIPING SYSTEM AND PANEL……………………………………………….5

6.3 CYLINDER FITTINGS……………………………………………………………………………………………6

6.3.1 VALVES……………………………………………………………………………………………………………….6

6.3.2 REGULATORS………………………………………………………………………………………………………6

6.3.3 GAUGES………………………………………………………………………………………………………………6

7 BAILOUT CYLINDER MAINTENANCE AND INSPECTION…………………………………………….6

7.1 FOUR STEPS TO IDENTIFING THREAD SIZES AND

PITCHES……………………………………..7

7.1.1 DETERMINE IF THE THREAD IS TAPERED OR

PARALLEL…………………………………………..7

7.1.2 DETERMINE THE PITCH…………………………………………………………………………………………

7

7.1.3 DETERMINE THE SIZE……………………………………………………………………………………………

8

7.1.4 DESIGNATE THE THREAD………………………………………………………………………………………

8

7.2 TECHNICIAN SERVICE

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

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PROCEDURE………………………………………………………………………..9

1 SAFE OPERATIONS PROCEDURE – COMPONENTS

Section No. Title

PPSB-INS-IPR-000 Index
PPSB-INS-IPR-001 Introduction
PPSB-INS-IPR-002 Digital Ultrasonic Thickness
PPSB-INS-IPR-003 Plasma Cutting
PPSB-INS-IPR-004 Ultrasonic Plate Inspection
PPSB-INS-IPR-005 Assessment of Ultrasonic Equipment Performance
PPSB-INS-IPR-006 Ultrasonic Flooded Member Detection
PPSB-INS-IPR-007 Still Photography using Hand Held Camera
PPSB-INS-IPR-008 Still Photography With a ROV
PPSB-INS-IPR-009 Video Recording using a Hand Held Camera
PPSB-INS-IPR-010 Video Recording With an ROV
Magnetic Particles Inspection using the Flexible Cable
PPSB-INS-IPR-011
Technique
PPSB-INS-IPR-012 Magnetic Particles Inspection using Current Flow Prod
Magnetic Particles Inspection using a Electronic Magnetic
PPSB-INS-IPR-013
Yoke
PPSB-INS-IPR-014 Magnetic Particles Inspection using a Permanent Magnet
PPSB-INS-IPR-015 General Visual Inspection by Diver
PPSB-INS-IPR-016 Visual Inspection using an ROV
PPSB-INS-IPR-017 Close Visual Inspection
PPSB-INS-IPR-018 Confirmatory and Remedial Grinding
PPSB-INS-IPR-019 Cleaning for Inspection
PPSB-INS-IPR-020 Use of OSEL ACPD
PPSB-INS-IPR-021 Potential Measurement Equipment Calibration Check
PPSB-INS-IPR-022 Potential Measurement using a Proximity Probe
PPSB-INS-IPR-023 Potential Measurement using a Contact Probe

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

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PPSB-INS-IPR-024 Marine Growth Survey

PPSB-INS-IPR-025 Coating and Corrosion Survey
PPSB-INS-IPR-026 Debris Survey
PPSB-INS-IPR-027 Scour Survey
PPSB-INS-IPR-028 Anode Survey
PPSB-INS-IPR-029 Riser Survey
PPSB-INS-IPR-030 Straightness Survey
PPSB-INS-IPR-031 Dent Survey
PPSB-INS-IPR-032 Underwater Inspection In-Leu of Dry Docking
PPSB-INS-IPR-033 Operating a High Pressure Waterblaster
PPSB-INS-IPR-034 Metrology Table Measurement
PPSB-INS-IPR-035 Bolt Tensioning 100%
PPSB-INS-IPR-036 Bolt Tensioning 50%
PPSB-INS-IPR-037 Broco Cutting
PPSB-INS-IPR-038 Working on Scaffolding Platform
PPSB-INS-IPR=039 Rigging
PPSB-INS-IPR-040 Lift Bag Operation
PPSB-INS-IPR-041 Chain Puller / Lever Hoist
PPSB-INS-IPR-042 Umbilical Stopper
PPSB-INS-IPR-043 Gas Cylinder and Safe Handling
PPSB-INS-IPR-044 Grit Blasting

PIONEER PEGASUS
 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 6 of 17

2 INTRODUCTION

This module is one of many “live” documents which make up the Diving Safety Management
System applied by Pioneer Pegasus Sdn Bhd (PPSB) to provide a safe place of work for its
employees.

The modules headed INS-IPR-001 to INS-IPR-043 make up the Safe Operations Procedure
however, relevant modules may be included in any other documentation packages where
required.

Each module is a complete document covering specific subjects in detail. They represent the
latest in industry standards and will be revised from time to time.

3 CLIENTS, GOVERNMENT AGENCIES, SUB CONTRACTORS

Copies of this document will be supplied when requested, to clients, government agencies and
sub-contractors.

4 ABBREVIATIONS

Abbreviation contained in this document can be found in INS-IPR-001

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

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5 REFERENCES

Ref: Code of Practice for The Initial and Periodic Examination, Testing and Certification
of Diving Plant and Equipment IMCA D 018 Rev 1

Ref: DESIGN for Surface Orientated (Air) Diving Systems IMCA D 023 Rev 1

Ref: DESIGN for Saturation (Bell) Diving Systems IMCA D 024 Rev 2

Ref: PARKER 4 Easy Steps to Identify Hydraulic Threads

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 6 of 17

6 CYLINDER HANDLING

6.1 Gas Quad & Cylinder Marking

The following is a standard color code recognised throughout the industry: -
CYL/QUAD CYL/QUAD TOP
GAS SYMBOL
BODY (“shoulder”)
HELIUM He Brown Brown
DIVING OXYGEN O2 Black White
He/O2 Brown Brown & White
HELIOX MIXTURES
Quarters
NITROGEN N2 Grey Black
ARGON Ar Dark Blue Bark Blue
AIR (BREATHING) AIR Grey Black & White Quarters
CARBON DIOXIDE CO2 Black Grey
CALIBRATION GASES As Appropriate Pink Pink

Following analysis and pressure testing, the gas quad or cylinder must be marked with the
date, contents and pressure. All portable quads and cylinders must be marked "full" or
"empty".
DO NOT USE THE ABBREVIATION "M.T.”

6.2 Colour Coding for Piping Systems & Panels

The following color code shall be applied to all the systems operated by SSS. Where
practicable, valve handles and quick connects should be painted to match their function.

Service Colour Code

Helium Brown
Helium Oxygen Mixture Brown / White
Air Black / White
Nitrox Mixtures Black / White
Oxygen White
Carbon Dioxide Grey
Argon Blue
Nitrogen Black

6.3 Cylinder Fittings

All equipment must be frequently inspected for defects and be properly maintained.
In particular, equipment must:
 be taken out of service if damage or malfunction is suspected.
 be protected from corrosion and dirt

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 6 of 17

 be free from contamination, particularly oil or grease when using oxygen.

6.3.1 Valves

Valves must: -

 be compatible with the threads of the equipment to be connected to them.

 never be used as a substitute for regulators even in the case of needle valves.

 be closed sufficiently to shut off gas pressure, but without use of excessive force.

6.3.2 Regulators

Regulators are sensitive items of equipment and must: -

 have inlet filters to protect the internal control mechanism from dirt and grit.
This is particularly important in the case of oxygen regulators.
 be suitable for the gas type and pressure, and not be interchanged.
 not be modified in any way to allow bypass and consequent increase in output
pressure.
 not have hoses hung on them during use.

6.3.3 Gauges

The correct gauge as recommended by the manufacture must be used with regulators
In particular, gauges must: -

 be compatible for use with oxygen

7 Bailout Cylinder Maintenance and Inspection

This section is to promote a uniform approach for the maintenance, Inspection and Testing of
in service Seamless Gas Cylinders Taken Underwater i.e. Divers Bailouts.
System Technicians are required to adhere to this procedure when carrying out Inspection and
Maintenance of Bailout Cylinders

7.1 Four Steps to Identifying Thread Sizes and Pitches

Knowing the correct thread is critical for selecting the right replacement parts for maintenance
and repair. Selecting the wrong part can result in damage to the thread during installation,
which compromises the pressure holding capacity and seal reliability of the fitting or adapter.
Quickly and properly identifying threads can help maintain safe, productive and profitable
operations

In order to differentiate between the various thread types, all that is needed is this reference
chart, a calliper and a thread gage. The most important tool is the thread gage (or pitch gage).
This tool, which has a “saw tooth” appearance, helps determine the thread pitch. It has a
specified number of serrations within a certain distance and is (usually) marked accordingly.

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 6 of 17

For metric threads, the pitch is considered as the distance, in millimetres, between each thread.
For all other threads, the pitch is considered as the number of threads per inch.
Four easy steps to Identifying thread pitches is highlighted below

Ref: Parker Fittings “Four Easy Steps to Identifying Hydraulic Threads”

7.1.1 Step 1 – Determine If the Thread Is Tapered or Parallel.

NPT/NPTF and BSPT are tapered threads while UN/UNF and BSPP are parallel. Metric Tapered
and Metric Parallel speak for themselves. In some cases, Step 1 can be accomplished by visual
inspection alone. Tapered threads get smaller in diameter toward the end of the fitting while
parallel threads maintain the same diameter from start to finish. If this is not obvious by
looking at the fitting, use the parallel jaws of a calliper to make a comparison. Furthermore, the
presence of an O-ring or the removal of a tube nut is usually an indication that the male thread
is parallel. Completion of Step 1 will eliminate three of the six possible thread forms.

7.1.2 Step 2 – Determine the Pitch.

This can be deciphered using a pitch gage for comparison or by accurately measuring and
calculating the number of threads within a given distance. It is much easier to compare threads
against a lighted background with a pitch gage. Because some thread pitches are relatively
similar, it is advisable to try a number of gages before deciding which one fits best. The result
from Step 2 will narrow down the possible thread forms even more because most have a
distinct pitch. Consult the “Step 2” column in Table 1 for possible pitches.

7.1.3 Step 3 – Determine the Size.

Combining the results of Steps 1 and 2 will determine – or help predict, in some cases – the

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 6 of 17

correct procedure for Step 3. There are two methods for determining the thread size – which to
use depends on whether the thread is a pipe thread (NPT/NPTF, BSPT, BSPP) or is not a pipe
thread (UN/UNF, Metric Parallel, Metric Tapered). Keep in mind that tapered (as determined in
Step 1) does not necessarily mean that it is a pipe
thread (e.g., Metric Tapered). Likewise, pipe thread can be parallel (e.g., BSPP).
For pipe thread, determine the size by comparing it with a nominal size profile, as shown in
Figure 1 (a useful tip – pipe sizes up to 2” nominal size can be determined by measuring the
actual outside diameter, subtracting ¼” then rounding-off). For non-pipe thread, the actual size
can be determined by measuring the outside diameter (major diameter) with a calliper, as
shown in Figure 2.

7.1.4 Step 4 – Designate the Thread.

Technically, this final step does not pertain to identifying the thread. Rather, it is a method of
designating the thread type in an industry standard format for others to understand. Examples
of the various formats are shown in the “Step 4” column of Table 1 below. These typically have
an indication of the thread size (whether nominal or actual), the type and – in some cases – the
pitch.

Technician Service Procedure

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 DIVING SAFETY
Title: INSPECTION MANUAL
MANAGEMENT SYSTEM
GAS CYLINDER AND SAFE HANDLING

Doc. No: PPSB-INS-IPR-043 Rev: 0 Date: 1 OCT 2018 Page 6 of 17

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