I’ve got a manifold system and pipeline on site, how do I know if it’s mine?
Quite simply, contact your procurement department to determine whether or not you are paying either your gas supplier or a pipeline company a monthly or quarterly rental for your system.
If you’re not paying any rental on your system, then it’s highly likely that you own the system and are responsible for its correct operation and maintenance.
Does my gas manifold and associated pipework need to be designed and installed by a specialist organisation?
It is strongly recommended that any high-pressure gas system be installed by a competent organisation.
British Compressed Gases Association Code of Practice 4 (BCGA CP4) states:
‘All persons involved in the design, installation, commissioning and testing of pressure systems shall (must) be competent in the work they are undertaking.
Competence requires that personnel have the appropriate level of skills, knowledge and experience, including a thorough knowledge of the relevant parts of this Code of Practice.’
During our work, we have found organisations that have used domestic plumbers to install high-pressure industrial gas systems. Domestic plumbers work with natural gas, which, at the gas meter outlet, has a standard working pressure of between 18.5 mbar and 23 mbar, which equates to roughly 3 psi.
Some industrial gas cylinders are filled to 4500 psi.
A list of BGCA members who are pipework installers can be found at:
www.bcga.co.uk > Members and Services > Services Directory > Pipework Installers
When my manifold and associated pipework have been installed, what information should I have been given by the designer and installer?
BCGA CP4 states:
The following technical and safety documentation shall (must) be handed over to the user for the safe operation of the pressure system.
The designer shall (must) provide the user with the following:
- safe operating limits to allow safe use, for example, for pressure and temperature;
- operating instructions, including emergency shut-down;
- drawings (P&ID, electrical circuit diagrams, etc.);
- information to allow a Written Scheme of Examination to be drawn up in accordance with the Pressure Systems Safety Regulations 2000;
- inspection and maintenance requirements, including instructions and, where applicable, testing requirements, for example, of safety shut-off systems;
- any additional information to allow the user to conduct an appropriate risk assessment to meet legal duties and to implement a safe system of work;
The installer shall (must) provide the user with the following:
- test certificates for any testing carried out by the installer;
- any accompanying documentation provided with any proprietary pressure equipment;
- a demonstration of the correct operation of the pressure system.
If the designer and/or installer has failed to provide you with any of the above, then we strongly recommend that you contact them and remedy the situation.
Does your training provide a practical session that shows us how the system works and how to changeover cylinders on the system?
The previous answer covers the fact that at the handover stage, the installer should have provided you with a demonstration as to the correct operation of your manifold system.
There are many manufacturers and suppliers of manifold systems.
Not all two systems are the same.
Our training covers how a generic autochageover manifold system operates and includes an interactive table-top exercise that covers how to correctly changeover a depleted gas cylinder on a generic system.
Our training is designed to complement the practical instruction that the installer of your system should have provided.
We are able to visually review your manifold system and comment on any visible safety issues.
In addition, our trainer is also able to question your operatives as to how they undertake a gas cylinder changeover procedure and comment on any safety or procedural issues.
What is a Written Scheme of Examination, and do I need one for my manifold system?
Pressure systems can store large amounts of energy — and if they fail, the consequences can be catastrophic. That is why the Pressure Systems Safety Regulations 2000 (PSSR) place clear duties on owners and users of pressure equipment.
One of the key requirements is to have a Written Scheme of Examination (WSE) in place.
A Written Scheme of Examination is a legal requirement under PSSR. Regulation 8 states that a pressure system must not be operated unless a WSE is in place, and Regulation 9 requires examinations to be carried out in accordance with it.
A Written Scheme of Examination is a formal document that sets out:
- Which parts of a pressure system need to be examined
- How they will be examined
- How often examinations are required, and
- The qualifications of the person certifying and carrying them out.
In short, it is the framework for ensuring that pressure systems remain safe to use.
The WSE must be drawn up by what the regulations term to be a competent person. However, not all manifold systems may require one.
In our experience, many organisations refer to their insurance company to ascertain whether or not their system falls within the scope of the regulations.
If you have a manifold system on site and if you don’t have a WSE in place, then we strongly recommend that you contact your insurance company to discuss the situation.
Do I need to have inspection and maintenance records for my manifold system?
Yes. Your manifold system is ‘work equipment’ and as such falls into the scope of the Provision and Use of Work Equipment Regulations (PUWER) 1998.
PUWER places duties on businesses to ensure that all workplace machinery and equipment is suitable, safe, properly maintained, and inspected in line with a planned maintenance programme.
We strongly recommend that your manifold and pipeline are regularly checked, tested and properly maintained.
