AS5034 Gas Distribution Systems

AS5034 Gas Distribution Systems

PBS uses factory trained technicians when dealing with AS5034 Gas Systems.

PBS install Brewery approved Harris AS5034 Compliant Gas regulator Boards with the gas distribution systems . The Regulator boards are fitted with High Flo Regulators,pressure relief valves and anti-whip cylinders leads ,all comply to AS5034.

PBS carries out six and twelve monthly maintenance and certification of gas distribution as laid down in AS5034 -2015

Beverage Gas Standard

On the 28th of October 2005 a new Australian Standard known as AS5034: Installation and use of inert gases for beverage dispensing came into effect. It sets out the requirements for the use of inert gases for beverage dispensing and looks at all areas associated with the hazards of compressed and refrigerated gases such as carbon dioxide.

Compressed inert gas systems (beer gas) consists of:

  • Gas Supply Systems – Cylinders (single and multiple, refrigerated liquid CO2 supply, on-site gas generation and mixing and compressed air;
  • Gas Distribution Systems – Regulator boards, safety devices and piping;
  • Beverage Dispensing Applications – Post mix and ready to drink (pre-mix) applications, bottled wine dispensing, draught beer and ready to drink kegs.

Due to all gas systems being under pressure, it is possible that the system and equipment connections may develop leaks, causing build-up of inert gases in cellars and low level areas which presents hazards for personnel working in those areas. Due to the pressure in gas systems CO2 Bottles contain 5000KPA Mixed gases up to 25000KPA ,safety devices are now part of the gas distribution system to ensure that in the event of a gas regulator failure high pressure can’t reach the keg ,causing it to explode in a worst case scenario . Kegs have a bursting pressure of anywhere between 350- 440KPA.

Compliance Dates

The new requirements were phased in, depending on location and ventilation properties of storage and cellar areas:

  1. Non-naturally ventilated areas need to be compliant by the end of 2007;
  2. Gas operated pumps requiring exhaust to the outside areas by end of 2007; and
  3. All other areas requiring compliance improvements by the end of 2011.

All areas needed to comply by the end of 2011

The AS5034 Beverage Gas Standard covers a number of areas including:

1. Design, Installation and testing including location and design of dispensing systems.

Key design requirements such as protecting dispensing systems from over pressure and back flow and being able to isolate key areas are required to comply with AS5034. By improving system design and increasing regular maintenance, the risks associated with an inert gas dispensing system will be further reduced.

2. Location and ventilation of supply systems including gas detection and emergency procedures

The preferred location of all inert gas (cylinders and mini-bulk) systems is outside in a well-ventilated area. Specifications are provided for the ventilation requirements of a cellar. The Requirements affect where the gas is located and whether your area will need monitoring. Most venues will need a monitor in both their cellar and cool room to comply to AS5034 even if your gas is stored outside. Storage areas that cannot comply with the ventilation requirements will require gas monitoring

3. System operation and maintenance including maintenance records

Weekly leak checks must be performed by the venue and more complex six monthly maintenance is required e.g. to calibrate your monitor and check safety valves. Twelve monthly maintenance including a pipeline pressure test is also required to meet AS5034. All maintenance records must be kept for at least two years.

4. Signage

Systems need to be labelled and appropriately signed. Examples of signs required include warning notices, operating instructions, inert gas warning signs, safe operating procedures, isolation valves, safety valves and pipeline contents.

5. Training of staff and contractors

AS5034 requires all staff to be trained in manual handling procedures, the properties and hazards of inert gases and the correct use of Personal Protective Equipment (PPE). There are also training requirements for any contractors entering a venue

What risks do inert gases cause?

  • Carbon Dioxide and Nitrogen gases are asphyxiants and can cause injury and death if the oxygen content is reduced below a certain level.
  • Carbon Dioxide is heavier than air & will fall to the floor and collect in confined spaces, unless ventilated.
  • Injuries & Deaths in cellars have occurred

References include: SAI GLOBAL AS5034-2005, AHA-NSW

Compliance to Australian Standard AS 5034

Beverage Regulators

(PICTURE
OF HARRIS
GAS BOARD
GOES HERE )

The Beverage regulators must be manufactured and tested to comply with all of the requirements of AS 5034-2005 “Installation and use of Inert Gases for beverage dispensing”

Boards must contain the following components and safety items
1. A high pressure primary single stage set pressure regulator on each board
2. Line isolation valve as required in AS 5034
3. Low pressure secondary regulator/s on each board.
4. Special connection blocks .875-14 UNF RH to AS5034 as nominated in AS 4840(so low pressure regulators can’t be attached to high pressure gas bottles .
5. Safety Relief Valves for secondary regulator
6. Non-Return Valves.
7. Safety Relief Valves vented to safe area in event of regulator failure.
8. Anti-Whip Connection lead.
9. Safety Relief Valve for primary regulator

All gas systems must be tested and certified every six months.

The following Standards apply to these items

Regulators Primary

AS 4267 “Pressure Regulators for use with industrial gas cylinders” as referred to in AS5034.
AS 4706-2001 “Pressure gauges for regulators used with compressed gas cylinders”.
Inlet pressure: 30,000 kPa. Outlet pressure: Set at 1000 kPa.

Regulators Secondary

AS 4840 Low Pressure Regulators for use in industrial compressed gas reticulation systems referred to in AS 5034.
This also includes the .875-14 UNF RH connection block and regulator inlet stem which is quite specifically nominated in both standards for regulators that are to be easily connected and disconnected.

AS 4706-2001 “Pressure gauges for regulators used with compressed gas cylinders”.
Inlet pressure: 20,000 kPa Outlet pressure : Set at 400 kPa (or less)

Safety Relief Valves

Meet AS 1271-3 for Class A and all requirements of AS 5034 in particular the required discharge rate at 125% of the set pressure. There are two types fitted, one to the primary (high pressure reduction) regulator set at a higher pressure and one for the secondary (low pressure )regulators and set to protect downstream equipment (kegs) from over pressurisation. All safety Relief valves are individually serial numbered and certified,

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