Safe Use of Gas Cylinder

Introduction

 Compressed gases used in a variety of industrial and laboratory

situations
 Compressed gases present a unique hazard. Depending on the
particular gas, there is a potential for simultaneous exposure to
both mechanical and chemical hazards
 Classification of Cylinder

• Flammable Gasses

• Oxygen and Oxidizing Gases

• Acid and Alkaline Gases

• Highly Toxic Gases

• Cryogenic Liquefied Gases

• Inert Gases
Segregation of Cylinders
Common Industrial Gases
 Flammables
Methane, Propane, Hydrogen
 Reactive
Acetylene, Vinyl Chloride, Tetrafluoroethylene
 Oxidizers
Hydrazine, Hydrogen
 Corrosives
Ammonia, Methylamine, Chlorine
 Oxygen and nitrous oxide cylinders must be separated from
flammables by minimum of 20 feet.
Main Causes of Accidents

 Inadequate training and supervision

 Poor installation
 Poor maintenance
 Faulty equipment and/or design(e.g
badly fitting valves or regulators)
 Poor handling
 Poor storage
 Inadequately ventilated working
conditions
 Main Hazards
 Impact from the blast of a gas cylinder
explosion or rapid relase of compressed gas
 Impact from parts of gas cylinders that fail
or any flying debris
 Contact with the released gas or fluid(such
as chlorine)
 Fire resulting from the escape of flammable
gas or fluids such as LPG
 Impact from falling cylinder
 Safe Working with Gas Cylinders:
Identification and Properties
 Clearly label all cylinders

 Labels should be durable

 Do not accept cylinders that are not clearly labeled

 Color-coding is not a reliable means of identification

 Cylinder colors vary from supplier to supplier

 If cylinder contents cannot be identified:

 Mark as “Contents Unknown”
 Contact the manufacturer
 Safe Working with Gas Cylinders
Work Practices

 Securely restrain cylinders to prevent them falling over

 Close the cylinder valve and replace dust caps when cylinder not in
use.
 Never drop a gas cylinder
 Never tamper with cylinders or subject them to abnormal
mechanical shocks which could damage the valve or safety device
 Never re-paint, change markings or identification or interfere with
threads
 Never disguise damage to a cylinder or valve. Label as faulty and
contact the supplier
 Never attempt to repair a cylinder
 Safe Working with Gas Cylinders
Work Practices

 Never scrap a cylinder

 Never subject cylinders to abnormally high or low temperatures
 Never mix gases in a cylinder
 Never try to refill a cylinder unless properly trained to do so
 Never transport by rolling them on the ground or use them as rollers
or supports
 Never pick them up by magnetic lifting
 Never subject to abnormal mechanical shocks whuch could damage
the valve or safety device
 Safe Working with Gas Cylinders
Daily Inspection
Cylinders should be inspected daily
and prior to each use for corrosion,
leaks, cracks, etc.
Inspection should include the
cylinder, piping, safety relief
devices, valves, protection caps and
stems.
Leaking regulators, cylinder valves
or other equipment should be taken
out of service.
Gas Cylinder Regulators
A regulator is a device that receives gas at a high
pressure and reduces it to a much lower working
pressure
 Precision instruments (Spring, diaphragm, etc.,)

 European/British Standard number and the pressures

up to which it can operate

 Leave the pressure adjustment knob/screw fully out

when the regulator is not in use (this ensures a
minimum of tension on the springs and diaphragms)
Flashback Arrestors

 Flashback is the result of mixture of fuel gas and oxygen burning

within the hose, flame travels and burns its way towards the gas
source at great speed, can result in force of explosion in either
cylinder
 Flashback arrestors must be fitted on both oxygen and fuel gas
regulators
 If flashback arrestor is dropped/damaged replace immediately
 Flashback arrestors should only be used with the gas they are
labelled for and the pressure they are designed for
 Common reasons for flashback: incorrect purging of hose/torch
prior to use, incorrect gas pressure, incorrect nozzle, damaged torch
valves, gas passages blocked within the torch, kinked or trapped
hose
 Hoses
 Correct hose bore size, pressure rating, length and color coding are
essential for safety BS EN 559
 Blue – oxygen, Red - acetylene and other fuel gases(except LPG)
 Black – inert and non combustible gases
 Orange – Liquefied Petroleum Gas
 Never use hoses that are longer than necessary
 Length of hose should be suitable for the task
 Keep hoses in good condition
 Examine the hose for cracks, deterioration, damage and test the hose for
leaks before use
 Purge hose thoroughly before lighting torch
 Do not put wrapping tape around hosing as this contains combustible
hydrocarbons
 Do not use copper piping with acetylene hoses as it is potentially
explosive
 Protect hosing from heat, oil, grease or mechanical damage
 Blow Pipes and Torches
 Leaks are a serious hazard as they are closest to the operator
 Always check condition before use, ensure tip is free of obstruction
 Signs of heat damage around the blow pipe or torch may indicate the equipment
has suffered internal damage and is leaking and should be replaced immediately
 Always fit the correct size nozzle for the job as per manufacturer
recommendation.
 Replace blow pipe or torch if
 Broken bent or loose gas control valve
 Bent mixer, misshapen cutter head
 Bent cutter tube
 Broken of bent cutting oxygen lever
 Leak test all connections and valves prior to use
 If replacing O ring seals always use the correct materials
Acetylene
Unique properties

 Acetylene gas under excess pressure

becomes unstable
 Cylinders should never be subject to intense
heat or physical impact as the rise in
temperature and pressure may cause the
acetylene to thermally decompose
 Prior to moving a cylinder that has been
subject to heat or severe impact contact
trained emergency personnel who can check
for temperature rise and apply correct
procedures
 The cylinder may appear normal but if it is
moved it may detonate with fatal
consequences
 Handling Gas Cylinders
 Wear PPE: gloves, protective footwear, eye protection
 Correct way to move cylinders is to: keep upright, secure and with
valves uppermost
 Use mechanical aids such as a trolley where reasonably
practicable( do a risk assessment)
 Use suitable cradles, slings, clamps or other effective means when
lifting with a hoist or crane
 For short distances on even ground the practice of ‘milk-churning’
(manually moving cylindres) can be used only by trained personnel
and never for longer distances, in uneven ground, wet or icy
conditions, poor lighting, or at speed a trolley should be used
 All personnel involved should have completed manual handling
training
 Never roll cylinders along the ground
 Never transport cylinder with valve and pressure regulator attached
or with the valve open
 Never attempt to catch a falling cylinder just get out of the way
 Never lift a cylinder by its cap, valve or guard/shroud
Remember that a cylinder is never empty
 Transporting Cylinders
Carriage of Dangerous Goods Regulations apply

 If possible carry in open vehicles or trailers

 If they must be carried in closed vans/cars ensure good
ventilation at all times
 If the load compartment is not separated from the driver do not
carry toxic gas cylinders (those with a toxic gas label and having
yellow as a colour on the cylinder)
 Secure cylinders properly so they cannot move or fall in transit
or do not project beyond the edges of the vehicle, normally in the
upright position unless instructions for transport state otherwise
 Ensure gas cylinders are clearly labelled to show contents and
associated hazards
 Fit suitable protective valve caps and covers to cylinders
Transporting Cylinders
Carriage of Dangerous Goods Regulations apply

 Disconnect hoses and regulators from cylinders

 Carry propane cylinders upright and do not
carry flammable gas cylinders in the same
compartment as toxic gas cylinders
 Do not smoke while carrying cylinders inside
vans/cars
 Unload the cylinders as soon as possible and
move to a well ventilated storage area
 If you suspect it is leaking, park the vehicle,
investigate the fault and contact the supplier
 If you are involved in an accident advise, any
emergency services involved what gas cylinders
are being carried
 Safe Storage
Each Storage area should be subject to unique risk assessment
 It is best to store gas cylinders in the open and on concrete in a fenced
compound with some weather protection
 In storage areas oxygen cylinders must be stored at least 3 metres
away/separated by a fire wall from fuel gases such as acetylene,
propane, methane etc.
 Full cylinders should be stored separately from empties and empty
oxygen cylinders should be segregated from empty fuel gas cylinders
 Other products should not be stored in the gas storage areas
especially not oil or corrosive liquids, sources of ignition or flammable
materials
 Ease of access into and around storage area, such as provision of aisle
>0.6m to prevent domino effect
 LPG cylinders have special requirements including storage 3m away
from other gases
 Pyrophoric and toxic gases should be stored seperately in locked,
suitable ventilated storage areas with restricted access
 Protect gas cylinders from external heat sources which may adversely
affect their mechanical integrity
 Cylinders should be secured and properly restrained, secure with
straps or chains connected to a wall bracket or other fixed surface, or
by use of a cylinder stand
 Cylinders should be clearly labelled to show contents and associated
hazards
 Safe Storage

 Store all cylinders upright and secure on a level surface to prevent

them from falling
 Acetylene and propane must never be stacked horizontally either in
storage or in use
 Storage arrangements should ensure turnaround of stock in adequate
time
 Storage areas with gas cylinders must have more than one exit
 Cylinders should be located away from any heat/source of ignition and
if possible away from the fire exits, elevators, walkways, building
egresses, unprotected platform edges, or in locations where heavy
moving objects may strike or fall on them
 Storage arrangements should be clearly described in the emergency
plan
 Storage area must have good housekeeping and adequate warning
signs with fire fighting equipment as necessary
 Cylinder Incident Response
Report any damaged/leaking cylinder to supplier

If a cylinder is leaking but the leak has not ignited and it is safe
to do so having considered the gases specific properties:
 Eliminate all sources of ignition
 Ensure the valve is closed but do not over-tighten it
 Put the cylinder in a safe place that is well-ventilated –
keep it upright
 Mark the cylinder as faulty and not to be used
 Warn everyone in the area of the gas leak
 Inform the supplier
 Ensure the work area is thoroughly ventilated before
continuing with any work
 If a hydrogen cylinder is involved be aware that
hydrogen burns with an invisible flame so seek expert
assistance
 Cylinder Incident Response
Report any damaged/leaking cylinder to supplier

If a cylinder is leaking and it has ignited it could

explode
 Call the emergency services and evacuate the
area to a minimum distance of 100 metres

Where a cylinder has been damaged

 If it has been dropped or physically damaged check it
for leakage and deal with as for a leaking cylinder
 For handling acetylene cylinders should not be moved
unless it is clearly established that there is no
thermal disassociation
 Clearly mark any cylinder that has been exposed to
excessive heat or physical impact and contact the
supplier
 Cylinder Incident Response
If a flashback has occurred:

 Close both blowpipe valves oxygen first

 Close both cylinder valves
 Check the temperature of the acetylene cylinder
for thermal decomposition
 Check the blowpipe has not overheated
 Check the nozzle is not damaged
 Open both blowpipe valves oxygen first to vent
the system
 Unwind the pressure adjustment screw on each
pressure regulator
 Before starting up again, check the integrity of
the whole system
 Cylinder Incident Response
Gas Cylinders on Fire
Depends on the gas, whether the gas is alight at the cylinder valve or if
the cylinder has been subject to severe pressure as a result of the
heat from the fire. Nature of hazard will determine procedure to be
applied

 If cylinder has been involved in fire do not approach, evacuate the area to
100m minimium to 300m
 Call fire brigade
 Use large quantities of water to cool the cylinders if safe to do so (do not
aim high pressure water direct at the cylinders) from a safe location and
await the arrival of trained emergency personnel ( Emergency plan training
should address)
 Remove any cylinders not involved in fire to safe place, ensure valves are
closed if safe to do so
 Inform gas supplier,
 If cylinder contents are unknown, treat as acetylene
In Your Workplace
Look Out for Gas Cylinders:
 In horizontol position/on the ground
 In contact with electrical cords
 Not protected from falling – chain not secure
 Damaged
 In an area where could be subject to impact
such as near operating forklift
 Stored near combustibles
 Oxygen and acetylene stored together
 Without valve caps
Deal with these Hazards IMMEDIATELY
 Conclusions
 Compressed gases present a unique hazard. Depending on the
particular gas, there is a potential for simultaneous exposure to
both mechanical and chemical hazards
 Inadequate training and supervision, poor installation, poor
maintenance, faulty equipment and/or design(e.g badly fitting valves
or regulators), poor handling, poor storage, inadequately ventilated
working conditions
 When working with compressed gases you need to know the
properties of the gas, safe use procedures and what to do when
things go wrong
 For detailed use of individual gases you should now review the
relevant Material Safety data Sheet (MSDS) for each gas used on
your site
Always Treat Gas Cylinders with Respect
For additional information which could be used as presentation handouts visit UK
HSE information on Gas Safety for a whole series of leaflets on the topic