Safe Use of

Cylinder Gases

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Team - World Wide Health & Safety

Professionals Online (W.W.H.S.P.O)

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Presentation Contents

Introduction to Gas Cylinder Safety

Main causes of Accidents
Main Hazards
Rules for Safe Working with Gas Cylinders
Gas Regulators
Flashback Arrestors
Hoses, Piping, Blow Pipes and Torches
Acetylene unique properties
Handling Gas Cylinders
Transporting Gas Cylinders
Safe Storage
Cylinder Incident Response
Gas Cylinders Hazards in Your Workplace
Conclusions
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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
Gases can be:
Flammable or combustible
Explosive
Corrosive
Poisonous/toxic
Inert
Cryogenic
Pyrophoric(burns on contact with air)
or a combination of hazards
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Introduction

Common Industrial Gases

Oxidants support combustion e.g. air & oxygen
Inerts do not generally react with other materials,
asphyxiants(leak displace air) e.g. nitrogen, argon,
helium
Flammables when mixed with oxidant and ignition
source will burn e.g. acetylene, hydrogen, propane
Toxics toxic in small concentrations e.g. ammonia,
chlorine, carbon dioxide
Corrosives react with materials causing reactions
e.g. chlorine, sulfur dioxide
Pyrophorics ignite spontaneously in air e.g. silane,
phosphine
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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
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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
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Safe Working with Gas Cylinders:

Identification and Properties
Read the label to see what gas you are dealing with and double
check tha the cylinder/gas is right for th eintended use
No compressed gas cylinder should be accepted for use that does
not legibly identify its contents by name
If the labeling on a cylinder becomes unclear or an attached tag
is defaced to the point the contents cannot be identified, the
cylinder should be marked "contents unknown" and returned
directly to the manufacturer
Never rely on the color of the cylinder for identification. Color
coding is not reliable because cylinder colors may vary with the
supplier. Additionally, labels on caps have little value because
caps are interchangeable
If there is a mismatch between the color of a cylinder and the
label. Do not use, contact the supplier immediately
Know the properties of the gas (read Material Safety Data Sheets
available from your Supervisor)
The cylinders contents should be identified at all times as well
as the cylinder status (full, empty or in service)
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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
Before connecting a gas cylinder to equipment or pipework make sure regulator and
pipework are suitable for the gas and pressure being used
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
Never scrap a cylinder
Never subject cylinders to abnormally high or low temperatures
Never mix gases in a cylinder
Never try refill a cylinder
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

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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.

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Safe Working with Gas Cylinders

Maintenance of cylinders and their valves or relief devices shall be
performed only by trained personnel.
An emergency response plan shall be developed and implemented
wherever compressed gas cylinders are used, handled or stored.
Never smoke around compressed gas cylinders.
Valve protection caps must remain in place at all times except when
cylinders are secured and connected to dispensing equipment
Only wrenches or tools provided by the cylinder supplier should be
used to open or close a valve. At no time should pliers be used to
open a cylinder valve.
Never apply PTFE tape, jointing compounds or any other sealing
material to the valve in an attempt to achieve a tight seal, if a gas
tight seal cannot be achieved metal to metal, replace the regulator or
change the cylinder

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Gas Cylinder Use

After the regulator is attached, the cylinder
valve should be opened just enough to
indicate pressure on the regulator gauge (no
more than one full turn) and all the
connections checked with a soap solution for
leaks.

Never use oil or grease on the regulator of a

cylinder valve.

Before a regulator is removed from a cylinder, the cylinder valve shall

be closed and the regulator relieved of gas pressure.The valve
cap shall be replaced, the cylinder clearly marked as "empty,"
and returned to a storage area for pickup by the supplier
Regulators, gauges, hoses and other apparatus shall not be used on
gas cylinders having different chemical properties
Valve outlet thread size is different for different products but the
same products from different gas suppliers will have the same
thread
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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 and MUST be handled with care
to avoid damage to their sensitive springs, diaphragms,
valve seals etc.
Equipment should display the relevant
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)
Cylinders should be placed with the valve accessible at
all times. The main cylinder valve should be closed as
soon as it is no longer necessary that it be open, it
should never be left open when the equipment is
unattended or not operating
This is necessary not only for safety when the cylinder is
under pressure, but also to prevent the corrosion and
contamination resulting from diffusion of air and
moisture into the cylinder after it has been emptied.
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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 oinly be used with the gas they
are labelled for and the presuure thay are designed for
Coomon 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
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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 Liquified Petroleum Gas
Never use hoses that are longer than necessary
Never use equipment while hoses are wrapped around the cylinders or trolley
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
Do not repair hoses unless you have the skill and means to test hem in
accordance with BS En 1256
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
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Piping
Distribution lines and their outlets should be
clearly labeled as to the type of gas contained
Piping systems should be inspected for leaks on a
regular basis
Special attention should be given to fittings as well
as possible cracks that may have developed

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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 equipemnt
has sufferd interal damage and is leaking and should be replaced immeidately
No sign of sideways movement of the cutting leaver as this could cause gas leaks
within the body of the torch that are difficult to detect
Always fit the correct size nozzle for the job( hole size and pressure set at
regulator determine gas flow and gas velocity exiting the nozzle, manufacturer
gives a pressure rating for the nozzle being use, if the gas exit velocity is slower
than the combustion velocity backfire and flashback may occur
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
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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
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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

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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
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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
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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
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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
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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
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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
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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
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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
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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

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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

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