Gas handling safety tips for general industry.

1. Gas Handling and
Safety: A
Comprehensive Guide
Discover the essential principles, standards, and best practices for safe
gas handling and storage. Learn about gas properties, hazards, risk
assessment, and emergency response procedures.
by Jude -Thaddeus D. Inyang
Gas Handling and Storage

2. Objectives of Gas Handling Safety Training
• To follow the applicable standards and regulation
• understanding gas properties and hazards
• conducting thorough risk assessments
• being prepared for emergencies, and
• Implementing best practices, you can ensure safe gas handling
and storage.

3. Introduction
Gases are widely used. While these gases are valuable tools, they can be
hazardous if not handled properly. Accidents related to gas handling can
result in injuries and other cataclysmic events involving environmental
damage, and financial losses. Therefore, it is vital to be aware of the
potential risks and to adopt safe practices to mitigate them.

4. Types of Gases in the Industry and
Handling Procedures
Inert Gases
Explore the characteristics, applications,
and safe handling procedures for inert
gases commonly used in various
industries.
Flammable Gases
Learn about the risks associated with
flammable gases and the proper
precautions and procedures for their
safe handling.
Toxic Gases
Discover the hazards of toxic gases and
the necessary protective measures and
techniques for their safe handling.
Reactive Gases
Understand the reactivity of various
gases and the precautions required to
handle reactive gases safely.

5. Gas Properties and Common Hazards
Chemical
Characteristics
Explore the
properties of different
gases and their
potential hazards,
including flammability,
toxicity, and reactivity.
Preventive
Measures
Discover strategies to
prevent accidents
and minimize risks
when working with
different types of
gases.

6. Risk Assessment and Hazard
Identification
Risk Assessment
Learn how to conduct a thorough risk
assessment to identify potential hazards
and develop strategies for risk mitigation
for gas handling.
Hazard Identification
Explore common hazards in gas
handling operations and discover
techniques for identifying and addressing
them efficiently.

7. Emergency Response Procedures
1 Emergency Preparedness
Develop an effective emergency response plan and learn how to handle gas-related
incidents safely and efficiently.
2 Evacuation Procedures
Understand the importance of timely evacuation in case of gas leaks or other
emergencies and know the necessary steps to follow.
3 Communication and Reporting
Learn how to communicate with relevant stakeholders and report incidents to ensure
proper coordination and effective response.

8. MODULE 1 Compressed
Cylinder Safety
Compressed Gas Handling Information
(HAZMAT)
Applicable Guidelines /Standards

9. Applicable Standards and Regulations
1 Industry Standards
Explore key standards
and regulations relevant
to safe gas handling,
including ISO, OSHA,
and local requirements.
2 Compliance
Guidelines
Understand the
importance of complying
with safety standards
and the consequences
of non-compliance.
3 Safe Operating
Procedures
Learn about
recommended practices
for handling, storing, and
transporting gases to
maintain a safe work
environment.

10. Best Practices for Safe Gas Handling and
Storage
Handling Procedures
Discover best
practices for
safely handling
gas cylinders,
including
proper storage,
transportation,
and usage
techniques.
Gas Leakage Prevention
Explore
effective
measures and
equipment for
detecting and
preventing gas
leaks in various
industrial
settings.
Storage Safety
Learn about
the
requirements
and best
practices for
storing gases
safely to
prevent
accidents and
ensure
compliance.
Personal Protection
Understand the
importance of
using
appropriate
personal
protective
equipment
when working
with gases to
minimize risks.

11. 29 CFR 1910 Subpart H
Hazardous Materials
1910.101
Compressed gases (general requirements)

12. "Compressed gas" means:
Any material or mixture of gases having in a container either an
absolute pressure exceeding 40 psi at 70 deg. F. or
any liquid flammable material having a Reid vapor pressure
exceeding 40 psi absolute at 100 deg. F
an absolute pressure exceeding 104 psi at 130 deg. F or both
or
See other definitions at 49 CFR 173.115
29 CFR 1910.1200

13. Compressed gas cylinder types
High Pressure Low Pressure
Comparative sizes

14. Compressedgascylindertypes
HighLowAcetyleneCryogenic
> 900
PSIG
.
.
.
.
Fusible
Plug
Fusible
Plug
Porous
Mass
Acetone
Solvent
42%
Volume
Very
Cold
Liquid
CO2
CL2
NO2
AR
O2
H2
N2
Vapor

15. Acetylene cylinders
.
.
.
.
Fusable
Plug
Fusable
Plug
Porous
Mass
Acetone
Solvent
42%
Volume
The
decomposition
characteristics of
acetylene gas are
avoided:
By providing a
porous mass
packing material
with minute
cellular spaces
No pockets of
appreciable size
remain where
“free” acetylene in
gaseous form can
collect
This porous mass
is saturated with
acetone, or other
suitable solvent, in
which the gaseous
acetylene
dissolves.

16. Gas suppliers advise end users to
• Check cylinders as they
are received
• Verify that labels, tags
and shipping papers are
appropriate
• Reject and return cylinders
with obvious damage
• Determine that required
caps and plugs are in
place

17. 3.2.6 - Bulges Cylinders are manufactured with reasonably
symmetrical shape. Cylinder which have definite bulges shall
be removed from service
Compressed Gas Association Inc.
CGA C-6 1968
Bulged -
cylinder wall
failure

18. Charring or burning of paint
Burning or scarfing of the metal
Distortion of the cylinder
Melted out fuse plugs
Burning or melting of valve
5.3.7 - Fire Damage
Cylinders shall be carefully
inspected for evidence of
exposure to fire
Compressed Gas Association Inc.
CGA C-6 1968
Cylinder burst
after fire
exposure

19. Burn
Gouge with deposit
of weld metal

20. Gouge
Cut
Reducing wall
thickness -
increasing stress

21. General corrosion
with pitting -
reducing cylinder
strength

22. Section 3.1 General
3.1.14 Never tamper with the
safety relief devices in valves or
cylinders
3.1.15 Never attempt to repair
or to alter cylinders, valves, or
safety relief devices.

23. 3.1.16 Never use
cylinders as rollers,
supports, or for any purpose
other than to contain the content
as received
Section 3.1 General
Big &
heavy

24. Section 3.1 General
Keep cylinder valve always closed,
except when the cylinder is in
active use.
Notify owner of cylinder if any
condition has occurred which
might permit any foreign
substance to enter the cylinder or
valve giving details and cylinder
serial number.

25. Section 3.1 General
Insulator
When the cylinders are used in conjunction with
electric welding, precautions must be taken
against accidentally grounding compressed gas
cylinders and allowing them to be burned by
electric welding arc.
Do not place cylinders where they might
become part of an electric circuit.
3.1.19

26. Section 3.2 Moving
Cylinders
CAPS IN
PLACE
LIFTING DROPPING
LIFTING
WITH
MAGNETS
DRAGGING

27. Section 3.2 Moving Cylinders
Concrete

28. Electro-magnet

29. Section 3.2 Moving Cylinders
3.2.6
Use suitable hand truck,
fork truck, roll platform
or similar device with
cylinder firmly
secured for
transporting and
unloading.
!

30. 3.3 Storing Cylinders
• Separation (different
types)
• Separation (charged &
empty)
• Kept in Storage rooms
• Highly flammable
substances to be separated
• Avoid dampness
• Protection of cylinders
from electrical sources
• Care of cylinders by daily
visual inspection
?

31. 3.3 Storing Cylinders
Do not store cylinders near highly
flammable substances such as
oil, gasoline or explosives. Fire is a threat
to containment!
MEK

32. 3.3 Storing Cylinders
?
Protect cylinders from
any object that will produce
a cut or other abrasion in the
surface of the metal….

33. 3.3 Storing Cylinders Cont’d
Do not store cylinders near
elevators or gangways, or in
locations where heavy
moving objects may strike
or fall on them….
?

34. Proper nesting
supports all
cylinders by
contact at three
points
proper nesting is considered safe
storage by the compressed gas
industry.
?

35. If cylinder content is not identified by marking,
return cylinder to the supplierwithout
using.
Transporting Compressed Cylinders
I’m not
labeled!!

36. 3.4.7
Where compressed gas
cylinders are connected to a
manifold, such a manifold and
its related equipment, such as
regulators, must be of proper
design.

37. 3.4 Withdrawing Cylinder
Content
Where compressed gas cylinders are
connected to a manifold, such a
manifold and its related
equipment, such as regulators,
must be of proper design.
Suitable pressure regulating devices
must be used in all cases where gas is
admitted to systems having pressure rating
limitations lower than the cylinder
pressure.

38. F – Flash arrestor chamber
G – Escape pipe
H – Cylinder
connection pipe
J – Check valve
and drain plug
K – Acetylene cylinders
A
B
C
D
E
F
G
J
K
K
H
A – Line valve
B – Release valve
C – Filler plug
D – Header pipe
E - Regulator

39. • 3.4.9
• Open cylinder valve slowly. Point the valve opening
away from yourself and other persons.
• Never use wrenches or tools except those provided
or approved by the gas manufacturer.
• Avoid the use of a wrench on valves equipped with
handwheels.
• Never hammer the valve wheel in attempting to
open or close the valve.
• For valves that are hard to open, or frozen because
of corrosion, contact the supplier for instructions.
3.4 Withdrawing Cylinder Content

40. Never force connections
that do not fit.
3.4 Withdrawing Cylinder Content

41. Indoor cylinder storage
• Well protected
• Well ventilated
• Dry
• Twenty feet
from flammable
or combustible
materials
20 Feet
Fuel
Gas
3.5 Flammable Gases
O
x
y
g
e
n
Flammable Gases

42. Do not store cylinders near highly flammable
solvents, combustible waste material and
similar substances, or near unprotected
electrical connections, gas flames or other
sources of ignition.
3.5 Flammable Gases
3.5 Flammable Gases

43. Never use a flame to detect flammable gas leaks.
Use soapy water.
3.5 Flammable Gases
3.5 Flammable Gases

44. Do not store reserve stocks of cylinders containing flammable
gases with cylinders containing oxygen.
3.5 Flammable Gases
Fuel
Gas Fuel
Gas
O
x
y
g
e
n

45. Personnel handling and using poison gases should
have available for immediate use gas masks or self-
contained breathing apparatus of a design approved
by U.S. Bureau of Mines for the particular service
desired.
3.6 Poisonous Gases

46. MODULE 2 Compressed
Cylinder Safety
Compressed Cylinder Handling Hazards
Hazard Identification

47. Subject to damage
from other activities in
the vicinity
Cylinder laying
in a horizontal
position.
Electrical cord in
Contact with the
cylinder

48. Cylinders are not protected from falling.
Note that the Chain is not secured across.
Chain

49. Small cylinder not tied off
Combustibles stored with cylinders
Poor Housekeeping
Acetylene and Oxygen stored
too close together and no chain.

50. 1. Cylinder with no valve or cap installed
2. Laying horizontal on the ground
3. Subject to damage

51. Cylinder is damaged. Should be taken out of service immediately!
Electrical arc
damage

52. Cylinder should be in storage protected from damage and not
laying on the ground regardless if it is full or empty

53. 1. Cylinders laying on the ground and improperly stored
2. Subject to damage from forklift operation in vicinity
Forklift

54. 1. Feed line exposed to damage/leak that could cause a fire/explosion
2. Tripping Hazard

55. 1. Inadequate housekeeping
2. Valve caps should be installed.

56. Unsecured cylinders

57. Regulator left pressurized after use

58. Improper Storage

59. Cylinders not
Secured properly

60. Free standing
cylinders
Exposed to damage
From construction
Activities in area

61. What a pressurized
Container can do
When the right amount
of heat is applied.

62. Or the importance of using flashback
arrestors on oxy-acetylene carts and
keeping spark producing activities
Away From You (min 35 ft.).
How not to blow yourself up

63. 30 CFR § 56.4600
Extinguishing equipment.
• WELDING/CUTTING/COMPRESSED GASES
(a) When welding, cutting, soldering, thawing, or bending
• (1) With an electric arc or with an open flame where an
electrically conductive extinguishing agent could create an
electrical hazard, a multipurpose dry-chemical fire extinguisher
or other extinguisher with at least a 2-A:10-B:C rating shall be
at the worksite.
• (2) With an open flame in an area where no electrical hazard
exists, a multipurpose dry-chemical fire extinguisher or
equivalent fire extinguishing equipment for the class of fire
hazard present shall be at the worksite.

64. 30 CFR & 56.4603
• Closure of valves.
To prevent accidental release of gases from hoses and
torches attached to oxygen and acetylene cylinders or
to manifold systems, cylinder or manifold system
valves shall be closed when
(a) The cylinders are moved;
(b) The torch and hoses are left unattended; or
(c) The task or series of tasks is completed.

65. 30 CFR § 56.15007
• Protective equipment or clothing for welding, cutting,
or working with molten metal.
• Protective clothing or equipment and face shields, or
goggles shall be worn when welding, cutting, or working
with molten metal.

66. MODULE 3 Compressed
Cylinder Safety
Recorded compressed gas incident
Case Studies – Gas Related Catastrophe

67. Case 1:
An Ironworker crew was modifying a temporary structural
steel bridge using an Oxygen/Acetylene torch setup on a cart, a
portable welder, and a grinder. Apparently, the Acetylene hose
developed a leak and ignited during the grinding operation
(Monday June 18, 2001)

69. The torch setup was not equipped with a “flashback” arrestor
check valve and the fire traveled through the hose into the
compressed cylinder.
All Oxygen/Acetylene setups must
have a “Flashback” arrestor check
valve at the regulators, NOT the
torch head, to prevent this type
of occurrence. This little device would
have prevented this fire.

70. Case 1:
Acetylene bottle stored in plumber's van
Gas ignited by remote door lock device.
22-10-09