Compressed Gas Cylinder Safety

1. 1
Compressed Gas Cylinder
Complies to the Guidelines of OSHAD Requirements
2023
Orient Management Consulting & Training

2. Ground Rules
• Fire alarm/exits
• Covid-19 protocols
• Smoking
• Drinks
• Breaks
• Lunch
• Questions
• Talking over others.

3. As a courtesy to others please set
your mobile phone to
SILENT MODE.
Housekeeping

4. COURSE OBJECTIVES
1. Properly use, handle, transport, store, dispose or, order,
receive, and maintain gas cylinders according to regulatory
standards and guidelines.
2. Identify the correct Personal Protection Equipment (PPE) to
wear when working with a gas cylinder.
3. Recognize the dangers associated with gas cylinders by
examining the labels on the gas cylinders and in the SDS.
4. Design an emergency plan and accurately describe what to
do in case an incident occurs with a gas cylinder.

5.  Gas Users
 Safety Committees
 Purchasing Agents
 Department Managers
 First Line Supervisors
 Maintenance Managers
 Shipping and Receiving Employees
 Accident Investigation Team Members
COURSE ATTENDEES

6. Compressed Gas Safety
• OSHAD SF – CoP - 49.0 - Compressed Gases and Air v3.0
English
• OSHAD SF – CoP - 1.0 - Hazardous Materials v3.1 English
• OSHA 29 CFR 1910.101 Compressed Gases (General
Requirements) &
• OSHA 29 CFR 1910.253 Oxygen-fuel gas Welding & cutting
• Safe Use, Handling and Storage
PPT043-01 1

7. What is Compressed Gas
The official definition from the Compressed Gas
Association’s (CGA) handbook is “Material or mixture
having the container an absolute pressure exceeding
40 PSI at 70°F (20°C) or, regardless of pressure at 70°F,
or having an absolute pressure exceeding 104 PSI at
130°F (54°C) or any liquid material having a vapor
pressure exceeding 40 PSI absolute at 100°F.”
7

8. Compressed Gases
The Globally Harmonized System (GHS) of classification
and labeling of chemicals defines “Gases under
Pressure” as gases that are contained in a receptacle at a
pressure of 200 kPa (gauge) or more, or which are
liquefied or liquefied and refrigerated. Gases under
pressure will be identified with the following pictogram:
8

9. Types of Compressed Gas
The types of compressed gas can be divided into
three categories, each with unique characteristics.
• Non-Liquefied Gas
• Dissolved Gas
• Liquefied Gas
9

10. • Non-Liquefied Gas: is a compressed,
pressurized or permanent gas. These gases do
not become liquid when they are compressed
at normal temperatures or even very high
pressures. Common examples are oxygen,
nitrogen, helium, and argon.
10
Types of Compressed Gas

11. • Dissolved Gas: can also be compressed. A
common example of dissolved gas is
acetylene. Care should be taken when using
acetylene for applications such as welding.
Consult your supervisor before using
acetylene.
11
Types of Compressed Gas

12. • Liquefied Gas: can become liquid at normal
temperatures when inside a cylinder under
pressure. When gas is removed from the
cylinder, enough liquid evaporates to replace
it, keeping the pressure in the cylinder
constant. Common examples include
anhydrous ammonia, chlorine, propane,
nitrous oxide, and carbon dioxide.
12
Types of Compressed Gas

13. ©Consultnet Limited
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

14. 14

15. 15

16. Specific Hazard Classes
• Flammable Gases
• No cylinders are to be stored near highly flammable solvents,
combustible waste material, unprotected electrical
connections, gas flames, or other sources of ignition.
Common examples of flammable gases include acetylene,
hydrogen, methane, propane, carbon monoxide, and
isobutane.
16

17. Flammable Gases Precautions
• At no time shall a flame be used to detect a leak. A soapy
water solution or approved commercial leak detection solution
shall be used.
• Inside buildings, stored oxygen shall be separated from
flammable gas cylinders by a minimum of 20 feet or separated
by a fire-resistant partition with a height no less than that of
the cylinders.
• Post “No Open Flames” signage on access doors to areas that
use or store flammable gases.
17

18. Poison Gases
• Poison gases shall only be used in force-ventilated
areas, preferably in hoods with forced ventilation, or
outdoor.
• Poison gas cylinders shall be of a size that will ensure
the complete usage of the cylinder within a
reasonable period of time.
18

19. Corrosive Gases
• Cylinders containing corrosive gases shall not be stored for
more than six months.
• Remove regulators after use and flush with dry air or nitrogen.
• Metals become brittle when used in corrosive gas service;
check equipment and lines frequently for leak.
• Use a diaphragm gauge with corrosive gases that would
destroy a steel or bronze gauge. Check with the gas supplier
for recommended equipment.
19

20. Cryogenic Liquids and Gases
• Cryogenic liquids and their boil-off gases rapidly freeze human
tissue and cause embrittlement of many common materials.
• All cryogenic liquids produce large volumes of gas when they
vaporize and may create oxygen-deficient conditions.
• Common examples of common cryogenic liquids include
liquid oxygen, nitrogen, hydrogen, neon, and helium.
20

21. • Use appropriate personal protective equipment, including
insulated gloves, lab coat, and eye protection (goggles and face
shield) during any transfer of cryogenic liquid.
• In the event of skin contact with a cryogenic liquid, do not rub
skin; place the affected part of the body in a warm water bath
(not to exceed 40°C [105°F]). If a burn is significant, seek medical
attention.
• Inspect containers for loss of insulating vacuum. If the outside
jacket on a container is cold or has frost, some vacuum has been
lost. Empty the contents into another cryogenic container and
remove the damaged unit from service. Repairs shall be made
by the manufacturer or an authorized company.
21
Cryogenic Liquids & Gases Precautions

22. • Transfer operations involving open cryogenic containers must be
conducted slowly to minimize boiling and splashing of the
cryogenic fluid.
• Ice or other foreign matter shall not be allowed to accumulate
beneath the vaporizer or the tank. Excessive ice buildup could
result in the discharge of excessively cold gas or structural
damage to the cryogenic container or surroundings.
• All cryogenic systems, including piping, must be equipped with
pressure relief devices to prevent excessive pressure build-up.
Pressure reliefs must be directed to a safe location.
• Hot air, steam, or hot water shall be used to thaw frozen
equipment.
Exception: Do not use water to thaw liquid helium equipment.
22
Cryogenic Liquids & Gases Precautions

23. High Pressure Fuel Gases
Fuel gases often use a combination of flammable and oxidizing
gases. Use of fuel gases must comply with applicable regulations
listed above.
High Pressure gases can be rated up to 3,000 pounds per square
inch (psi). Typical uses for high pressure gases include:
• Inert welding gas mixtures
• Cryogenics
• Non-toxic gas distribution
• Medical gas distribution
• Emergency oxygen services
23

24. Oxidizing Gases
Oxidizing gases are non-flammable but in the presence of an
ignition source and fuel can support and vigorously accelerate
combustion. Do not use oil in any apparatus where oxygen will
be used. Gauges and regulators for oxygen shall bear the
warning “Oxygen – Use No Oil.”
Oxidizing gases include:
• Oxygen
• Chlorine
• Fluorine
• Nitrous Oxide
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25. ©Consultnet Limited

26. Recognition
Know the properties of the materials involved!
• Is the gas a health hazard? Is it toxic?
• Can it cause severe damage to the eyes, respiratory
system, skin, etc.?
• Is it carcinogenic?
• Is it an asphyxiant?
• Is it a physical hazard?
• Is it explosive, flammable, pyrophoric, corrosive, etc.?
27

27. Three people, including a firefighter, have been taken to hospital after a major gas
explosion caused an "inferno" at a block of 20 flats in Bedford. (Monday 4 July 2022
17:52, UK)
28
NOTE: For Education Purpose only

28. Twenty-nine people were taken to hospital with breathing problems and a major incident
was declared following a gas (Chlorine) leak at the London Aquatics Centre.
29
NOTE: For Education Purpose only

29. NOTE: for Education Purpose only
30
In this still image from CCTV footage from a handout video, a cloud of chlorine gas is seen
after a storage tank fell from a winch in Aqaba, Jordan on June 27, 2022. © via Reuters -
JORDAN TV

30. ©Consultnet Limited
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

31. ©Consultnet Limited
Main Hazards
 Impact from the blast of a gas cylinder explosion
or rapid release 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

32. Employers’ Duties
· Provide safe place, safe equipments and safe system
of work
· Carry out a suitable and sufficient risk assessment
· Take the necessary action to prevent exposure
· Ensure that equipment is being properly used by
having procedures in place
· Have maintenance systems which ensure plant and
equipment are in efficient repair

33. 35
· Carry out a review of systems of work and
supervisory actions at regular intervals
· Monitor the workforce for exposure to hazardous
materials
· Provide adequate training, information and
instruction
· Arrange through planning actions to deal with
emergencies, accidents and other incidents.
Employers’ Duties

34. Employees’ Duties
• Cooperate with the employer to enable the employer
to be compliant with regulations
• Use fully and properly all control measures put in place
• Ensure equipment used is returned to proper storage
• Report any defects of equipment used
• Attend any medical examinations as required
• Report any incident which may have led to a release of
hazardous substances.
NEXT

35. ©Consultnet Limited
Identification and Properties
 Read the label to see what gas you are dealing with
and double check that the cylinder/gas is right for
the intended 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/supplier

36.  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 colour of a cylinder
and the label. Do not use, contact the supplier
immediately
 Know the properties of the gas (read Safety Data Sheets
available from your Supervisor)
 The cylinder’s contents should be identified at all times as
well as the cylinder status (full, empty or in service)
38
Identification and Properties

37. Understanding the
Safety Data Sheet (SDS)

38. HazCom Requirement
• 1910.1200(g) requires chemical manufacturers,
distributors, or importers provide Safety Data Sheets
(SDSs) for each hazardous chemical to downstream
users to communicate information on these hazards
• Information contained in SDS largely same as MSDS,
except SDS required to be presented in consistent,
user-friendly, 16-section format

39. Sections
• Section 1- Identification
• Section 2- Hazard(s) Identification
• Section 3- Composition/
Information Ingredients
• Section 4- First-Aid Measures
• Section 5- Fire-Fighting Measures
• Section 6- Accidental Release
Measures
• Section 7- Handling and Storage
• Section 8-Exposure
Controls/Personal Protective
Equipment
• Section 9- Physical and Chemical
Properties
• Section 10- Stability and Reactivity
• Section 11- Toxicological Information
• Section 12- Ecological Information
(non-mandatory)
• Section 13- Disposal Considerations
(non-mandatory)
• Section 14- Transportation
Information (non-mandatory)
• Section 15- Regulatory Information
(non-mandatory)
• Section 16- Other Information

40. 42

41. 43

42. NFPA Rating
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43. 45

44. Labeling
• Compressed gas cylinders shall be legibly marked for the
purpose of identifying the gas content with either the
chemical or the trade name of the gas. Such marking shall be
by means of stenciling, stamping, or labeling, and shall not be
readily removable. The marking shall be located on the
shoulder of the cylinder.
• If the labeling on the gas cylinder becomes unclear or defaced
so that the contents cannot be identified, the cylinder should
be marked “contents unknown” and the manufacturer must
be contacted regarding appropriate procedures for removal.
46

45. • Cylinders must bear an identification tag stating the name of
the gas or mixture and illustrating one of three conditions:
Empty, In-Use or Full.
• Mixed gases must be clearly labeled with the contents of the
cylinder.
• Know the contents of each cylinder that you are using.
Preferred labeling includes the identity of the material,
statement of hazard, and the associated signal word.
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Labeling

46. 48
Safe Use
• Do not rely on cylinder color
• The cylinder should be clearly stenciled or stamped
• The identification label should be permanently attached to
the cylinder
If in doubt do not use the cylinder! Contact your supervisor or HSE department
Identify the Compressed Gas

47. Labeling
As shown in the photo for Nitrogen, labeling must list
contents, concentrations, hazards classes, safety precautions
and the manufacturer or supplier:
49

48. Labels
PPT-043-01 38
FTSC Code
Standard numerical code
for a gas indicating:
 Flammability
 Toxicity
 State of the gas
 Corrosiveness
CGA V-7 pamphlet provides more
in-depth information.

49. ©Consultnet Limited
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

50.  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 to refill a cylinder unless properly trained to do so
 Never transport by rolling them on the ground
 Never pick them up by magnetic lifting
 Never subject to abnormal mechanical shocks which could
damage the valve or safety device
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Safe Working with Gas Cylinders
Work Practices

51. ©Consultnet Limited
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.

52. ©Consultnet Limited
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,
 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 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

53. ©Consultnet Limited
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.
Gas Cylinder Use

54. 56
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
Gas Cylinder Use

55. ©Consultnet Limited
Gas Cylinder Regulators
A regulator is a device that receives gas at a high
pressure and reduces it to a much lower
working pressure
 MUST be handled with care to avoid damage to
their sensitive springs, diaphragms, valve seals
etc.
 Eequipment 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)

56. 58
 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.
Gas Cylinder Regulators

57. ©Consultnet Limited
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

58. ©Consultnet Limited
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

59. HOSES
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
Pprotect hosing from heat, oil, grease or mechanical
damage
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60. ©Consultnet Limited
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

61. ©Consultnet Limited
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 integral damage and is leaking and should be replaced immediately
 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

62. Cryogenic
PPT-043-01 30
• Heat expands a gas
• If we pressurize a gas while
cooling it, we can turn a gas into a
liquefied gas
• Further cooling and pressure may
convert it to a cryogenic gas
• This increases the amount of
product that can be put in a
cylinder

63. Gas Containers
PPT-043-01 31
 Lecture Bottles
 Cylinders
 Tank Trucks

64. Gas Containers
PPT-043-01 32
• Railroad Tank Cars
• Portable Tanks
• Fixed Storage
• Pipelines

65. Cylinders
PPT-043-01 33
Construction:
Must be compatible
with the material
contained
Markings:
Labeling required to
identify the gas in storage
and during shipment

66. Markings
PPT-043-01 34
• Nomenclature related to
the cylinder and its contents
will assist in the safety
process
• Low Pressure: Below 900 psi
• High Pressure: 900 psi or
greater

67. Storage Pressure
PPT-043-01 35
Storage Ignition
Types Pressure (PSI) Temperature
Methane up to 6000psi 999F
Ethane 544 959
Propane 109.7 871
Butane 31 761
Nitrogen 2,000/below 200 as cryogen Inert
Oxygen 2,000/below 200 as cryogen Inert
Arsine 219.7 (*see note)
*Note: Arsine has no given Ignition Temperature but
decomposes into arsenic and hydrogen between 446 F
to 464 degrees F

68. Diaphragm Valve
39
• Diaphragm Valve better retains
the cylinder contents
• Not as prone to leakage as the
packed valve
• Note the diaphragm’s location
• Note also the relief valve’s
location in the product line

69. Packed Valve
40
The Packed Valve has packing
between the upper stem and
bonnet
This type is known for leaking
through the packing
Often the leak may be secured
by tightening the bonnet nut

70. Pressure Relief Valve (PRV):
PPT-043-01 41
Some gas valves will have
Pressure Relief Valves should the
internal cylinder pressure rise. It
is a means to vent-off over
pressurization so the cylinder
does not fail violently.
The PRV is in the product line.

71. Fusible Plug/Combination
PPT-043-01 42
Fusible plug melts at a designated
temperature and permits the
product of a cylinder to be released
to avert a catastrophic rupture
Combination relief: One with a
rupture disk and fusible plug
Both are Non-resealing

72. Rupture Disk
PPT-043-1 43
• Rupture disk (frangible disk) -
Operating part of a PRV:
ruptures at a predetermined
pressure allowing cylinder
contents to escape
• Non-resealing
• Poison gas cylinders do not have
a PRV Depending on their
classification PRVs are
“prohibited”

73. Cylinder Hazards
PPT-043-01 44
Material Hazards
• Flammability
• Spontaneously Flammable
(arsine, silane and phosphine)
• Corrosivity
• Reactivity
• Poison
• Carcinogenic
Container Behavior
• Frostbite
• Rupture
• Rocketing
• BLEVE (Boiling Liquid
Expanding Vapor Explosion)

74. ©Consultnet Limited
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

75. ©Consultnet Limited
Handling Gas Cylinders
 Wear PPE: gloves, protective footwear, eye protection
 keep upright, secure and with valves uppermost
 Use mechanical aids such as a trolley where reasonably practicable
 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 (manually
moving cylinders) 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

76. 78
 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
 Rremember that a cylinder is never empty
Handling Gas Cylinders

77. 79
• Many accidents occur while moving or transporting
cylinders.
• Handle cylinders gently. They may look strong and solid, but
if a cylinder is damaged it can become an uncontrolled
projectile damaging anyone or anything in its path.
Transporting Cylinders
Cylinders Transported in Upright Position

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Transporting Cylinders
 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)
 Ssecure 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

79. ©Consultnet Limited
Transporting Cylinders
 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
 Uunload 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

80. Storage
• Proper storage is critical for the safe usage of compressed and
liquefied gases. Cylinder storage areas should be prominently
posted with hazard information regarding the gases stored.
• The NFPA 704 diamond with a cylinder indicated in the
“specific hazard” (white) section of the diamond and the
corresponding flammability, health and reactivity hazard
sections also marked is an accepted method of signage. Other
storage requirements are outlined below:
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81. ©Consultnet Limited
Safe Storage
 It is best to store gas cylinders in the open and on concrete in a
fenced compound with some weather protection
 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
20 feet

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• Segregate cylinders by hazardous gases.
• Incompatible gases must be stored by hazard class in separate
areas, even when the cylinder is empty. Separate the
incompatible cylinders by:
• A distance of at least 20 feet, or a five foot firewall with a fire
rating of 1 hour
Safe Storage
20 feet

83. 85
 Ease of access into and around storage area
 Pyrophoric and toxic gases should be stored separately in locked,
suitable ventilated storage areas with restricted access
 Protect gas cylinders from external heat sources
 Cylinders should be secured and properly restrained, secure with
straps or chains connected to a wall bracket, or by cylinder stand
 Cylinders should be clearly labelled to show contents and
associated hazards
Safe Storage
Each Storage area should be subject to unique risk assessment

84. ©Consultnet Limited
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 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

85. ©Consultnet Limited
Unsafe Condition
 In horizontal 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

86. Hydro Test Intervals
75
• Hydro test intervals are based
on the composition of the
cylinder
• Retesting of cylinders can be
found in
– 49 CFR 173.34 and
– CGA C-1 Methods for
Hydrostatic Testing of
Compressed Gas Cylinders

87. Possible Gas Accidents
PPT-043-01 77
 LP Gas tank fire
 Gas pipeline explosion

88. Release Events
PPT-043-01 78

89. ©Consultnet Limited
Cylinder Incident Response
(Leakage)
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

91. ©Consultnet Limited
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

92. ©Consultnet Limited
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 minimum to 300m
 Call fire brigade (997)
 Use large quantities of water to cool the cylinders if safe to do so 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

93. Detection & Monitoring
PPT-043-01 79
• Determine leaks with various detectors:
• Combustible Gas Indicators (CGI) or
• Gas Detector (gas specific)
• You will need to know:
• Gas LEL/UEL and
• IDLH limits before monitoring for gas

94. Detection
PPT-043-01 80
 Portable leak detector
 Broom used to detect burning
hydrogen due to it burning light
blue to almost invisible.

95. Detection
PPT-043-01 81
Similar “broom” method may also be used:
 If attempting to detect presence of Chlorine, wrap clean cloth
around broom
 Put ammonia on cloth and wave in suspected Chlorine cloud
 If cloth fumes, you’ve detected presence of Chlorine
 If looking for ammonia leaks, cloth treated with Chlorine
bleach may be wrapped around broom
 Waved in suspect area, if fuming occurs, ammonia present
Both methods rely on chemical reactions – you’ll need training
and PPE: USE CAUTION

96. Emergency Response Methods
PPT-043-01 82
An extraction hood used for daily
operations may be used to vent
escaping gas from a cylinder up
through a filter
Hoods and vents may also be equipped
with a “scrubber” to neutralize various
gases
Some poison gases may be “scrubbed”
this way

97. Response
PPT-043-01 83
• Do you have a trained team?
• Or will you call specialty responders?
• Will special response equipment be
needed?
• Special precautions are required for
spontaneously combustible gases
such as silane.

98. Containment
PPT-043-01 85
• Containment is a team effort
• Remote openers also exist for
containers which may be suspect
so responders are not subjected
to pressure injuries

99. Chlorine “A” Kit
PPT-043-01 86
Chlorine “A” kit to be used for
leaking Chlorine cylinders
The pressures of some gases may
limit the kit’s use to Chlorine
Teams should be trained in
proper use

100. Chlorine “B” Kit
PPT-043-01 87
• “B” kit is used to control leaks on 1 ton
containers of Chlorine
• Where contents can not be pumped out
of a container, the container might be
able to be drilled
• Drilling requires pressure reduction
(cooling) and highly trained responders

101. Response
PPT-043-01 88
• Determine if you will handle an
event alone or with off-site help
• Pre-plan potential zones of harm
should your facility have a release
• Practice safety and be safe in
handling, use, storage and
response to gas incidents

102. ©Consultnet Limited
Conclusions
 Compressed gases present a unique hazard. Depending on the
particular gas, there is a potential for simultaneous exposure to
both Physical 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 Safety Data Sheet (SDS) for each gas used on your site
Always Treat Gas Cylinders with Respect

103. The End