This document provides safety guidelines for working with compressed gases. It states that all compressed gas cylinders should be handled carefully and according to the specific gas's properties. Damaged cylinders should be inspected before use. Gases are identified by color (red for flammable, green for non-flammable) and labeling. Proper transportation, storage, connection, and use of regulators are outlined to prevent leaks, explosions, and other accidents. Personnel should be aware of each gas's hazards like flammability, toxicity, and corrosiveness. Overall, the document aims to promote safe practices for compressed gas handling.

1. Safety Work Instruction for
Compressed Gas
By : KOMARUL FAUSIYAH

2. Procedure
• All compressed gases should be handled
in accordance with the safe practices
applicable to the particular compressed
gas. All compressed gas cylinders
subjected to physical damage should be
referred to Safety Department for
evaluation prior to further usage.

3. Identification …
1. Compressed commercial gases are defined as
follows ;




Combustible non-liquefied gases.
Combustible liquefied gases.
Non-combustible, non-liquefied gases.
Non-combustible, liquefied gases
2. Flammable gases are usually contained in a red
painted cylinder.
3. Non - flammable gases are usually contained in a
green painted cylinder.

4. Identification
• The following is a list of typical compressed
gases :
– Acetylene
– Hydrogen
– Oxygen
-
– Argon
– Freon
– Nitrogen
-
Flammable
Flammable
Non-flammable (It will explode
when brought into contact with
oil, grease and other organic
materials).
Non-flammable
Non-flammable
Non-flammable

5. Transportation and Handling
• Do not abuse or miss-handle gas cylinders. They should
never be dropped, permitted to strike each other, or to
strike any other object.
• Rope or chain slings should never be used to carry
cylinders. If necessary to hoist, use a proper designed
basket.
• Empty cylinders should be labeled “empty” and
segregated from full cylinders.
• Protecting valve caps should always be used when
valves on cylinders are not in use.

6. Storage
• Cylinders must be stored on a upright (standing) position
and tied or otherwise made secure.
• Cylinders should not be stored near highly flammable
substances.
• Do not store cylinders near aisles, or in locations where
moving objects may strike or fall on them.
• Cylinders containing acetylene should always be stored
in a separate group, never with store together with
oxygen cylinders.

7. Usage …
 Never mix gases in a cylinder.
 Never attempt repairs to valves or gauges, return them
to the Maintenance Department.
 Make sure that the threads on regulators correspond to
those on the cylinder valve outlet.
 Never force connections that do not fit. Different
threads and thread sizes are used on cylinders to
prevent interchange of equipment.
 Cylinder valves should be opened slowly to avoid
pressure surges

8. Usage …
 When “cracking the valve”, opening the valve for an
instant to clear the opening for dust or dirt, the
following precautions should be taken ;
1) Never open a valve near a flame or other sources of
ignition.
2) Always point the valve opening away from the body, but
not toward anyone else.
3) Compressed gas cylinders containing highly toxic gas
should not be opened to atmosphere.
 Never permit the gas to enter a regulator suddenly.
Open all valves slowly.
 Before removing regulator from cylinder, close the
cylinder valve and release all gas from the regulator.

9. Usage …
 Never attempt to stop a leak between a cylinder and a
regulator by tightening the adjusting nut, unless the cylinder
valve has been closed.
 Do not allow sparks, molten metal, electric current,
excessive heat or flames to come in contact with the
cylinder, the hose or the regulator.
 Do not use oil or grease on attachments for oxygen
cylinders. (BEWARE DANGER OF EXPLOSIVE).
 When valve protection hoods become frozen or filled with
ice, let them melt out in a warm room. Never use steam or
any other sources to melt them out.

10. Usage
 Cylinders should never be used for any purpose other than
containers for the particular gases for which they were
designed.
 Cylinders must be used in an upright position, they must be
secured to a substantial structure to prevent their falling over.
 Never use compressed gas to dust off clothing.
 Cylinder valves should be tightly closed when not in use or
empty.
 Never use flame to detect gas leaks. Use soapy water.
 Cylinders with leaking valves should be removed to a safe
location and tagged as having a defective valve.
 Oxygen should never be used as a substitute for air and
should always be designated by its proper name.

11. Equipment
• Combustible gas regulators, hose or other
appliances should never be interchanged
with similar equipment intended for use
with other gases.

12. Compressed Gas Cylinders
Compressed gas cylinder safety is insured by the
supplier through his adherence to regulations set forth,
and by his supplying cylinders with specific valves,
labels, and/or markings in accordance with recognized
standards. It is mandatory for the supplier to ship
cylinders manufactured, hydrostatic test certificate,
inspected and filled in conformance with the regulations
and to used approved safety devices. This procedures
outlines the basic requirements for the handling, storage
and used of compressed gas cylinders.

13. Handling …
• Cylinder valve shall be closed before cylinders may be
moved.
• Cylinder regulators shall be removed and valve
protection caps screwed down hand tight before
cylinders may be moved, except when cylinders are
mounted on a truck designed for movement with
regulators assembled to cylinders.
• Cylinders should be manually moved only by means of a
suitable hand truck. Where this is impractical, cylinders
may be hand rolled in the vertical position. Never drag,
drop or slide a cylinder.

14. Handling …
• For in-plant transport by motor vehicle, cylinders
must be carried in the vertical position. Cylinders
shall be positively secured against toppling, rolling
about and sliding while in transport.
• In lifting and lowering cylinders with hoists, cranes,
etc., a cradle boat or similar device must be
employed. Slings or electric magnets shall not be
used. Never use valve protection caps for lifting
cylinders.

15. Handling
• Carelessness in the handling of an empty cylinder could
result in its being mistaken for a full cylinder. The
connecting of an empty cylinder to a high pressure system
could cause foreign matter to back up into the cylinder,
resulting in all the attendant hazards of suck-back and
possible violent reaction within the cylinder. Therefore, it is
necessary to keep empty cylinders carefully segregated
from full cylinders. Always handle empty cylinders with the
same care afforded full ones, because an “empty” cylinder
may contain a pressure greater than 1,000 psig.
• Carefully protect cylinders from impact and friction.

16. Usage …
• For purposes other than certain Engineering Test
applications, automatic pressure regulators with flow
control valves shall be used on cylinders. Do not force a
fit between a regulator and a cylinder outlet. A poor fit
may indicate that the regulator is not intended for use on
the gas chosen. Cylinder threads vary according to the
kinds of gases the cylinders are intended for.

17. Usage …
• Knowledge of Properties :
1. It is essential that personnel be aware of the
hazardous properties (flammability, toxicity,
corrosiveness, and chemical effects) of the gas
they are to use. These properties may vary
according to how the gas is used. For example :
In a hood with an open flame, the flammability of
carbon Monoxide might be a major hazard, while
in using Carbon Monoxide as a reactant in
another location, leakage, and therefore toxicity,
may be the major hazard

18. 2. Only a very small concentrations are necessary to create
flammable mixtures of the liquefied petroleum gases such as
butane and propane. Acetylene, Carbon Monoxide, Ethylene
Oxide, Hydrogen, and Hydrogen Sulphide form explosive mixtures
with air under a wide variety of conditions.
3. Construction materials should be chosen to avoid the possibility of
equipment failure through the action of a corrosive, and avoid the
possible formation of hazardous compounds, such as Acetylides
formed by the reaction of copper with Acetylene or gases
containing Acetylene as an impurity, or the possible formation of
fulminates when Mercury is used in the presence of Ammonia.
4. It is advisable that an indicator be used to warn of hazardous
concentrations of toxic gases. For example, strips of lead acetate
paper can be hung in an area where hydrogen Sulphide is being
used. While this gas has a disagreeable odor, it soon deadens the
sense of smell, rendering the user incapable of detecting
increasingly dangerous concentrations by odor.

19. Usage …
• When corrosive gases are being used, the cylinder valve stem
should be worked frequently to prevent freezing. Corrosive
gas regulators and valves should be flushed with Dry Air or
Nitrogen after use. Such control devices should not be left on
a corrosive gas cylinder unless it is in frequent use.
a) Do not completely exhaust empty cylinders. The
cylinder should be considered empty while positive
pressure (25 psig or more) still remains, in order to
prevent suck-back and contamination. Failure to close
the valve on an empty cylinder will allow air and
moisture to be drawn into the cylinder as it “breathes”
during temperature changes; an explosive mixture may
build up if the gas is flammable; and an extremely
corrosive condition will be created in cylinders
containing Chlorine, Hydrogen Chloride, or other acid
forming or corrosive gases.

20. b) Before making connection to a cylinder valve outlet,
except that of a hydrogen cylinder, “crack” the valve for
an instant to clear the opening of particles of dust and
dirt which otherwise might impair the function of the
regulator. However, do not crack hydrogen cylinder
valves. Always stand to one side of the valve opening
when cracking the valve.
c) After making connection, open the cylinder valve slightly
at first then all the way. (Exception : Open acetylene
cylinder valves no more than 1-1/2 turns. Never use
acetylene at pressure over 15 psig) Stand to one side of
gauge faces when opening valves.
d) Use only the hands, no tools, in opening and closing
hand wheel type valves. Use only the special T wrenches on acetylene cylinder valves.

21. d) Make pressure regulator connections with a regulator
wrench. To prevent leakage, be sure the nut is pulled
uptight. Never tighten a leaky regulator connection
without first closing the cylinder valve.
e) After making connections to cylinders of flammable and
toxic gases, test the connections for leaks with a non-fat
soap and water solution or other leak test solution that is
compatible with the gas to be used.
f) After each use of a cylinder, close the cylinder valve,
relieving pressure on the regulator. Replace the valve
protection cap immediately upon removal of the
regulator.
g) Cylinders shall be positively secured in the vertical
position, by means of iron or fabric strapping, chain,
cable or rope.

22. Storage
• Full cylinders, except for working stocks at
job sites, shall be stored in a designated
location, with the various gases
segregated as building markings direction.
• Empty cylinders shall be stored in a
designated location, with the various
gases segregated as building markings
direction.

23. Thanks for Your Attention
Safety Is Start From Ourselves