Compressed Gas Cylinder Safety

Oklahoma State
University
 INTRODUCTION

Many industrial and laboratory

operations require the use of
compressed gases for a variety
of different operations.

Return to Online Training

 INTRODUCTION

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 may be:

Flammable or combustible
Explosive
Corrosive
Poisonous
Inert
or a combination of hazards

Return to Online Training

 INTRODUCTION

If the gas is flammable, flash points lower than room

temperature compounded by high rates of diffusion present a
danger of fire or explosion.
Additional hazards of reactivity and toxicity of the gas, as
well as asphyxiation, can be caused by high
concentrations of even "harmless" gases such as
nitrogen.
Since the gases are contained in heavy, highly pressurized
metal containers, the large amount of potential energy
resulting from compression of the gas makes the cylinder a
potential rocket or fragmentation bomb.
Return to Online Training
 INTRODUCTION

Careful procedures are necessary for handling the various

compressed gases, the cylinders containing the compressed
gases, regulators or valves used to control gas flow, and the
piping used to confine gases during flow.

Return to Online Training

 IDENTIFICATION

The contents of any compressed gas cylinder must be clearly

identified. Such identification should be stenciled or stamped
on the cylinder or a label. Commercially available three-part
tag systems may also be used for identification and inventory.

Return to Online Training

 IDENTIFICATION
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.

Return to Online Training

 IDENTIFICATION

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.

Always read the label!

Return to Online Training

 IDENTIFICATION
All gas lines leading from a compressed gas supply should
be clearly labeled to identify the gas, the laboratory or area
served, and the relevant emergency telephone numbers.

Return to Online Training

 IDENTIFICATION

The labels should be color coded to distinguish hazardous

gases (such as flammable, toxic, or corrosive substances)
(e.g., a yellow background and black letters).

Return to Online Training

 IDENTIFICATION
Signs should be conspicuously posted in areas where
flammable compressed gases are stored, identifying the
substances and appropriate precautions (e.g., HYDROGEN -
FLAMMABLE GAS - NO SMOKING - NO OPEN FLAMES).

Return to Online Training

 HANDLING & USE

Gas cylinders must be secured at all times to prevent tipping.

Return to Online Training

 HANDLING & USE

Cylinders may be attached to a bench top, individually to the

wall, placed in a holding cage, or have a non-tip base
attached. Chains or sturdy straps may be used to secure
them.

Return to Online Training

 HANDLING & USE

If a leaking cylinder is discovered, move it to a safe place (if it

is safe to do so) and inform the Environmental Health &
Safety Department. You should also call the vendor as soon
as possible.

Under no circumstances
should any attempt be made to repair
a cylinder or valve.

Return to Online Training

 HANDLING & USE

Standard cylinder-valve outlet connections have been

devised by the Compressed Gas Association (CGA) to
prevent mixing of incompatible gases.

The outlet threads used vary in diameter; some are

internal, some are external; some are right-handed,
some are left-handed.

In general, right-handed threads are used for non-fuel and

water-pumped gases, while left-handed threads are used for
fuel and oil-pump gases.
Return to Online Training
 HANDLING & USE

To minimize undesirable connections, only CGA standard

combinations of valves and fittings should be used in
compressed gas installations; the assembly of miscellaneous
parts should be avoided.

The threads on cylinder valves, regulators and other

fittings should be examined to ensure they correspond
and are undamaged.

Return to Online Training

 HANDLING & USE

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 (i.e., 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.

Return to Online Training

 HANDLING & USE
Cylinders are equipped with either a hand wheel or stem
valve. For cylinders equipped with a stem valve, the valve
spindle key should remain on the stem while the cylinder is in
service.

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.

Some valves may require washers; this should be checked

before the regulator is fitted.

Return to Online Training

 HANDLING & USE
Cylinder valves should be opened slowly. Oxygen cylinder valves
should be opened all the way.
Open up the oxygen cylinder valve stem just a crack. Once
the needle on the high pressure gauge has stopped, open up
the valve all the way. This back-seats the valve.
Oxygen cylinders must have the valve opened up all the way
because of the high pressure in the cylinder. There is a back-
seating valve on the oxygen cylinder. This prevents the high-
pressure gas from leaking out through the threaded stem.

When opening the valve on a cylinder containing an irritating or

toxic gas, the user should position the cylinder with the valve
pointing away from them and warn those working nearby.
Return to Online Training
 HANDLING & USE
Cylinders containing flammable gases such as hydrogen or
acetylene must not be stored in close proximity to open
flames, areas where electrical sparks are generated, or where
other sources of ignition may be present.

Cylinders containing acetylene shall never be stored on

their side.
Return to Online Training
 HANDLING & USE
An open flame shall never be used to detect leaks of
flammable gases. Hydrogen flame is invisible, so "feel" for
heat.

One common practice is to use a natural bristle broom to

"sweep" the air in front of you.

All cylinders containing flammable

gases should be stored in a well-
ventilated area.

Return to Online Training

 HANDLING & USE
Oxygen cylinders, full or empty, shall not be stored in the
same vicinity as flammable gases.

The proper storage for oxygen cylinders requires that a

minimum of 20 feet be maintained between flammable gas
cylinders and oxygen cylinders or the storage areas be
separated, at a minimum, by a fire wall five feet high with a
fire rating of 0.5 hours.

Greasy and oily materials shall never

be stored around oxygen; nor should
oil or grease be applied to fittings.

Return to Online Training

 HANDLING & USE

Regulators are gas specific and

not necessarily interchangeable!

Always make sure that the

regulator and valve fittings are
compatible.

Return to Online Training

 HANDLING & 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.
Return to Online Training
 HANDLING & USE

If there is any question as to

the suitability of a regulator
for a particular gas, check
with the Environmental
Health & Safety Department
or call your vendor for
advice.

Return to Online Training

 HANDLING & USE

The following rules should always be followed in regards to

piping:

Plastic piping shall not be used for any portion of a

high pressure system.
Do not use cast iron pipe for chlorine.
Do not conceal distribution lines where a high
concentration of a leaking hazardous gas can build up
and cause an accident.
Copper piping shall not be used for acetylene.
Return to Online Training
 HANDLING & USE

The following rules should always be followed in regards to

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.

Return to Online Training

 HANDLING & USE

A cylinder should never be emptied to a pressure lower than

172 kPa (25 psi/in2) (the residual contents may become
contaminated if the valve is left open).

When work involving a compressed gas is completed, the

cylinder must be turned off, and if possible, the lines bled.

Return to Online Training

 HANDLING & USE
When the cylinder needs to be removed or is empty, all
valves shall be closed, the system bled, and the regulator
removed.

The valve cap shall be replaced, the cylinder clearly

marked as "empty," and returned to a storage area for
pickup by the supplier.

Empty and full cylinders should be stored in separate areas.

Return to Online Training

 HANDLING & USE
Where the possibility of flow reversal exists, the cylinder
discharge lines should be equipped with approved check
valves to prevent inadvertent contamination of cylinders
connected to a closed system.
"Sucking back" is particularly troublesome where gases
are used as reactants in a closed system.

A cylinder in such a system should be shut off and removed

from the system when the pressure remaining in the cylinder
is at least 172 kPa (25 psi/in2).
If there is a possibility that the container has been
contaminated, it should be so labeled and returned to the
supplier.
Return to Online Training
 HANDLING & USE
Liquid bulk cylinders may be used in laboratories where a
high volume of gas is needed.

These cylinders usually have a number of valves on the

top of the cylinder.

All valves should be clearly marked as to their function.

These cylinders will also vent their contents when a preset

internal pressure is reached, therefore, they should be
stored or placed in service where there is adequate
ventilation.
Return to Online Training
 HANDLING & USE

Always use safety glasses (preferably with a face shield)

when handling and using compressed gases, especially
when connecting and disconnecting compressed gas
regulators and lines.

Return to Online Training

 HANDLING & USE

All compressed gas cylinders, including lecture-size

cylinders, must be returned to the supplier when empty or no
longer in use.

Return to Online Training

 TRANSPORTATION OF CYLINDERS
The cylinders that contain compressed gases are primarily
shipping containers and should not be subjected to rough
handling or abuse.

Such misuse can seriously weaken the cylinder and render

it unfit for further use or transform it into a rocket having
sufficient thrust to drive it through masonry walls.

Return to Online Training

 TRANSPORTATION OF CYLINDERS

1. To protect the valve during transportation, the cover cap

should be screwed on hand tight and remain on until the
cylinder is in place and ready for use.

2. Cylinders should never be rolled or dragged.

3. When moving large cylinders, they should be strapped to

a properly designed wheeled cart to ensure stability.

4. Only one cylinder should be handled (moved) at a time.

Return to Online Training