Chapter 28

CARE IN USE & HANDLING OF

COMPRESSED GAS CYLINDERS
CONTENTS
1. Scope
2. Purpose
3. Definitions
4. Responsibilities
5. Instructions
6. References
7. Attachments
1. SCOPE
Procedure applies to all works involving compressed gas in cylinder on
construction sites.

2. PURPOSE
Purpose of this procedure is to ensure that those responsible for handling and use
of compressed gases in cylinders are familiar with required safety precautions.

Compressed gases present a unique hazard. Depending on 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

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
gas, as well as asphyxiation, can be caused by high concentrations of even "harmless" gases such
as nitrogen. Since gases are contained in heavy, highly pressurized metal containers, large
amount of potential energy resulting from compression of gas makes the cylinder a potential
rocket or fragmentation bomb (One That Got Away).

Careful procedures are necessary for handling various compressed gases, cylinders containing
compressed gases, regulators or valves used to control gas flow and piping used to confine gases
during flow.

3. DEFINITIONS
Definitions regarding certain terms
1. Safety means safety, health & environment disciplines to support project activities
2. Company means an organization carrying out or prosecuting project
3. Contractor means organization that has won project from client
4. Subcontractor means an organization that has won part of a project work from Contractor
organization
5. Client means an organization entitle Company in contractual terms that has entrusted
project to organization of Contractor
6. Personnel means all personnel involved on project site activities

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 7. Responsibility means job & contract responsibility
8. Training means training imparted for specific safety topic on job on project site
9. Management means organization top, middle & lower management
10. Safety Manager means a person with job title Safety Manager deployed by certain
organization
11. Project Manager means a person as such with PM title deployed by Contractor
12. Engineer means a person appointed by client or client company for an overall project
responsibility

EMPLOYER Project Owner

EPC CONTRACTOR Contractor
BS 349:1973 British Standard for gas cylinders identification, excluding
medical cylinders
LPG Liquefied Petroleum Gas
MSDS Material Safety Data Sheet

RESPONSIBILITIES IN GENERAL RESPECTING CERTAIN CONTRACT

POSITIONS
1. Project Manager responsible for overall obligations, to provide schedule, all resources,
direction, engineering resolutions.
2. Site Manager responsible for overall site prosecution management over works &
subcontrcators.
3. Site Safety Officer responsible for overall safety management on site & report to Project
Manager / Site Manager / Corporate Safety Manager
4. Construction Manager responsible to arrange all safety related resources & provide site
team all requirements
5. Project Site Engineer responsible to carry out safety issues within section
6. Site Safety Inspector/Engineer responsible to supervise safety measures on site & control
safety issues, should bring to site line management to adopt correct measures.
7. Site Foremen responsible for compliance of safety measures as standards or as directed
8. An individual working on site responsible to maintain safety measures. In case, missing,
should bring to site team attention

4. RESPONSIBILITIES
4.1 Site Manager has an overall responsibility for ensuring that this procedure is
understood and followed by all people including Subcontractors personnel
involved in use and handling of compressed gas cylinders on site.
4.2 EPC CONTRACTOR and Subcontractor Supervisors are responsible for
ensuring that personnel under their control are educated in understanding
details of this procedure.
4.4 Site HSE Manager shall ensure that requirements of this procedure are
communicated to all levels in organization through education (toolbox
talks). Shall liaise with maintenance and construction superintendents in
identifying work hazards and precautions to pursue.
4.5 Gas Suppliers: Where practicable, gas cylinders should be delivered to and
dispatched from construction site by gas suppliers for safe transport and
handling.

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1. INSTRUCTIONS
1.1. Safe Transport and handling:
5.1.1 If arranging collection / return of gases prescribed as dangerous under
road traffic, driver must be properly instructed for safe handling, loading
and transport of cylinders and in dealing with emergencies.
5.1.2 An appropriate Transport Emergency Card or other suitable safety data
sheets must also, be carried on with vehicle.
5.1.3 Purpose designed transport should be used when possible. Preference
should be given to open vehicles or trailers. Cylinders must be secured,
and always be put vertical in case of acetylene and LPG, valves remaining
shut and not leaking. If carried in closed Vans or cars, there must be good
ventilation and smoking should be banned.
5.1.4 Travelling with equipment attached to cylinders should be avoided. Valves
must be shut and protective valve caps fitted, where provided.
5.1.5 If quantity of dangerous gas in cylinders weighing 500 kg or more, vehicle
used for carrying it must display prescribes reflective orange plates to
front and rear.
5.1.6 In event of road accident, emergency services must be advised as to nature
of cylinders being carried by showing relevant Transport Emergency Card
or Safety Data Sheet.
5.1.7 Cylinders should not be lifted with magnets or chains. A rope or nylon
sling may be used to lift one cylinder at a time, provided it is correctly
adjusted to prevent slippage. If more than one cylinder has to be hoisted, a
properly designed cradle with chain/wire suspension should be used and
each cylinder must be securely fastened.
5.1.8 Cylinders should never be lifted by their valve cap or guard unless
supplier states that they are designed for that purpose.
5.1.9 Cylinders should not be rolled along ground as this may damage
identification of cylinder and may also, cause valve to be damaged or
opened.
5.1.10 Oil, grease or other readily combustible substances must be prevented
from coming into contact with cylinders of oxygen, their valves or other
fittings. High pressure oxygen in contact with oil or grease may explode.
5.1.11 Vehicle carrying flammable gas should carry at least one suitable fire
extinguisher of adequate capacity (i.e. dry powder) in load compartment
and additional suitable extinguisher in cabin.
5.2 Storage of compressed gas cylinders
5.2.1 Storage areas should preferably be purpose built compounds in open air,
fenced to a height of approximately two (2.0m) meters. Fence should be
made of non combustible material and not inhibit natural ventilation,
particularly at low level (steel mesh is particularly suitable).
5.2.2 Cylinders should be protected from hot weather from direct rays of sun.
Tarpaulins or some other cover must not be used in direct contact with
cylinders. Cylinders must not be placed on materials, which are likely to
cause corrosion of cylinder base.
5.2.3 If storage in open air is not reasonably practicable then an adequately
ventilated storeroom constructed of fire resisting material may be used. It
must be in a safe position not near cellars, drains or excavations, where
heavy gases could accumulate in event of cylinder leak. Avoid storage
near corrosive influences, such as battery charging shop. LPG may be
stored with acetylene.
5.2.4 No sources of ignition are allowed in stores or storage compounds, where
compressed flammable gas cylinders are kept.
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 5.2.5 Lighting for stores containing acetylene or other combustible gas cylinders
should either be of approved flameproof type or should be outside store.
5.2.6 For flammable gas stores, electrical switches must be of approved
flameproof construction and placed outside store.
5.2.7 Stores or storage compounds for flammable gases should have at least two
means of exit. Gates or doors should open outwards and be open able from
inside store even, when locked from outside. Suitable fire fighting
equipment shall be provided.
5.2.8 For small quantities of flammable gases (less than 300 kg) a lockable wire
cage in open air may be provided. A single gate is then adequate, if there is
no risk of persons being trapped in enclosure.
5.2.9 Full and empty cylinders should be kept apart and FULL and EMPTY
notices displayed accordingly.
5.2.10 Different categories of gas cylinders (toxic, flammable etc) should be
segregated and marked by signs in storage area.
5.2.11 Oxygen and oxidants should not be stored with flammable gases, but in
separate store of at least 6 meters distance.
5.2.12 LPG and Acetylene cylinders must never be stacked horizontally in
storage or use.
5.2.13 Cylinders should normally be stored upright and secured, so that it shall
not fall. They should never be left free standing i.e. certain LPG
cylinders-- (unless designed to remain stable in such circumstances, but
securely lashed to an adjacent structure
5.2.14 Where cylinders contain gases, which permit safe storage of cylinders in a
horizontal position, they may be so stacked. Large wedges should then be
used at each end of stack. Large cylinders should be placed at bottom of
stack and it should not be more than 4 cylinders high.
5.2.15 Particular guidance for stacking LPG cylinders (in vertical position) is
given in following table:

Amount of LPG in a Amount of LPG in a vertical column of stack

vertical cylinder

Kilograms (Kg) Palletized (Kg) non-palletized (Kg)

Up to 6 35 30
6 to 15 75 45
15 to 20 80 50
20 to 55 110 55

5.2.16 Cylinders should be stored well away from stoves, boilers, radiators and
other heat sources.
5.2.17 Personnel must not smoke, wear oily clothes or have any naked light in
any place, where flammable compressed gases are stored or where,
oxygen is stored.
5.2.18 Cylinder valves should be kept in good condition and grit, dirt, oil, greases
or water should be prevented from entering them.
5.2.19 Should a cylinder become accidentally damaged, it must be taken out of
service, labelled as defective and supplier notified at once.
5.2.20 Storage arrangements should ensure adequate stock turn around. Periodic
checks for general condition of cylinders and leakage should be made.
5.2.21 Storage compounds/storage rooms must have appropriate warning signs
located so that persons, both entering/ working adjacent are aware of gases

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 stored and safety precautions to be applied. LPG stores or storage
compounds in particular should be provided with external signs reading
‘Highly Flammable’, ‘No Smoking’ and ‘No Naked Lights’
5.3 Care in use of cylinders
5.3.1 Cylinders should not be used as rollers or support or for any other purpose
than to contain as supplied.
5.3.2 Cylinders must not be allowed to come into contact with electrical
apparatus, especially arc welding tools or live wires.
5.3.3 For LPG cylinder, which is leaking and on fire, if valve can readily be
closed, this should be done and fire thus extinguished. If valve has been
damaged, again evacuate area and call fire brigade indicating that LPG is
involved.
5.3.4 For hydrogen cylinders leaking and on fire, do not attempt valve
enclosure, but evacuate area and call fire brigade indicating them that
hydrogen is involved.
5.3.5 For cylinders containing compressed gases, which have become heated by
an adjacent outbreak of fire, evacuate area. Call fire brigade indicating
what gas is involved then try to fight fire from a protected position using a
copious amount of water to cool cylinders and control fire.
5.3.6 Every effort should be made to avoid leakages. Tests should always be
conducted with soapy water and a brush and never, by means of naked
flame.
5.3.7 In a confined space, all gases are potentially hazardous whether, they are
toxic and / or they are flammable, asphyxiating or as in case of oxygen,
capable of increasing risk of fire. Importance of good ventilation cannot
therefore, be overstressed.
5.3.8 Personnel should never lubricate any valve or fitting. White or red lead
jointing compound or jointing tape should also, not be used.
5.3.9 Joint fittings or piping made of copper or silver should on no account, be
used in acetylene cylinders as acetylene must never be allowed to come
into contact with copper or any alloy containing more than 70% copper.
5.3.10 During use as well as storage, cylinders and valves should be kept clean.
Grit, dust, oil or dirty water should not be allowed to contaminate valves
or fittings and common malpractice of allowing cylinders to lie in mud on
construction sites should always be prohibited.
5.3.11 Cylinder valves may be cleared of loose dirt by ‘snifting’ some gas
through valve (except hydrogen). With all gases ensure good ventilation,
when carrying out snifting operation.
5.3.12 Hydrogen should never be snifted, as it may ignite spontaneously
5.3.13 Main cylinder valve should always be shut off, when work has to be
stopped for more than a few minutes or when, cylinder is empty.
5.3.14 Cylinders should be removed from working area and put back into store at
end of working period.
5.4 Valves, regulators and gauges
5.4.1 Valves
5.4.1.1 Cylinder valves should always be opened slowly.
5.4.1.2 An open valve should be left a half turn back from full open.
5.4.1.3 Valve should be closed clockwise sufficient to stop gas flow, but
not wrench shut.
5.4.1.4 Excessive force should not be used and only recommended
cylinder valve key should be used. Increased leverage by
use of spanner or longer keys should be prohibited.

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 5.4.1.5 If valve spindle is too stiff to open by hand or is damaged or
broken, cylinder should be returned to supplier unused.
Removal of gland nut should never be attempted.
5.4.1.6 Cylinders should not be moved from place to place with regulators
and hoses fitted, unless a proper trolley or carrier is used.
Main cylinder should always be shut during transit. Valve
protection guards or caps should, where practicable, be
fitted before moving cylinders
5.4.1.7 Never use a needle valve in place of a regulator. A needle valve
may cause bursting of hose if gases are cut off at torch, as
hose shall be subject to cylinder pressure.
5.4.1.8 Use needle valve for fine adjustment only downstream of pressure
regulator.

5.4.2 Regulators
5.4.2.1 Welding or cutting apparatus should not be used unless automatic
pressure regulators are fitted to oxygen and fuel gas
cylinders.
5.4.2.2 Before fitting a pressure gas regulator onto a full cylinder,
adjusting screw for regulating outlet pressure should be set
to zero.
5.4.2.3 Correct regulator must be used for particular cylinder and
compatibility of threads checked accordingly.
5.4.2.4 Outlets of industrial gas cylinder valve feature screwed 3/8 in BSP
thread: Right hand for oxygen and non flammable gases,
Left hand for acetylene, hydrogen and flammable gases.
5.4.2.5 Cross threaded connections should never be forced and worn
threads, jointing compound or tape should not be used.
5.4.2.6 Where cylinders are connected to manifolds or headers, equipment
must be properly designed, installed and fitted with one or
more pressure regulators.
5.4.2.7 No attempt must be made to interchange regulators. Each is
designed for use with a specific gas and should be marked
accordingly
5.4.3 Gauges
5.4.3.1 Only pressure gauges recommended by supplier should be used. If
a gauge attached to a regulator is defective, complete
regulator should be exchanged and amateur repairs
prohibited.
5.4.3.2 Gauges for oxygen should be marked ‘OXYGEN’ and must not be
tested for leak with oil – always with soap and water
5.4.3.3 Gauges used to show contents of oxygen, nitrogen and hydrogen
cylinders should have a maximum dial reading of not less
than 225bar (3260 lb/in2)
5.4.3.4 Gauges used to show contents of acetylene cylinders should have a
maximum dial reading of not less than 40 bars (530 lb/in2).
5.4.4 Hoses and torches
5.4.4.1 Only hose that conforms to BS 5120 should be used to connect
torch to gas cylinders.
5.4.4.2 Hoses should conform to accepted colour coding: Blue - oxygen,
Red - Acetylene, Orange -Propane
5.4.4.3 Lengths of hoses are supplied with ends firmly grimed to nipples
having screwed unions suitable for connecting to standard
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 regulator outlets and torch inlets. Makeshift connections
should on no account be used.
5.4.4.4 Length of hose should be kept as short as possible. Where hoses
must be joined, only approved coupling should be used and
dismantled, when job is complete.
5.4.4.5 Joint fittings or piping made of copper should not be used, where
acetylene is used.
5.4.4.6 Non return check valves should be fitted to each hose at torch, as
with oxy fuel gas equipment, flashbacks can occur.
5.4.4.7 HSE approved flashback arrestors designed to quench flashback
and release pressure should be fitted to both fuel gas and
oxygen regulators. In addition, they should incorporate cut
off valves for automatically cut off gas supply.
5.4.4.8 Hoses should not be dragged round sharp corners or placed, where
they can be run over by site vehicles. Hose connections,
hoses and torches should be inspected at least daily before
use.
5.4.4.9 Torch nozzles should be examined regularly.
5.4.4.10 Cylinders should not be used to support work, nor should
torch flame be allowed to come into contact with cylinder.
5.4.4.11 Torch when alight should not be hunt on cylinder or
regulator, nor should torch ever be left burning and
unattended.
5.4.5 General precautions
5.4.5.1 Inspect rubber hoses periodically to see that it is free from cuts,
cracks, burns and worn places and arrange it, so that it
cannot be run over, cut by contact with sharp edges or
corners, falling metals, sparks or torch flame.
5.4.5.2 Use hoses, which are as short as possible and of equal lengths and
do not coil any surplus hose round regulators or cylinders.
5.4.5.3 Do not use odd bits of tubing and remember that copper or high
copper content alloy should not be used in acetylene hose
or other parts in contact with acetylene. Use a proper
adaptor.
5.4.5.4 Be sure to observe carefully maker’s instructions for lighting and
using torches.
5.4.5.5 Do not use pressures in excess of those recommended for heavy
duty high delivery regulators, where only low pressures are
required.
5.4.5.6 Never attempt to light a torch, until sufficient time has elapsed,
after opening torch acetylene valve for gas in hose to
normalize at correct working pressure and all air to be
blown from hose.
5.4.5.7 Always follow equipment manufacturer’s instructions.
5.4.5.8 Do not locate or use cylinders adjacent to intake of air compressors
or internal combustion engines.
General Explanation
Identification
1. Contents of any compressed gas cylinder must be clearly identified.

2. Such identification should be stenciled or stamped on cylinder or a label. Commercially

available three part tag systems may also, be used for identification and inventory.

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 3. No compressed gas cylinder should be accepted for use that does not legibly identify its
contents by name. If labeling on a cylinder becomes unclear or an attached tag is defaced
to point contents cannot be identified, cylinder should be marked "contents unknown"
and returned directly to manufacturer.

Never rely on color of cylinder for identification.

1. Color coding is not reliable because cylinder colors may vary with supplier. Additionally,
labels on caps have little value because caps are interchangeable.

2. All gas lines leading from a compressed gas supply should be clearly labeled to
identify gas, laboratory or area served and relevant emergency telephone numbers.
3. Labels should be color coded to distinguish hazardous gases (such as flammable, toxic or
corrosive substances) (e.g. a yellow background and black letters).
4. Signs should be conspicuously posted in areas, where flammable compressed gases are
stored, identifying substances and appropriate precautions (e.g. HYDROGEN -
FLAMMABLE GAS - NO SMOKING - NO OPEN FLAMES).

Handling & Use

2. Gas cylinders must be secured or chained all times to prevent tipping

1. Cylinders may be attached to a bench top, individually to wall, placed in a holding cage
or have a non tip base attached. Chains or sturdy straps may be used to secure them.
2. If a leaking cylinder is discovered, move it to a safe place (if it is safe to do so) and
inform Environmental Health & Safety Department. Vendor should also, be called as
soon as possible.

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

4. Standard cylinder valve outlet connections have been devised by Compressed Gas
Association (CGA) to prevent mixing of incompatible gases. Outlet threads used vary in
diameter. Some are internal, some are external. Some are right handed. Some are left
handed.
5. 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.

6. To minimize undesirable connections, only CGA standard combinations of valves and

fittings should be used in compressed gas installations. Assembly of miscellaneous parts
should be avoided. Threads on cylinder valves, regulators and other fittings should be
examined to ensure that they correspond and remain undamaged.

7. Cylinders should be placed with valve accessible at all times. Main cylinder valve should
be closed as soon as, it is no longer necessary to remain open (it should never be left
open, when equipment is unattended or not operating). This is necessary, not only for
safety when cylinder is under pressure, but also, to prevent corrosion and contamination
resulting from diffusion of air and moisture into cylinder, after it has been emptied.
8. Cylinders are equipped with either a hand wheel or stem valve. For cylinders equipped
with a stem valve, valve spindle key should remain on stem, while cylinder is in service.
Only wrenches or tools provided by 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 regulator is fitted.

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 9. 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.
10. Cylinders containing acetylene shall never be stored on their side.
11. An open flame shall never be used to detect leaks of flammable gases.
12. Hydrogen flame is invisible, so "feel" for heat. One common practice is to use a natural
bristle broom to "sweep" air in front of you. All cylinders containing flammable gases
should be stored in a well ventilated area.

13. Oxygen cylinders, full or empty, shall not be stored in same vicinity as flammable gases.
Proper storage for oxygen cylinders requires that a minimum of 20 feet be maintained
between flammable gas cylinders and oxygen cylinders or 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.

14. Regulators are gas specific and not necessarily interchangeable

15. Always make sure that regulator and valve fittings are compatible.
16. If there is a question as to suitability of a regulator for a particular gas, check with
Environmental Health & Safety Services or call vendor for advice. After regulator is
attached, cylinder valve should be opened just enough to indicate pressure on regulator
gauge and all connections checked with a soap solution for leaks. Never use oil or grease
on regulator of a cylinder valve.

The following rules should always be followed in regards to piping:

1. Copper piping shall not be used for acetylene.
2. Plastic piping shall not be used for any portion of a high pressure system.
3. Do not use cast iron pipe for chlorine.
4. Do not conceal distribution lines, where a high concentration of a leaking hazardous gas
can build up and cause an accident.

5. Distribution lines and their outlets should be clearly labeled as to type of gas contained.
6. Piping systems should be inspected for leaks on a regular basis.
7. Special attention should be given to fittings as well as, possible cracks that may have
developed.
8. A cylinder should never be emptied to a pressure lower than 172 kPa (25 psi/in2)
(residual contents may become contaminated if valve is left open). When work involving
a compressed gas is completed, cylinder must be turned off and if possible, lines bled.
9. Empty and full cylinders should be stored in separate areas.

10. Where possibility of flow reversal exists, 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 system, when pressure remaining in cylinder is at least 172 kPa (25 psi/in2). If
there is a possibility that container has been contaminated, it should be so labeled and
returned to supplier.

11. 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 top of cylinder. All valves should be
clearly marked as to their function. These cylinders will also, vent their contents, when a

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 preset internal pressure is reached therefore, should be stored or placed in service, where
adequate ventilation is available.

Transportation of Cylinders
1. Cylinders that contain compressed gases are primarily, shipping containers and should
not be subjected to rough handling or abuse. Such misuse can seriously weaken cylinder
and render it unfit for further use or transform it into a rocket having sufficient thrust to
drive it through masonry walls.
a. To protect valve during transportation, cover cap should be screwed on hand tight and
remain on until cylinder is in place and placed for use.
b. Cylinders should never be rolled or dragged.
c. When moving large cylinders, they should be strapped to a properly designed wheeled
cart to ensure stability.
d. Only one cylinder should be handled (moved) at a time.

6. REFERENCES
BS, Internet
7. ATTACHMENTS
N/A

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