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The Petroleum Institute

30-hr Lab Safety Training

HSE/LS: 12 - Compressed Gas
Safety

Learning Objective
Attendees will be able to:

Know about hazards associated with gas cylinders

Classify compressed gases
Outline procedure for using pressure regulators and fittings
Specify safe storage of cylinders
Discuss safe handling of compressed gas
Outline procedure in emergency situation
Identify unsafe conditions and work practice involving gas cylinders

Introduction
Three major groups of gases.
Non-Liquefied gases (Cryogenic Gases)
Do not liquefy at ambient temperature regardless of pressures applied (from 25 to
2500 psig. )
Elements or compound having relatively low boiling point. (-90 C )
Liquefy at very low temperature (-276.16 C to -150 C)
Cryogenic Gases - Eg: liquid nitrogen

Liquefied gases
Boiling point will be closer to atmospheric temperature (-90 C to 20 C )
Liquefies at temperature (-90 C to -1 C) and at pressure 25 to 1500 psig.
These become solid in those temperature at which cryogenic gases become liquid.

Dissolved gas

Eg. Acetylene
Explode at pressure 15 psig . Shiping is impossible.
Dissolved in acetone placed in cylinder that is filled with an porous material.
Safely transport at pressure 250 psig

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Consider Oxygen, Nitrogen

Shipped in liquid or gaseous forms.
Liquid form is expensive (required special equipment)

Other gases like Anhydrous ammonia, chlorine, propane, nitrous

oxide and carbon dioxide
Shipped in liquefied form

Head Space
Vapor pressure

Liquefied gas

Introduction (Continued)

Common Industrial Gases

Compressed gases present a unique hazard. Depending on the particular

gas, there is a potential for simultaneous exposure to both mechanical and
chemical hazards
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, sulphur
dioxide
Pyrophorics ignite spontaneously in air e.g. silane, phosphine

Factor Affecting Compressed Gas Safety

1. Quality of construction of gas cylinder
2. Materials and equipments selected to be used with compressed gas
3. Proper use of compressed gas cylinder

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Main Causes of Accidents

Inadequate training and supervision
Poor installation
Poor maintenance
Faulty equipment and/or design(ex. badly fitting
valves or regulators)
Poor handling
Poor storage
Inadequately ventilated working conditions

How to
avoid
these
causes?

KNOW YOUR GASES

Label, MSDS
KNOW ABOUT YOUR CYLINDERS AND VALVES

A. Size and capacity

B. Typical permanent identification marks on cylinders
C. Cylinder valves
D. Valve guards and valve protection caps
E. Valve outlets thread
F. OPENING or CLOSING cylinder valves
G. Pressure relief devices
H. Pressure regulators: operation and handling
I. Hoses
J. How to install a regulator on a compressed gas tank
SAFE HANDLING
Moving cylinders
SAFE STORAGE
HANDLING EMERGENCY

Leaking damaged cylinders

Cylinder on fire

1. KNOW YOUR GASES

1.

Label
a. The label is the primary means of identification of the cylinder contents
b. If the label is illegible or missing, DO NOT use the cylinder but return it to
the gas company for a satisfactory replacement.

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c. Labels vary in shape, size and their positioning

d. Make note of this class diamonds

Classification of Hazardous Materials

The DOT has broad authority to regulate hazardous materials that are in transport, including the discretion to determine whic h materials shall be classified as "hazardous". These materials are placed in one of nine categories,
based on their chemical and physical properties. Based on the classification of the material, the DOT is also responsible for determining the appropriate packaging materials for shipping or transport. Finally, also based on the
material classification, strict guidelines are furnished for proper labeling/marking of packages of hazardous materials offer ed for transport, and for placarding of transport vehicles.

Class 1: Explosives
Division 1.1 Explosives with a mass explosion hazard
Division 1.2 Explosives with a projection hazard
Division 1.3 Explosives with predominantly a fire hazard
Division 1.4 Explosives with no significant blast hazard
Division 1.5 Very insensitive explosives
Division 1.6 Extremely insensitive explosive articles
Class 2: Gases
Division 2.1 Flammable gases
Division 2.2 Nonflammable gases
Division 2.3 Poison gas
Division 2.4 Corrosive gases
Class 3: Flammable liquids.
Division 3.1 Flashpoint below -18oC (0oF)
Division 3.2 Flashpoint -18oC and above, but less than 23oC (73oF)
Division 3.3 Flashpoint 23oC and up to 61oC (141oF)
Class 4: Flammable solids; spontaneously combustible materials; and materials that are dangerous when wet
Division 4.1 Flammable solids
Division 4.2 Spontaneously combustible materials
Division 4.3 Materials that are dangerous when wet
Class 5: Oxidizers and organic peroxides
Division 5.1 Oxidizers
Division 5.2 Organic peroxides
Class 6: Poisons and etiologic materials
Division 6.1 Poisonous materials
Division 6.2 Etiologic (infectious) materials
Class 7: Radioactive materials
Any material, or combination of materials, that spontaneously gives off ionizing radiation. It has a specific activity greater than 0.002
microcuries per gram.
Class 8: Corrosives
A material, liquid or solid, that causes visible destruction or irreversible alteration to human skin or a liquid that has a severe corrosion
rate on steel or aluminum.
Class 9: Miscellaneous
A material which presents a hazard during transport, but which is not included in any other hazard class (such as a hazardous
substance or a hazardous waste).
ORM-D: Other regulated material
A material which, although otherwise subjected to regulations, presents a limited hazard during transportation due to its form, quantity
and packaging.

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2. MSDS

How to
avoid
these
causes

Know your gases

Label, MSDS
Know about your cylinders and valves
A. Size and capacity
B. Typical permanent identification marks on cylinders
C. Cylinder valves
D. Valve guards and valve protection caps
E. Valve outlets thread
F. OPENING or CLOSING cylinder valves
G. Pressure relief devices
H. Pressure regulators: operation and handling
I. Hoses
J. How to install a regulator on a compressed gas tank
Safe Handling
Moving cylinders
Safe Storage
Handling Emergency

2. KNOW ABOUT YOUR CYLINDERS AND VALVES

a. Size and capacity

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b. Typical Permanent Identification Marks On Cylinders

c. Cylinder Valves
1. All cylinders containing gas under pressure are fitted with a cylinder valve which MUST
NOT be removed or tampered with at any time as this will compromise the safety of
the cylinder.
2. Removing fittings under pressure may result in serious personal injury as fittings may be
projected at high velocity.
3. Each valve outlet is specially threaded to receive commercially available pressure
regulators. (CGA Approved). Regulators are first screwed in fully to the cylinder valve
outlet by hand and then tightened using the regulator spanner.

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c. Cylinder Valves
In the case of a key operated cylinder valve, turn the rectangular key ANTICLOCKWISE
using the cylinder valve key.
Most cylinders are fitted with hand wheels. This avoids the need to use a cylinder valve
key.

d. OPENING or CLOSING cylinder valves

1. OPEN by turning the hand wheel or cylinder valve key anticlockwise. Only use reasonable
force.
2. CLOSE by turning the hand wheel or cylinder valve key clockwise. Only use reasonable force.
3. When in use, cylinder valves used in the fully open position may become stuck in this open
position. To prevent this ensure that the hand wheel or cylinder valve key is turned back half a
turn.

e. Valve Guards and Valve protection caps

1. Some cylinders are fitted with valve guards or valve protection caps.
2. DO NOT remove valve guards.
3. DO replace valve protection caps whenever the cylinder not in use.

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f. Valve outlets thread

For safety reasons, flammable gases and
non-flammable gases have their cylinder
valve outlets threaded opposite hand.
This prevents the connection of the incorrect
regulator to cylinder valve outlets.

Valve outlets for flammable gases are

screwed LEFT-HAND (anticlockwise to
tighten). Identifiable by its notched
appearance.
Eg. flammable gases like acetylene,
hydrogen, propane and mixtures containing
fuel gas

Valve outlets thread

Valve outlets for non-flammable

gases are screwed RIGHT-HAND
(clockwise to tighten).
Cylinders containing non-flammable/
non-toxic gases all have conventional
right-hand threads.
Non-flammable gases can be oxidising e.g.
oxygen; or
nonflammable, non-toxic e.g. nitrogen, argon
and air.

In 2006, air and nitrogen cylinder valve outlet sizes and

threads were differentiated from oxygen to prevent:
1. incorrect connection of an oxygen cylinder to applications
where an inert gas is required
2. incorrect connection of an oxygen cylinder to applications
where only air (21%) oxygen is required.
DO NOT damage the threaded portions by connecting
an incorrect regulator
DO NOT over-tighten or use excessive force to
connect equipment
DO call vendor for a replacement cylinder if the
regulator does not connect properly

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f. Pressure relief devices

Most cylinders or manifold cylinder packs are fitted with a relief device. In a situation
where excess pressure is encountered, this is designed to discharge cylinder contents
either completely or only discharge the excess pressure. This is accompanied by a high
pitched noise.
There are three types of commonly used pressure relief devices:
1. burst disc (most common)
2. fusible plug (e.g. acetylene)
3. pressure relief valve (e.g. LPG)

Burst disc
In the event of overpressure, this is designed
to burst, leaving an open passage for gas
contents to escape completely.
e.g. Carbon Dioxide (CO2) cylinders are fitted
with a burst disc which operates at
approximately 207 bar and is fitted on the
cylinder valve.

Fusible plug
This plug is designed to melt, releasing contents
completely.
e.g. Acetylene cylinders are fitted with fusible
plugs which melt at approximately 100C.

Pressure relief valves

This valve is designed to relieve excess pressure
and close again after relieving the excess
pressure.
e.g. BOC Handigas (LPG) cylinders are fitted
with pressure relief valves which operate at
approximately 26 bar.

G. Pressure Regulators: Operation and Handling

Cylinder Valve (V1)
1.
2.
3.
4.
5.

Photo

Part of cylinder
CCW for open
CW close
(Just as a Tap)
If prolong use (Days) open
full, - this will press a
internal seal which will
prevent leak

6. If short term use (hrs) two

or three rotation is enough
7. For acetylene NEVER open
the valve more than 1
rotation.

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Pressure Regulators: Operation and Handling

Two stage Pressure regulator

Tank Pressure Gauge (P1)

1. Displays pressure inside the
cylinder. (not the qty)

Photo

2. For constant pressure no

need
- so may not be available also
-

You can judge using the

display

Pressure Regulators: Operation and Handling

Pressure Adjusting Valve
(V2)
-

Photo

adjust the pressure that

leaves the regulator

2. CCW to decrease the

pressure
3. CW to increase
(Opposite to Tap)
Mistakes are common.
To avoid. always
Rotate CCW until the valve is
free to move.

Pressure Regulators: Operation and Handling

Pressure gauge(P2)
-pressure goes into the system
-if no reading check needle
valve

Photo

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Pressure Regulators: Operation and Handling

Needle Valve (V-3)
-Controls the volume of gas
leaving the regulator

Photo

CCW to open

CW to close (Just as a Tap)

May be or may not be (but

easily can be added)

I. General safety consideration for Hoses

Correct hose bore size, pressure rating,
length and colour 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 Liquefied Petroleum Gas
Never use hoses that are longer than
necessary

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I. General safety consideration for Hoses

Examine the hose for cracks, deterioration,

damage and test the hose for leaks before use
Do not use copper piping with acetylene hoses
as it is potentially explosive
Protect hosing from heat, oil, grease or
mechanical damage

J. Using regulator safely

1.
2.
3.

Open tank valve slowly

After operation regulator shall not be left in the
cylinder pressurized
Close the cylinder valve and bleed the excess gas in
the regulator.

Test for leak

1. Check pressure gauges

2. Check using soap solution or solution recommend by manufacturer or
SNOOP

How to
avoid
these
causes?

KNOW YOUR GASES

Label, MSDS
KNOW ABOUT YOUR CYLINDERS AND VALVES

A. Size and capacity

B. Typical permanent identification marks on cylinders
C. Cylinder valves
D. Valve guards and valve protection caps
E. Valve outlets thread
F. OPENING or CLOSING cylinder valves
G. Pressure relief devices
H. Pressure regulators: operation and handling
I. Hoses
J. How to install a regulator on a compressed gas tank
SAFE HANDLING
Moving cylinders
SAFE STORAGE
HANDLING EMERGENCY

Leaking damaged cylinders

Cylinder on fire

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SAFE HANDLING OF GAS CYLINDERS

Moving cylinders manual risks involved
1. Always close the cylinder valve before relocating the cylinder!
2. When using a cylinder trolley to move cylinders, make sure cylinders are
properly secured, and the cylinder valves are closed.
3. Never transport cylinders with the pressure regulator and hose attached.

Moving cylinders
For short distances on even ground the practice of

milk-churning (manually moving cylinders) can be

used only by trained personnel and never for longer
distances, in uneven ground, wet conditions, poor
lighting, or at speed, else a trolley should be used
Never roll cylinders along the ground
Never lift a cylinder by its cap, valve or guard
Remember that a cylinder is never empty

1.

Once in place, the cylinder must be secured by cylinder wall brackets, before ancillary
equipment is connected.

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Importance of Cylinder Cap and

Securing Compressed Gas Cylinder

Safe Storage
Each Storage area should be subject to unique risk assessment
All cylinders must be secured to a wall, bench or fixed support using a chain or strap
placed 2/3 of the way up.
Cylinders should not be stored with a regulator attached.
Secure the proper gas cap to the threaded portion on the top of the cylinder to
protect the valve.
Do not store full and empty cylinders together. Tag/ Label them
Oxidizers and flammable gases should be stored in areas separated by at
least 6 m or by a noncombustible wall fire Hr fire rated.

Cylinders should not be stored near heat sources.

No part of a cylinder should be subjected to a temperature higher than 125oF.
A flame should never be permitted to come in contact with any part of a compressed gas
cylinder.
Do not place cylinders where they may become part of an electric circuit.
Keep the number of cylinders in a laboratory to a minimum to reduce the fire and toxicity
hazards.
Use gas storage room at building number 2, 3 and Arzanah to store unused cylinders.
Lecture bottles should always be returned to the distributor or manufacturer promptly when
no longer needed or discarded.
NEVER place acetylene cylinders on their side.

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NEVER
NEVER let oil or grease contact your cylinder or its valve and fittings
Oxygen under pressure and hydrocarbons (oil and grease) can react violently, resulting in
explosions, fire, and injury to personnel and damage to property. Never allow oil or grease to
come into contact with oxygen under pressure. Even a small amount of hydrocarbon can be
hazardous in the presence of high oxygen concentrations. In fact, any organic matter in contact
with oxygen under pressure could have a violent reaction.

Example of oil in contact with oxygen under pressure. This worker, employed by a construction
contractor in Nigeria, had oil on his left hand while adjusting the pressure on an
oxygen regulator. There was an oxygen leak at the hose clamp.

NEVER
NEVER use cylinders as support structures.
NEVER lubricate cylinder valves and fittings.
High pressure oxygen will react violently with oils and grease and cause a
violent explosion or localised ignition leading to injury of the user and
damage to equipment.
Oxygen equipment is at most risk from oil and grease so keep greasy
hands, rags and gloves away from any part of the cylinder and fittings.

Cylinder Incident Response

Report any damaged/leaking cylinder to supplier

If a cylinder is leaking but the leak has not ignited and it is safe to do
(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

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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(999) 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 it as a leaking cylinder
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

Cylinder Incident Response

Gas Cylinders on Fire
If cylinder has been involved in fire do not approach, evacuate the area
to 100m minimum to 300m
Call fire brigade (999)
Inform gas supplier

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
Avoid moving a cylinder that has been subject to heat or severe
impact.
The cylinder may appear normal but if it is moved it may
detonate with fatal consequences

Acetylene cylinders have a porous filler material that helps

stabilize the extremely volatile gas

Acetone is used to stabilize the acetylene, but pockets of pure

acetylene can develop at the valve stem if the cylinder is not
kept in an upright position, or if the cylinder is dented or
damaged.

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ARGON Gas Safety facts

http://www.airproducts.com/en/company/Sustainability/environment-health-andsafety/~/media/Files/PDF/company/safetygram-3.ashx

Hydrogen Gas Safety facts

http://www.youtube.com/watch?v=kIp-Le2dJ60

Gas and its Major Hazards

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Gas and its Major Hazards

Always check MSDS for more hazards and precautions

https://apdirect.airproducts.com/msds/

Violations

Violations

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Cylinder Unsafe storage

Cylinder not secured
Close to traffic
movement
No identification
Electrical cord
running around

5
5

Cylinder Unsafe storage

This cylinder should
be taken to detected
storage and
Area housekeeping
should be improved.

5
6

Cylinder Unsafe storage

Cylinders not secured

properly !!!!!

57

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Never lift a cylinder by its cap, guard or valve.

58

Good practice

Conclusions
Compressed gases present a unique hazard. Depending on the particular
gas, there is a potential for simultaneous exposure to both mechanical and
chemical hazards
Inadequate training and supervision, poor installation, poor maintenance,
faulty equipment and/or design (ex. 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
Material Safety data Sheet (MSDS) for each gas used on your lab
For additional information refer Safety Information sheet available on
PI HSE Website

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Presentation by:
Team HSE
The Petroleum Institute

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