The American University in Cairo

Environmental Health & Safety

Department

COMPRESSED GASES & GAS CYLINDERS

Introduction:
Many industrial and laboratory operations require the use of compressed
gases for a variety of different operations.

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.

Definitions:
Oxidizing Gas:
A gas that can support and accelerate combustion of other materials.

Pyrophoric Gas:
A gas that will spontaneously ignite in air at or below a temperature of
130º F (54.4º C).

Cryogenic Liquid:
A liquid having a boiling point lower than - 150º F (- 101º C) at 14.7 psia.

Toxic Gases:
A gas having a health hazard rating of 3 or 4 as defined in NFPA-704.

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 The American University in Cairo
Environmental Health & Safety
Department
Hazards of Compressed Gases:
a- Physical Hazards:
Compressed gases have potentially serious physical hazards because they
are under high pressure. If that pressure is released suddenly through a
broken valve, a gas cylinder can fly out of control. This unguided missile
can travel through walls.

b- Chemical Hazards:
Gases are chemicals, so they have chemical hazards. Keep flammable and
explosive gases, such as hydrogen, propane, and acetylene, away from
sparks, flames, and other sources. Chemicals such as anhydrous
ammonia, hydrogen chloride and nitric oxide are corrosive or reactive,
keep them away from all incompatible chemicals.

c- Health Hazards:
Gases also have health hazards. Inhalation is the most common route of
entry. Corrosive gases can burn or irritate the lining of the respiratory
tract. Others, such as hydrogen cyanide or carbon monoxide, can enter the
bloodstream and bind with hemoglobin to prevent it from picking up
oxygen. Some gases irritate skin.
Even "inert" gases, such as helium or nitrogen, are hazardous. They
displace breathable air.

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 The American University in Cairo
Environmental Health & Safety
Department
Hazard Controls:
 Color coding of cylinders.

 Cylinder inspection.

 Employee training.

 Properly designed storage areas.

 Segregation of empty & full cylinders.

 Segregation of incompatible gasses.

 Use of correct pressure regulators.

Safe Storage, Transport, and Handling of Compressed Gas:

The outward appearance of a compressed gas cylinder is deceptive. The
average standard size cylinder is pressurized at 2200 pounds per square
inch. These cylinders are safe under normal use; however, serious
accidents have resulted from the misuse, abuse, or improper handling of
compressed gases.
The following principles must be adhered to for safe storage, use, and
transportation of compressed gas cylinders.
1. Use cylinders in an upright position, unless equipment
manufacturer provides specific instructions otherwise.
2. All compressed gas cylinders in service must be securely held
upright. Fasten them with an approved restraint device to rigid
structure so they will not fall or be knocked over. They must be
secured at a point approximately 2/3 of its height.
3. Cylinders must be secured individually, i.e. one restraint per
cylinder.
4. Turn all valves off when not in use. Always release pressure from
regulator before disconnecting.
5. Do not modify relief valves.
6. Know the contents, properties, and health hazards associated with
the contents. Contents must be clearly labeled.
7. Check to make sure that a label is attached or the identification of
the contents is stenciled on the cylinder when a cylinder is brought
to you.

8. Do not accept a cylinder if the contents are not clearly identified.

Do not rely on color coding to identify the contents of a gas
cylinder; color coding is not standardized.
9. Locate cylinders away from pedestrian traffic areas. Make sure
they are in a well ventilated location. Keep cylinders out of the
direct sun and do not allow them to be heated.
10.When cylinders are not being used, the valve protection cap must
be in place to protect the valve.
11.Never store cylinders of flammable gases (empty or full) near
cylinders of oxygen or other oxidizers. A minimum separation of
20 feet or specially designed separation wall must be maintained.

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 The American University in Cairo
Environmental Health & Safety
Department

12.Never store cylinders in a means of egress.

13.Clearly mark "empty" cylinders with tag or sign. Separate "empty"
and "full" cylinders to avoid confusion and do not store empty
cylinders in your laboratory.
14.Never roll or drag full or empty cylinders. Preferred transport
method is to secure cylinders (with valve covers in place) to a hand
truck or similar mode of transport.
15.Cylinders must be hydrostatically tested every 10 years. The date
of each test must be stamped on the cylinder. Acetylene cylinders
are not tested hydrostatically.
16.Keep amount of flammable gases to a minimum. The number of
flammable gas cylinders (10" x 50") must not exceed 3 cylinders
per 500 square feet in a non-sprinkled building or 6 cylinders per
500 square feet in sprinkled building.
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The American University in Cairo
Environmental Health & Safety
Department
17.Treat "empty" cylinders with same respect as "full" cylinders.
18.Use safety glasses when using compressed gas, use face shield &
other required PPE for cryogenic gases.

19.Do not vent flammable gases inside a building.

20.Check regulators for damage, and check all hoses before use.
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The American University in Cairo
Environmental Health & Safety
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21.If a bottle valve leaks, take outdoors and slowly empty bottle.
22.Open cylinder valves slowly, and never fully open cylinder valves.
23.Do not completely empty a cylinder. A slight pressure prevents
contamination. A completely emptied cylinder must be purged
before it can be refilled. (not less than 25 psi residual pressure).
24.Leaks may develop without warning. Do not use oil-contaminated
regulators with oxygen or other oxidizers; this create a fire hazard.
25.The cylinder should be placed so that the valve handle at the top is
easily accessible at all times.
26.If using a toxic or irritating gas, the valve should be opened only
while the cylinder is in a working fume hood and even so, it would
also be prudent to direct the valve and potential gas flow away
from lab personnel.
27.Never heat the cylinder to raise the pressure of the gas.
28.All gas lines leading from a compressed gas supply should be
clearly labeled to identify the gas, the laboratory or the area served.
29.Signs should be conspicuously posted in areas where flammable
compressed gases are stored, identifying the substances and
appropriate precautions.
30.Under no circumstances should any attempt be made to repair a
cylinder or valve.
31.Standard cylinder-valve outlet connections have been devised to
prevent mixing of incompatible gases. The outlet treads used vary
in diameter; some are internal, some are external; some are right-
handed, some are left-handed.
32.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. At no time
should pliers be used to open a cylinder valve.
33.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 source
of ignition may be present.
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The American University in Cairo

Environmental Health & Safety
Department

34.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.
35.Copper piping shall not be used for acetylene.
36.Use 30 psi or less when using compressed air for cleaning.
37.Never use old clips or twisted wire for hose connections. If a hose
works loose and fails around, serious injury could result. Poor hose
connections are common cause of accidents.
38.Acetylene under pressure can explode. Never use acetylene outside
of the cylinder at a pressure over 15 psig.

Cylinder Safety Devices:

Most cylinders have one or more safety-relief devices. These devices can
prevent rupture of the cylinder if internal pressure builds up to levels
exceeding design limits. Pressure can become dangerously high if a
cylinder is exposed to fire or heat, including high storage temperature.

There are three types of safety-relief devices. Each relieves excessive gas
pressures in a different way:

1. Safety- or Pressure - Relief Valves:

These valves are usually a part of the cylinder. They are normally
held closed by a spring. The valve opens if the cylinder pressure
exceeds the set safety limit. Gas is released until the cylinder
pressure drops back to the safety limit, the valve then closes and
retains the remaining gas in the cylinder.

2. Rupture Discs:
These discs are usually made of metal. They burst at a certain
pressure, releasing the gas in the cylinder. The bursting pressure is
designed so that the disc ruptures before the cylinder test pressure
 is reached. These devices cannot be reclosed, so the entire contents
of the cylinder are released.

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The American University in Cairo
Environmental Health & Safety
Department

3. Fusible Plugs:
Temperature, not pressure, activates fusible plugs. These safety
devices are used where heat could initiate an explosive chemical
reaction. A pressure-relief valve or rupture disc acts too slowly and
too late to prevent rupture of the cylinder if an explosive reaction
has already begun. The fusible plug releases the gas before the
hazardous reaction can begin. Fusible plugs are made of metals that
melts at low temperatures. For example, acetylene cylinders have a
fusible plug which melts at about 100º C (212º F). This
temperature is safely below the temperature at which hazardous
polymerization may occur.

Not all compressed gas cylinders have safety devices. Some gases are so
toxic that their release through a safety device would be more hazardous
than cylinder rupture or explosion. Cylinders for these gases are built to
withstand higher pressures than normal cylinders. When these "toxic gas"
cylinders are involved in a fire, the area must be evacuated.
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