Dangote Oil Refinery Company Ltd.

Gas Cylinder Safety Procedure

DOC. NO.: DORC-HSE-DOC-

GAS CYLINDER
SAFETY
PROCEDURE
 Dangote Oil Refinery Company Ltd.

Gas Cylinder Safety Procedure

DOC. NO.: DORC-HSE-DOC-

Contents

Sr. No. Clause Details Page Nos.

1 Purpose
2 Scope
3
Associated Risks and Hazards of Handling Gasses
4 Additional Information on Handling
5 Definitions
6 Responsibilities
7 Receipt, Storage & Transport of Compressed Gas Cylinders
8 Use of Compressed Gas Cylinders
9
Criteria for Rejection of Compressed Gas Cylinders
10 Typical Permanent Identification Marks on Cylinders
Appendix 1: Compressed Gas Cylinder Colour Code Table

Appendix 2: Gas Cylinder Checklist

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GUIIDELINES FOR GAS CYLINDER SAFETY

1. Purpose

The purpose of this document is to establish workplace controls that ensure compressed gas
cylinders are used and transported on Dangote sites in a safe and incident free manner:

 Gas cylinders must be delivered in a safe condition from suppliers secured in a certified
rack where required
 Management personnel must be aware of the condition of gas cylinders delivered to them
and why those failing to comply with the company rules should be rejected and returned to
the supplier
 Operations personnel must be aware of the correct procedures and equipment to be used
when storing, transporting, and using compressed gas cylinders
 Gas cylinders should all comply with the BOC colour coding system shown at Appendix 1

2. Scope
This document applies to all compressed gas cylinders used, stored and transported by Company
and contractor personnel in all Dangote operational areas and facilities.
3. Associated risks and hazards of handling gases
Since gases are invisible and some have little or no smell their presence is not easily detected and
even worse they have the potential to asphyxiate, burn or harm those using them.
Each year there are many incidents involving the use of compressed or liquefied gases, most of
which could have been avoided if the individual using them had followed information contained in
the Safety Data Sheet (SDS) or had referenced this document or other similar freely available
information.
Label
The label is the primary means of identification of the cylinder contents (see next page). If the label
is illegible or missing, DO NOT use the cylinder but return it to the supplier and request they
supply a cylinder that is clearly marked as to its contents.
Cylinder Colour
The colour of the gas cylinder is the secondary means of identifying the contents of the cylinder
and the nature of the hazard associated with the gas contained in the cylinder.
4. Additional information on Handling
In the interests of personal safety, employees MUST familiarize themselves with: The SDS for the
gas being used by them and have easy access to every SDS for the gasses that are stored on site
and may be used by them so they are aware of the rules for;
 Storage
 Handling
 Transport issues
 Personal Protective Equipment
 Incident response
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Main gases hazard classifications. Special precautions when handling.

Toxic
A gas that is known to be
 toxic or corrosive to humans as to pose a hazard to health; or
 presumed to be toxic or corrosive to humans because it
has an LC 50 value equal to or less than 5000 ml/m3 (ppm).
 Hues of Yellow

Flammable
A gas which will burn in air at a pressure of 101.3 kPa absolute.
Hues of Red

Oxidising
A gas which gives up oxygen readily, removes hydrogen from a compound, or
readily accepts electrons.
Hues of Black, White, or bright Blue

Non-flammable,non-toxic
A gas which is non-flammable, non-toxic, non-oxidising, and is resistant to
chemical action under normally encountered conditions.
Hues of Brown, Green or dark Blue

Cylinder and pack identification label

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5. Definitions

Condemned - A cylinder that is no longer fit for service and cannot be returned to serviceable
condition. Condemned cylinders should be destroyed by the supplier

Corrosion / Pitting - Loss of gas cylinder wall thickness through oxidation. There are several
types of corrosion that may be observed:
 Crevice corrosion: Corrosion that occurs where the foot-ring or head-ring of a cylinder
come into contact with the shell.
 Pitting: Small, isolated pits that do not appreciably weaken a cylinder.
 Line corrosion: Corrosion that appears in a continuous pattern or line on a cylinder shell;
usually caused by cylinders laid horizontally on a wet surface.
 General corrosion: Pitting and flaking that covers a large area of cylinder shell surface.
General corrosion weakens a cylinder and reduces its structural strength.
Cuts and Gouges - Deformities in a gas cylinder shell caused by contact with a sharp object.
Cuts and gouges decrease wall thickness and strength.
Dents - Deformities in a gas cylinder shell caused by contact with a blunt object. Dents do not
decrease wall thickness, and may not be cause for rejection.
Fire Safety Zone - A 15 foot (4.5 m) minimum buffer area around dedicated gas cylinder storage
locations that contain compressed gases must be set up. Fire Safety Zones must be clear of
vegetation, flammable liquids, hydrocarbon processing equipment, and ordinary combustibles.
Smoking is forbidden inside Fire Safety Zones.
Fire Safety Zones are not required for temporary gas cylinder storage locations such as welding
set racks, or gas cylinder storage areas in processing facilities for specific hot work and inerting
operations.
High Pressure - Most industrial gases, with the exception of acetylene come in high pressure
cylinders these are cylinders with a marked service pressure of 900 psig (6210 kpa) or more.
Low Pressure - Cooking gas and acetylene come in low pressure cylinders i.e. cylinders with a
marked service pressure less than 900 psig (6210 kpa).

Rejected - A cylinder not fit for service in its current condition. Rejected cylinders should be
returned to the supplier for repair/testing & re-qualification. Cylinders that do not pass re-
qualification should be condemned and destroyed by the supplier.
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6. Responsibilities
Compressed Gas Cylinder End User
Company and contractor end users will store, transport, and use compressed gas cylinders in
accordance with this document. End users will not accept any gas cylinder that does not meet the
criteria detailed here.
Such cylinders should be immediately returned to the compressed gas supplier. Compressed gas
cylinders procured by contractors will be acceptable if they comply with this document.
Contractors are responsible for rejecting & returning unacceptable compressed gas cylinders that
they procure.
Training
Personnel who use gas cylinders should be suitably trained and have the necessary skills to carry
out their job safely. They should understand the risks associated with compressed gas and basic
storage, transportation, and use safety precautions. New employees who are involved in
compressed gas cylinder handling should receive initial training and close supervision before
being allowed to work independently.

7. Receipt, Storage & Transport of Compressed Gas Cylinders

Receipt of Compressed Gas Cylinders
Gas cylinders received from suppliers will meet the “BOC” colour code shown in Appendix 1.
Company and contractors must exercise care to ensure that cylinder colour matches the contents
listed on the order sheet/manifest. Colour code & markings must be unambiguous and in good
condition.
 Cylinders with the wrong colour code or markings must be rejected
 Cylinders must be rejected if markings have been defaced or if markings, labels, tags, or
stencil marks used for identification have been removed.
 Cylinders without valve caps must be rejected
 Ensure gas cylinders have caps in place.
 Tape in lieu of caps is unacceptable.
Perform a visual examination of each cylinder using the criteria in Section 8 and the checklist in
Appendix 2. Rejected gas cylinders should be removed immediately by the compressed gas
supplier (do not allow them to be left at the warehouse). Cylinder shipments must be accompanied
by accurate manifests and Safety Data Sheets.
Storage of Compressed Gas Cylinders
Compressed gas cylinders must be secured in an upright position to prevent them from being
knocked over or damaged.
Compressed gas cylinders shall be stored separately from combustible and flammable materials.
Oxygen cylinders and flammable gas cylinders (e.g., acetylene, propane, propylene, and cooking
gas) shall be separated by a minimum distance of 20 feet (6 meters) or by a metal wall 5 feet (1.5
meters) high and ¼ inch (6.4 millimetres) thick and as wide as the storage rack.

Gas cylinders will be stored in shaded areas to avoid increased pressure from heat expansion.
Canopies or storage area roofs should be non-combustible. Cylinders shall not be exposed to
temperatures above 125°F (52°C), open flames, or areas where heavy equipment is being moved.
Cylinders shall not be placed where they might become part of an electrical circuit.
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Storage areas will be protected (e.g., fenced) against unauthorized access.

Storage areas should have a minimum of 25% of the perimeter open to the atmosphere for
emergency response access and to allow dissipation of gas should a leak occur. Enclosures shall
be constructed to resist fire for a minimum of 1 hour fire around compressed gas storage areas.
NEVER store compressed gas cylinders in standing water, or where water can accumulate around
cylinders. Cylinders should be elevated on a section of fiberglass grating to help prevent
corrosion.
You must segregate empty and full cylinders and mark “EMPTY” on the storage cage containing
them. NEVER assume empty cylinders are depressurized; take the same safety precautions with
empty cylinders that you take with full ones.

Transport of Compressed Gas Cylinders

All shipments of compressed gas cylinders should be accompanied by an Safety Data Sheet
(SDS).
Gas welding sets may be transported in racks designed for that purpose. Gas welding sets are
limited to a single fuel cylinder and a single oxygen cylinder.
All cylinders must be transported in the upright position unless clear instructions state
otherwise
Valve caps shall be in place when cylinders are not in use and when they are being moved.
Cylinders shall not be lifted by their caps. (Note: caps and covers prevent moisture and dirt from
gathering in the valve of the cylinder) you must disconnect regulators and hoses from cylinders
before transportation.
DO NOT let gas cylinders project beyond the sides or ends of a vehicle.
Cylinder outlets shall be plugged during transportation.
Hand trucks should be used to move cylinders (never drag cylinders). Hand rolling by the bottom
is permissible if properly trained on the technique. Do not lift cylinders by the valve / valve cap or
use sling / rope chokers to move cylinders. Cylinders shall be securely fastened to hand trucks
when being moved.
“Short” cylinders (i.e., cylinders that are not restrained by both transport rack side rails) shall be
securely tied in place, such as to taller adjacent cylinder, so that they cannot slip under the single
side rail. As an alternative, short cylinders can be transported in baskets, as long as they are
secured in an upright position.
8. Use of Compressed Gas Cylinders
Handle ALL cylinders as though they are full and always double check that the cylinder/gas is the
right one for the intended use.
If there is a problem with a gas cylinder you should call the supplier to deal with it NEVER attempt
to work on the cylinder yourself.
Cylinder valves shall be kept capped & closed at all times except when a cylinder is in active use.
Caps must fit securely, and not be cross-threaded.
Open cylinder valves slowly, with the valve pointing away from personnel.
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Personnel must check there are no leaks by spraying soapy water onto valves and hose
connections prior to the torch being lit to prevent a flashback which could cause major problems
and result in an explosion which could cause major injury/damage.
Compressed gas cylinders shall not be used as rollers, as supports, or for any other purpose
except contain gas. When moving compressed gas cylinders around a jobsite, they may be
moved by hand truck or rack. Cylinders may also be rolled on the bottom edge, but never
dragged. Never allow cylinders to drop, fall over, or be allowed to strike other cylinders.
 Never lift cylinders by the valve or valve cap.
 Never use sling or rope chokers to move cylinders.
 Keep cylinders upright during storage and use, either in a rack, or securely tied off so that
they cannot fall over.
 Tying them in place with twine, a piece of wire, or similar flimsy means is unacceptable.
Compressed gas shall not be used for purposes other than for those for which they are intended.
For example, never use compressed gases for cleaning or “drying parts”. This may cause serious
injury to personnel or create a fire hazard.
Regulators, gauges, and hoses provided for use with a particular gas or group of gases shall not
be used on cylinders containing gases having different properties. Properly sized wrenches shall
be used with cylinder valve accessories (don’t use pipe wrenches).
Remember Oxygen supports combustion, when pure oxygen comes in contact with oil or grease, a
spontaneous explosion and fire could occur. To prevent this, never lubricate or allow oil or grease
to get on oxygen connections. Keep oxygen and hydrocarbons separated. Never use oxygen in
place of compressed air or as a source of pressure or in self-contained breathing apparatus and
never handle oxygen regulators with greasy hands or gloves.
Acetylene should never be used with the cylinder secured more than 45 degrees from a vertical
position. Acetylene is unstable above 15 psig. To reduce the possibility of an explosion, never use
acetylene at a hose pressure exceeding 15 psig.
Compressed gas cylinders used for welding or cutting shall be equipped with flashback arrestors
on the welding/cutting assembly and regulator during use and a bottle containing soapy water
should be available with each set so operators can check for leaks prior to lighting the torch
Never allow sparks, molten metal, electrical currents, excessive heat, or flames to come into
contact with compressed gas cylinders or attachments.
9. Criteria for Rejection of Compressed Gas Cylinders
Compressed gas cylinder rejection is based on:
 Recognition of defects (see Definitions):
 Measurement of defects: Exterior corrosion, denting, bulging, gouges, and cuts & digs are
usually measured by simple direct measurements with scales or depth gauges. To
measure gas cylinder wall thickness loss, a straight edge is placed over the defect, and a
scale (e.g. a ruler, calliper, feeler gauge)) is used to measure the distance from the bottom
of the straightedge to the bottom of the defect. The depth of small pits can be measured
by marking a wire inserted into the pit, or by using a commercial depth gauge.
 Hydro test data: Low pressure cylinders may or may not require periodic hydro testing. All
high pressure cylinders require periodic hydro testing and will be stamped with the last
hydro test date. Reject all cylinders that have not been hydro tested within 10 years.
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Low Pressure Cylinders

Weight: Corroded cylinders may be weighed to determine metal loss. Reject cylinders with a tare
weight less than 95% of the original stamped tare weight (90% if the cylinder exhibits corrosion).
Weight can only be used to assess the condition of the cylinder when it is completely empty.
Dents: Reject cylinders that have significant dents near or on welds, or when dents are deep with
relatively sharp edges (i.e., dents appear to have been “punched” into a cylinder). “Significant
dents on welds” means dents that are more than 0.25 inches (6.35 mm) deep. Dents can be
tolerated when they are shallow, and there is little deformation (i.e., the depth of a dent is no more
than 10% of the length or width of the dent, whichever is greater).
Cuts, gouges, and digs: Use general corrosion criteria.
Leaks: Reject all leaking cylinders and store them in a quarantined area.
Fire damage: Reject all cylinders that show evidence of fire damage. Fire damaged cylinders
must be examined, retested, and recertified by the supplier, before they may be used on Company
premises. Evidence of fire damage includes:
 paint charring or burning
 burned or scarfed cylinder metal
 distorted (bulged) cylinder
 melted fuse plugs
 burned or melted valve
Arc and torch burns: Reject all cylinders with evidence of arc and torch burns (metal removal or
deposition; burn marks)
Bulges: Reject all cylinders with noticeable bulges.
Attachments: Foot-rings are attached to the bottom of compressed gas cylinders to provide a
stable bearing surface and keep cylinders upright. Head-rings protect cylinder valves. Examine
foot-rings and head-rings for excessive corrosion, distortion, looseness, cracking, and weld failure.
Reject cylinders with significant foot-ring or head-ring damage.
High Pressure Cylinders
Hydro Test Date: Reject cylinders that have not been hydro tested within the last 10 years look
for information regarding hydro testing criteria and compressed gas cylinder stamps
In the case of general corrosion, if the original tare weight is provided on a cylinder,
reject/condemn the cylinder when the actual weight is less than 95% of the original tare weight.
Dents: Dents may be tolerated when the cylinder wall is not excessively deformed or has sharp
“punched” edges. Appearance plays a major role in whether a dent is acceptable or not. Industry
practice allows a 1/16 inch deep (1.59 mm) dent in a 9 inch (229 mm) diameter cylinder as long as
the dent is either 2 inches (51 mm) long or wide.
Cuts, gouges, and digs: Use general corrosion criteria
Leaks: Reject all leaking cylinders.
Fire damage: Reject all cylinders that show evidence of fire damage. Fire damaged cylinders
must be examined, retested, and recertified by the supplier, before they may be used on Company
premises. Evidence of fire damage includes:
 paint charring or burning
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 burned or scarfed cylinder metal

 distorted (bulged) cylinder
 melted fuse plugs
 burned or melted valve
Arc and torch burns: Reject all cylinders with evidence of arc and torch burns (metal removal or
deposition; burn marks)

Evidence of welding: Welding is not permitted on high pressure cylinders. Reject any cylinders
that have evidence of welding repairs (note that high pressure gas cylinders are seamless
construction – any welding is a sign of a repair)
Bulges: Reject all cylinders with noticeable bulges.
Attachments: Foot-rings are attached to the bottom of compressed gas cylinders to provide a
stable bearing surface and keep the cylinder upright. Head-rings protect cylinder valves. Examine
foot-rings and head-rings for excessive corrosion, distortion, looseness, cracking, and weld failure.
Reject cylinders with significant foot-ring or head-ring damage.
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10. Typical permanent identification marks on cylinders

For seamless cylinders, permanent identification markings are usually found on the shoulder or
base of the cylinders. For fabricated cylinders, markings are found on the valve protection ring
(VPR).
Owner Stamp Mark
Weight
Serial No.
Test pressure of shell
Manufacturer’s stamp
Test date (retest date)
Specification
Charging pressure
Water capacity
Gas traffic
Owner Stamp Mark
Weight empty with mass embossed by
BOC
Serial No.
Test pressure of shell
Manufacturer’s stamp
Test date (retest date)
Porous mass manufacturer/type
BOC – Inspector’s approval stamp
Water capacity
Owner Stamp Mark
Empty weight & Tare weight
Serial No.
Test pressure of shell
Manufacturer’s stamp
Test date (retest date)
Specification
Water capacity

NEVER
 change a cylinder’s contents from what was otherwise intended
 repaint a cylinder
 change a cylinder’s markings or identification
It is extremely dangerous to change the contents or external colour of a cylinder
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Flashback Arrestors O Ring Oxy/Acetylene Hoses

Gas Cylinder Trolley

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Appendix 1: Compressed Gas Cylinder Colour Code Table

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Appendix 2: Gas Cylinder Checklist

No. Item Comment
Note: If any of the checklist answers are no, a hazard exists, and the comments should explain what is being
being done to remove the hazard from the workplace.
Delivery
4.1.1 Gas cylinders meet BOC colour code Yes      
No
4.1.2 Gas cylinder marking, labels, tags are Yes      
legible and correct No
4.1.3 Cylinders pass visual inspection, see Yes      
Section 7 (note deficiencies in No
comments)
 Checked for isolated pitting
 Checked for general corrosion
 Checked for line/crevice corrosion
 Checked for dents
 Checked for cuts, gouges, digs
 Checked for leaks
 Checked for fire damage
 Checked for arc & torch burns
 Checked for bulges
 Head-ring OK
 Foot-ring OK

Storage
4.2.1 Compressed gas cylinders are stored in an Yes      
upright position & secured against falling. No
4.2.2 Compressed gases are stored away from Yes      
other flammable / combustible materials. No
4.2.2 Oxygen and flammable gas cylinders are Yes      
stored 20 feet (6 m) apart, or are separated No
by steel plate.
4.2.3 Compressed gas cylinders do not exceed Yes      
125 oF (52 oC) temperature. No
4.2.4 Compressed gas cylinders cannot become Yes      
part of an electrical circuit. No
4.2.5 Cylinder storage areas are fenced, or Yes      
secured against unauthorized access No
4.2.6 Cylinder storage areas are at least 25% Yes      
open to air, or No
4.2.7 Cylinder storage areas have adequate Yes      
ventilation No
4.2.8 “Quick opening” cylinders are segregated Yes      
from general industrial use gases. No
4.2.9 Fire Safety Zone established around Yes      
dedicated cylinder storage areas. No
4.2.10 Hazard identification signs placed at the Yes      
entrance to cylinder storage locations. No
MSDS available.
4.2.11 Cylinders stored so that they are not subject Yes      
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to bottom corrosion (on grating). No

4.2.12 Empty cylinders placed in an area clearly Yes      
marked as “EMPTY” and segregated from No
full cylinders by at least 5 metres.

Transport
5.1 Cylinder shipment is manifested. All Yes      
warning labels & placards in place. No
5.2 Cylinder shipment is accompanied by MSDS Yes      
No
5.4 Cylinder shipment is contained in a rack Yes      
designed for the purpose: No
 Rack certified with current inspection
certificate.
 Cylinders secured from falling
 Four part sling / padeyes
 Two horizontal rails
 Rack in serviceable condition
5.5 All cylinders transported vertically, never Yes      
horizontally unless clear instructions state No
otherwise
5.6 Cylinder caps are in place, and fit correctly. Yes      
Cylinders not lifted by caps. No
5.7 Cylinder valves are plugged during Yes      
transportation No
5.8 Cylinders moved at job site with hand truck, Yes      
or by rolling bottom (do not drag) No
5.9 “short cylinders” secured from falling from Yes      
racks (OK to move in baskets) No
Use
6.1 – No unsafe behaviour observed: Yes      
6.12  No maintenance on cylinders No
 Cylinders moved safely
 Gases used appropriately, not for “drying
parts” for example
 Cylinders kept upright at job site
 Cylinders capped except during use
 Cylinders plugged during transport
 Cylinders located in a safe area
 Cylinders not lifted by the cap or valve,
or with a choker
6.3 Cylinder valves kept closed except during Yes      
use No
6.8 Regulators appropriate for the gas cylinder Yes      
(don’t try to adapt a regulator for a use that it No
wasn’t designed for)
6.9 No lubrication on oxygen cylinder fittings. Yes      
Don’t handle oxygen equipment with greasy No
hands/gloves
6.10 Acetylene used at 15 psig or less. Yes      
No
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6.11 Gas torches and regulators equipped with Yes      

flashback protection. No
Other:       Yes      
No
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Move cylinders in handcarts or other devices designed for moving cylinders.