Safe Handling of

Compressed Gases

Reasons for a Safety Seminar

To heighten the awareness of the
dangers associated with compressed
gases
To encourage safe operating practices
in their everyday use
To help ensure the right equipment is
used for your application

Definition
Compressed Gas

Any material or mixture

with an in-container
pressure exceeding 40 psia
at 70F, or a pressure
exceeding 104 psia at
130F, or any liquid
flammable material having
a vapor pressure exceeding
40 psia at 100F [sec.
173.300(a)].

The Gas: Rule #1!

Know the properties of the materials involved
Gases may be:
Under high pressure
Toxic
Corrosive
Flammable
Pyrophoric
Oxidizers

High Pressure Gas

Can cause equip. to fail with explosive force
When released can diffuse into the atmosphere
very rapidly, and an entire room may be
thoroughly contaminated within seconds!
A common 9 dia X 52 high cylinder
pressurized to 2000 psi has the stored energy
equivalent to one pound of dynamite!
Cylinders are commonly filled to standard
pressures of 2000 psi, 2490 psi, 3500 psi and
6000 psi.

Toxic Gases
Have the ability to cause injury or
death when ingested or absorbed by
the skin
Examples include Ammonia, Vinyl
Chloride and Phosgene

Corrosive Gases
Will attack and damage human tissue
Will have an adverse effect on
improper materials of construction
Examples of corrosive materials are
Hydrogen Chloride, Hydrogen
Fluoride

Flammable & Pyrophoric Gases

Flammable gases easily catch fire and burn
rapidly in air
Examples of flammable gases are Acetylene,
Hydrogen, Propane, and Propylene
Pyrophoric gases spontaneously ignite and
burn when exposed to the atmosphere
Silane is a pyrophoric gas which is commonly
used in the electronics industry

Liquefied Compressed Gases

Contents of a
liquefied compressed
gas cannot be
determined by the
pressure in the
cylinder, and a
cylinder scale must
be used

Shipping Regulations
Dept. of Transport (D.O.T.) regulations specify the familiar
diamond shaped tag that must be affixed to each cylinder being
shipped

Material Safety Data Sheets

Required in workplace
Substance fact sheet listing
characteristics, hazards and as
much detail as possible
concerning the particular gas
SECTION 4 FIRST AID MEASURES
SECTION 4 FIRST AID MEASURES
INHALATION: If adverse effects occur, remove to
INHALATION:area.
If adverse
effects occur,
remove
to
uncontaminated
Give artificial
respiration
if not
uncontaminated
area.isGive
artificial
respiration
breathing.
If breathing
difficult,
oxygen
should if
benot
breathing.
If
breathing
is
difficult,
oxygen
should
administered by qualified personnel. Get immediatebe
administered
by qualified personnel. Get immediate
medical
attention.
medical
attention.If frostbite or freezing occur,
SKIN
CONTACT:
SKIN
CONTACT:
If frostbite
freezing occur,
immediately flush with
plenty oforlukewarm
water
immediately
flushC).
with plenty of lukewarm water
(105-115
F; 41-46
(105-115 F; 41-46 C).

Threshold Limit Values (TLVs)

Time Weighted Average (TWA)
- Average 8 hour exposure, 5 days a week
Short Term Exposure Limit (STEL)
- 15 minutes, 4 times a day
Immediately Dangerous to Life and Health
(IDLH)

Personal & Fixed Gas Monitors

Compressed Gas Cylinders

Come in many shapes and
sizes
Commonly constructed of
Carbon Steel or Aluminum
Standard size 1A cylinder
pressurized to 2200 psig holds
approx. 225 ft3 of gas in an
internal volume of 1 ft3!

Cylinder Identification
And Markings
1

Specification number consists of three sections.

DOT- signifies that the cylinder

conforms to Department of
Transportation (DOT) specification.
3AA - specifies type and material of
cylinder construction.
2265 - indicates service pressure
for which the cylinder is designed
at 70F.

Cylinder Identification
And Markings
2

Cylinder serial number

(Matheson Tri-Gas number)

Cylinder Identification
And Markings
3

Date of initial hydrostatic

testing

Cylinder Identification
And Markings
4

Original inspector's insignia

Cylinder Retest Schedule

Specification under which
Specification under which
cylinder was made
cylinder was made
DOT-3
DOT-3
3D
3D
4
4
DOT-9
DOT-9
26 for filling at over 450 psi
26 for filling at over 450 psi
33
33

Minimum
Minimum
retest pressure (psi)
retest pressure (psi)
3000 psi
3000 psi
5/3 times service pressure
5/3 times service pressure
700 psi
700 psi
400 psi (maximum 600 psi)
400 psi (maximum 600 psi)
5/3 times service pressure
5/3 times service pressure
800 psi
800 psi

Retest
Retest
period (years
period (years
5
5
5
5
10
10
5
5
5
5
5
5

CGA Connections
Compressed Gas Assoc.
Reasons for CGA standards
CGA gaskets/washers
Restricted flow orifices

CGA Connections

Matheson Tri-Gas
Product Safety & Code Compliance
Primary Governing Bodies / Safety Codes
Compressed Gas Association (CGA)
Semiconductor Equipment & Materials International (SEMI)
US Environmental Protection Agency (EPA)
Uniform Fire Code / Local City Regulatory Committee (UFC)
Uniform Building Code (UBC) / BOCA
National Fire Prevention Code (NFPC)
International Conference of Building Officials (IBOC)
Toxic Gas Ordinance (TGO)

Cylinder Handling and

Transportation
Upon receipt, visually inspect the cylinders for obvious
defects such as dents, large amounts of rust and missing
or loose safety caps.
Cylinders shouldnt be accepted unless identified with
the appropriate labeling, and all them agree with one
another!
Use a cylinder cart and secure the cylinders with a chain
when moving.
Dont use the protective valve caps for moving or lifting
the cylinders.

Cylinder Handling and

Transportation
Dont drop a cylinder, permit them to strike each other
violently or be handled roughly.
Unless cylinders are secured, regulators should be
removed, valves closed and protective caps in place
before cylinders are moved.
Rolling cylinders in a vertical position on the bottom
edge is to be avoided as much as possible. Gas cylinders
must never be dragged or rolled in the horizontal
position.

Cylinder Storage
Double restrain cylinders with
non-combustible material (i.e.,
chain)
Label Full versus Empty
Signs for hazardous gases
Keep away from traffic areas
Store in fire resistant, well
ventilated, dry areas

Cylinder Storage

Keep away from flames or sparks

Keep caps on when not in use
Store in areas <125F
Keep oxidizers 20 ft. from
flammables
Corrosives should be stored less than
6 months

Pressure Regulators
and How They Work

Single Stage Regulator

Outlet
gauge

Inlet
gauge

Temporary
shut-off
valve

CGA inlet
connection
P/A knob

Single Stage Regulator

Reduces the inlet supply

pressure in one step,
from the inlet supply
pressure to the final outlet
pressure

Single Stage Regulator

Applications:

Intermittent use - where a

sample of gas is required
from a cylinder
Where pressure rise in a set
delivery pressure is not
critical
As a line regulator where
there is a second pressure
regulator at the gas supply
source

Single Stage Regulator

Characteristics:
Rule of thumb: for every
100 psig drop on the inlet
pressure, there will be 1
psig rise on the outlet
working pressure

Two-Stage Regulator

Reduces the pressure in

two steps from a high
pressure inlet source, to the
final outlet working
pressure

Two-Stage Regulator
Characteristics:

Delivery set pressure

remains constant as the inlet
supply pressure decays
Becomes a single stage regulator
when the source supply pressure
becomes less than the set pressure
of the first stage (~300 psig)
Can be supplied with an inter-stage
relief valve as insurance in the
event of first stage seat failure

Two-Stage Regulator
Applications:
Recommended for continuous
use applications, such as carrier
gas supply to GCs or other
analytical instruments, where
it is critical that a constant
delivery set pressure be
maintained

Regulator Installation
Do not use CGA adaptors or change
CGA connections on regulators for a
different gas service unless work is
done by qualified personnel!
Always ensure there are no nicks and
scratches on regulator CGA connections
Never use Teflon tape to achieve a proper
seal
Always leak check connections using a
soap bubble solution or electronic leak
detector

Regulator Operation
Always ensure the P/A knob is backed off counterclockwise to
ensure there is no load on the regulator load spring prior to
opening the cyl valve!
Never open a cylinder valve all the way. 1 to 2 turns is usually
sufficient
Always stand with the cylinder valve between you and the
regulator when opening the cylinder valve and/or adjusting
pressure on the regulator
Do not use the temporary shut-off valve to turn off gas flow if the
shut-off duration will be longer than 20 min.
Use cross or T-purge assemblies if regulators are to be used for
toxic or corrosive gases!

Regulator Failures
95% of regulator failures are due to seat
failures, caused by:
Corrosion buildup on the seat
Contamination (dirt, metal filings, Teflon tape)
that scores the seat at a high velocity

Set pressure creep on the delivery pressure

gauge indicates a seat failure!

Regulator Failures
A Pressure gauge that will not read zero
indicates the bourdon tube has been
damaged and the gauge must be replaced!
Gas leaking through the bonnet assembly of
the regulator indicates a diaphragm failure
(Typically caused by failure to ensure the
regulator is shut off prior to installing it on
a new cylinder)

Safety Devices:
Check valve: prevents reverse gas
flow
Flash Arrestor: prevents ignition
source from reaching regulator and
cylinder for flammables
Excess Flow Valve: restricts flow
in the event of a gas line break

Things Not To Do!

Never roll a cylinder to move it.
Never carry a cylinder by the valve.
Never leave a cylinder unsecured.
Never force improper attachments
on to the wrong cylinder.
Never grease or oil the regulator, valve
or fittings of an oxygen cylinder.
Never refill a cylinder.
Never attempt to mix gases in a cylinder.

Safe Gas Usage

Compressed gases serve laboratories and industrial
plants in many ways, but the cylinders and gases present
a number of hazards.
Treat all gas cylinders, full or empty, as objects that
have a very real potential to injure you severely.

Emergency Plan
Every location where compressed gases are
handled should have a written emergency
plan covering steps to be taken in the event
of an accidental release of gas
This plan should consider the nature of the
gases being handled, that is their chemical
and physical properties

Plan Elements
At a minimum, the plan should specify the
following :
Alarm System & Evacuation Procedure
Response Personnel
Emergency Equipment
Containment or disposal methods

Additional Safety Information

Additional Safety Information

Safety is our First Priority

Test Questions
1. Treat all gas cylinders, full or empty, as
objects that have a very real potential to injure
you severely. True or False
2. Gases may be:
a. Under high pressure
b. Toxic
c. Both a & b

Test Questions
3. Never grease or oil the regulator, valve
or fittings of an oxygen cylinder. T or F
4. Never force improper attachments on to the
wrong cylinder. T or F
5. The check valve is considered a safety device.
T or F
6. The excess flow valve prevents reverse gas
flow.
T or F

Test Questions
7. What Reduces the inlet supply pressure in one
step, from the inlet supply pressure to the final
outlet pressure?
a. Single Stage Regulator
b. Double Stage Regulator
c. Triple Stage Regulator
8. Dept. of Transport (D.O.T.) regulations specify the
familiar diamond shaped tag that must be affixed to
each cylinder being shipped ?
T

or

Test Questions
9. Always stand with the cylinder valve between you
and the regulator when opening the cylinder valve and/or
adjusting pressure on the regulator. T or F
10. Always leak check connections using a soap
bubble solution or electronic leak detector.
T

or