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Compressed Gas Safety
Compressed Gas Safety
Cylinder Gases
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Introduction
Compressed gases used in a variety of industrial and
laboratory situations
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 can be:
– Flammable or combustible
– Explosive
– Corrosive
– Poisonous/toxic
– Inert
– Cryogenic
– Pyrophoric(burns on contact with air)
– or a combination of hazards
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Introduction
Common Industrial Gases
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, sulfur dioxide
Pyrophorics ignite spontaneously in air e.g. silane,
phosphine
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Main Causes of Accidents
Inadequate training and supervision
Poor installation
Poor maintenance
Faulty equipment and/or design(e.g badly
fitting valves or regulators)
Poor handling
Poor storage
Inadequately ventilated working conditions
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Main Hazards
Impact from the blast of a gas cylinder
explosion or rapid relase of compressed gas
Impact from parts of gas cylinders that fail
or any flying debris
Contact with the released gas or fluid(such
as chlorine)
Fire resulting from the escape of flammable
gas or fluids such as LPG
Impact from falling cylinder
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Safe Working with Gas Cylinders:
Identification and Properties
Read the label to see what gas you are dealing with and double
check tha the cylinder/gas is right for th eintended use
No compressed gas cylinder should be accepted for use that
does not legibly identify its contents by name
If the labeling on a cylinder becomes unclear or an attached tag
is defaced to the point the contents cannot be identified, the
cylinder should be marked "contents unknown" and returned
directly to the manufacturer
Never rely on the color of the cylinder for identification. Color
coding is not reliable because cylinder colors may vary with the
supplier. Additionally, labels on caps have little value because
caps are interchangeable
If there is a mismatch between the color of a cylinder and the
label. Do not use, contact the supplier immediately
Know the properties of the gas (read Material Safety Data Sheets
available from your Supervisor)
The cylinder’s contents should be identified at all times as well
as the cylinder status (full, empty or in service)
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Safe Working with Gas Cylinders
Work Practices
Securely restrain cylinders to prevent them falling over
Close the cylinder valve and replace dust caps when cylinder not in use
Before connecting a gas cylinder to equipment or pipework make sure regulator and
pipework are suitable for the gas and pressure being used
Never drop a gas cylinder
Never tamper with cylinders or subject them to abnormal mechanical shocks which
could damage the valve or safety device
Never re-paint, change markings or identification or interfere with threads
Never disguise damage to a cylinder or valve. Label as faulty and contact the supplier
Never attempt to repair a cylinder
Never scrap a cylinder
Never subject cylinders to abnormally high or low temperatures
Never mix gases in a cylinder
Never try to refill a cylinder unless properly trained to do so
Never transport by rolling them on the ground or use them as rollers or supports
Never pick them up by magnetic lifting
Never subject to abnormal mechanical shocks whuch could damage the valve or safety
device
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Safe Working with Gas Cylinders
Daily Inspection
Cylinders should be inspected daily
and prior to each use for corrosion,
leaks, cracks, etc.
Inspection should include the
cylinder, piping, safety relief
devices, valves, protection caps and
stems.
Leaking regulators, cylinder valves
or other equipment should be taken
out of service.
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Safe Working with Gas Cylinders
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Gas Cylinder Use
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.
Before a regulator is removed from a cylinder, the cylinder valve shall
be closed and the regulator relieved of gas pressure.The valve
cap shall be replaced, the cylinder clearly marked as "empty,"
and returned to a storage area for pickup by the supplier
Regulators, gauges, hoses and other apparatus shall not be used on
gas cylinders having different chemical properties
Valve outlet thread size is different for different products but the
same products from different gas suppliers will have the same
thread
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Gas Cylinder Regulators
A regulator is a device that receives gas at a high
pressure and reduces it to a much lower working
pressure
Precision instruments and MUST be handled with care
to avoid damage to their sensitive springs, diaphragms,
valve seals etc.
Equipment should display the relevant
European/British Standard number and the pressures
up to which it can operate
Leave the pressure adjustment knob/screw fully out
when the regulator is not in use (this ensures a
minimum of tension on the springs and diaphragms)
Cylinders should be placed with the valve accessible at
all times. The main cylinder valve should be closed as
soon as it is no longer necessary that it be open, it
should never be left open when the equipment is
unattended or not operating
This is necessary not only for safety when the cylinder is
under pressure, but also to prevent the corrosion and
contamination resulting from diffusion of air and
moisture into the cylinder after it has been emptied.
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Flashback Arrestors
Flashback is the result of mixture of fuel gas and oxygen
burning within the hose, flame travels and burns its way
towards the gas source at great speed, can result in force of
explosion in either cylinder
Flashback arrestors must be fitted on both oxygen and fuel
gas regulators
If flashback arrestor is dropped/damaged replace
immediately
Flashback arrestors should oinly be used with the gas they
are labelled for and the presuure thay are designed for
Comon reasons for flashback: incorrect purging of hose/torch
prior to use, incorrect gas pressure, incorrect nozzle,
damaged torch valves, gas passages blocked within the torch,
kinked or trapped hose
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Hoses
Correct hose bore size, pressure rating, length and color 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 – Liquified Petroleum Gas
Never use hoses that are longer than necessary
Never use equipment while hoses are wrapped around the cylinders or trolley
Length of hose should be suitable for the task
Keep hoses in good condition
Examine the hose for cracks, deterioration, damage and test the hose for
leaks before use
Do not repair hoses unless you have the skill and means to test hem in
accordance with BS En 1256
Purge hose thoroughly before lighting torch
Do not put wrapping tape around hosing as this contains combustible
hydrocarbons
Do not use copper piping with acetylene hoses as it is potentially explosive
Protect hosing from heat, oil, grease or mechanical damage
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Piping
Distribution lines and their outlets should be
clearly labeled as to the type of gas contained
Piping systems should be inspected for leaks on a
regular basis
Special attention should be given to fittings as well
as possible cracks that may have developed
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Blow Pipes and Torches
Leaks are a serious hazard as they are closest to the operator
Always check condition before use, ensure tip is free of obstruction
Signs of heat damage around the blow pipe or torch may indicate the equipemnt
has sufferd interal damage and is leaking and should be replaced immeidately
No sign of sideways movement of the cutting leaver as this could cause gas
leaks within the body of the torch that are difficult to detect
Always fit the correct size nozzle for the job( hole size and pressure set at
regulator determine gas flow and gas velocity exiting the nozzle, manufacturer
gives a pressure rating for the nozzle being use, if the gas exit velocity is slower
than the combustion velocity backfire and flashback may occur
Replace blow pipe or torch if
Broken bent or loose gas control valve
Bent mixer, misshapen cutter head
Bent cutter tube
Broken of bent cutting oxygen lever
Leak test all connections and valves prior to use
If replacing O ring seals always use the correct materials
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Acetylene
Unique properties
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Handling Gas Cylinders
Wear PPE: gloves, protective footwear, eye protection
Correct way to move cylinders is to: keep upright, secure and with
valves uppermost
Use mechanical aids such as a trolley where reasonably
practicable( do a risk assessment)
Use suitable cradles, slings, clamps or other effective means when
lifting with a hoist or crane
For short distances on even ground the practice of ‘milk-churning’
(manually moving cylindres) can be used only by trained personnel
and never for longer distances, in uneven ground, wet or icy
conditions, poor lighting, or at speed a trolley should be used
All personnel involved should have completed manual handling
training
Never roll cylinders along the ground
Never transport cylinder with valve and pressure regulator attached
or with the valve open
Never attempt to catch a falling cylinder just get out of the way
Never lift a cylinder by its cap, valve or guard/shroud
Remember that a cylinder is never empty
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Transporting Cylinders
Carriage of Dangerous Goods Regulations apply
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Transporting Cylinders
Carriage of Dangerous Goods Regulations apply
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