Compress Gas and Cylinder Safety Handling

Safety & Loss Prevention

Compressed Gas Cylinder SafetyWhen gas is put into a cylinder, it is squeezed down significantly. For example, 260 cubic ft. of Acetylene fits in a normal size cylinderWhile this is what makes Compressed gas easy to transport and use, the severe pressure can lead to dangerous situations. The pressure and specific hazard of the gas involved are the principal hazards associated when dealing with compressed gases.

Compressed Gas Cylinder Safety, contd.Damaged cylinder can cause a multitude of serious problems, depending on how they have been damaged. If the cylinders base has been bent from rolling or dragging it from the floor, the cylinder will often be unstable when it is set up. This not only creates a falling hazard but can lead to leaks and even breaks in gas line.

Damaged cylinder valves can also cause serious problems. If a significant rupture occurs, or the valve breaks off completely, the rapid release of gas can turn a cylinder into virtual rocket

Compressed Gas Cylinder Safety, contd.Some types of compressed gases have additional hazards. A good example is Cryogenic materials, produce extremely low temperatures. These characteristics can create special hazard:Valves and washers can become brittle and easy to breakThe steel gas cylinder itself can get brittle and can rapture on impactContact can cause severe burn to the skin (frostbite)

Compressed Gas Cylinder SafetyBefore hooking up a gas cylinder, there are several types of equipment you should know aboutThree different pieces of equipment are used on most cylinders:RegulatorsCGA fittingsPressure Relief DeviceNever install a regulator without a CGA fitting

Compressed Gas Cylinder Safety, contd.Regulator control the speed at which a gas comes out of the cylinder.CGA Fittings it connects directly to the cylinder valve and allows the gas to leave the cylinder.Pressure Relief Device (PRD) these devices are designed to prevent ruptures or violent pressure releases that could occur if cylinders are exposed to extreme heat. There are no Pressure Relief Devices on cylinders of toxic or poisonous and inert gases the dangers presented by releasing the gas itself are felt to be greater than the possibility of the cylinder exploding

Compressed Gas Cylinder Safety, contd.Flashback ArrestorA device installed on all oxy-acetylene set up both at the side of the torch and regulator, that prevents the flame to travel through the hose and into the cylinder

Compressed Gas Cylinder Safety, contd.Know what is inside any cylinder you work with.You cant assume that the color of the cylinder will tell you what gas is inside.Cylinder colors are chosen by the owner of the cylinder.Each owner may have a different color coding system.There is no standard color coding used on cylinders.Proper labeling and color codingProper Storing of Compressed Gas Cylinder

Compressed Gas Cylinder Safety, contd.One thing to remember about working with Compressed Gas Cylinders is that with many gases a small leak can cause major problems.For example, with even a tiny leak in a cylinder full of compressed flammable gas, the intense pressure will force gas out of the cylinder continuously.As gas spreads, it can pass over ignition sources such as:Electrical equipmentSparks from operating machineryOpen flamesHeating elements

Compressed gas cylinders can be very sensitive to a number of conditions. So you always take care when storing cylindersSo you should always take special care when storing cylinders.Specific storage information can usually be found on cylinders label. You can also consult the MSDS Storage information labelsCompressed Gas Cylinder Safety, contd.

All compressed gas cylinders including empty ones shall be kept upright and chained at all times and properly capped when not in use.Proper Storing of Compressed Gas CylinderCompressed Gas Cylinder Safety, contd.

Compressed gas cylinder storage area shall be located in an open / well ventilated area, with sun protection.

Compressed Gas Cylinder Safety, contd.

Isolation barrier must be 5 ft. high min., made of non-combustible materials with at least hour fire rating Isolation barrierCompressed Gas Cylinder Safety, contd.

Why must acetylene and oxygen cylinders be stored separately?Acetylene is highly flammable (a fuel)Oxygen greatly supports combustionIf both leak, and they are stored together, mixing of two gases combined with external heat, can result in fire / explosion (fire triangle principle)20 ft.6.0 mMinimum distance w/o isolation barrierCompressed Gas Cylinder Safety, contd.AcetyleneOxygenOxygenAcetylene

Compressed Gas Cylinder Safety, contd.Under no circumstances, cylinders will be located or stored closer than 15 meters from source of heat or ignition such as open flame operation, generators, welding machines, compressors, ovens etc.

Compressed Gas Cylinder Safety, contd. FULLEMPTYAlways store cylinders: in racks; in the upright position; secured with steel chains or clamps; and with the cylinder valve fully closed.Because empty cylinders still contain a small amount of gas, the cylinder valve must still be closed.

Store full and empty cylinders separately according to gas type.

Compressed Gas Cylinder Safety, contd.Compressed gas cylinders shall be located where they cannot become part of an electrical circuitElectrical cord

Compressed Gas Cylinder Safety, contd.Electrode must not be struck against the cylinder to strike an arc.Electrical arc damage should be taken out immediately

Compressed Gas Cylinder Safety, contd.No compressed gas cylinders of any kind including their accessories shall be placed, stored, or left in a confined space including vessels, tanks, pipes, deep excavation etc. whether full or empty

Compressed Gas Cylinder Safety, contd.Lifting / hoisting of compressed gas cylinders shall be done only by means of approved material basket or cradle. Hoisting by slings is strictly NOT allowed.

Always transport Acetylene and LPG cylinders in the upright position.Always secure cylinders with steel clamps or chains to prevent excessive movement.Never transport cylinders in the cab of the vehicle.Never allow any part of a cylinder to overhang the vehicle. TRANSPORTING CYLINDERS IN A VEHICLECompressed Gas Cylinder Safety, contd.

Your hands should be free of grit, grease and oil when manually handling cylinders to prevent:

the cylinders from slipping; and grit or oil entering the cylinder valve.

Cylinders must be moved and staged in bottle carts with appropriate size wheels for the area.

MANUAL HANDLING OF CYLINDERSCompressed Gas Cylinder Safety, contd.

Cylinders are not protected from falling. Note that the Chain is not secured across.Chain Electrical cord draped over. Cylinders not securedCompressed Gas Cylinder Safety, contd.

Small cylinder not tied offCombustibles stored with cylindersBad housekeepingAcetylene and Oxygen stored too close and not secured

Cylinder should be in storage protected from damage and not laying on the ground regardless if it is full or emptyCompressed Gas Cylinder Safety, contd.Electrical arcdamage

Old, corroded cylinder that should have been disposed of a long time ago.Cylinder with no valve or cap installedLeft lying on the ground Compressed Gas Cylinder Safety

1. Cylinders laying on the ground and improperly stored2. Subject to damage from forklift operation in vicinityForklift1. Feed line exposed to damage/leak that could cause a fire/explosionCompressed Gas Cylinder Safety

1. Inadequate housekeeping2. Valve caps should be installed.Unsecured acetylene cylinder Exposed to damageCompressed Gas Cylinder Safety

Unsecured cylindersRegulator left pressurized after useCompressed Gas Cylinder Safety

Improper StorageNylon rope being use to secure the cylinderCompressed Gas Cylinder Safety

Improper storage of cylinders- acetylene and oxygen stored next to each otherEvidence of smoking next to acetylene cylindersCompressed Gas Cylinder Safety

This cylinder should be taken to storage and housekeeping should be improved.Cooking equipment within 20 ftOf the cylinderCompressed Gas Cylinder Safety

oxy-acetylene torch connectedTo the cylinder without the torch connected.Remove all connection when not in use and install cap to the cylinderCompressed Gas Cylinder Safety

What a pressurizedContainer can doWhen the right amountof heat is applied. Compressed Gas Cylinder Safety

An Ironworker crew was modifying a temporary structural steel bridge using an Oxygen/Acetylene torch setup on a cart, a portable welder, and a grinder. Apparently the Acetylene hose developed a leak and ignited during the grinding operation (Monday June 18, 2001)Compressed Gas Cylinder Safety

The torch setup was not equipped with a flashback arrestorcheck valve and the fire traveled through the hose into thecompressed cylinder. Compressed Gas Cylinder Safety

Compressed Gas Cylinder Safetyend