S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.

in
 Editorial

Gases may become flammable and an explosive when compressed. It can quickly spread to a large area
in the event of a leak in the cylinder. The cylinder can itself become a rocket, if the cylinder valve is bro-
ken. Therefore, appropriate care in the handling of compressed gas cylinders is essential.

Potential hazards associated with the use of compressed gas include - rupturing ,explosion or fire. Gas
leak from the cylinder may lead to serious accidents.

The present document provides some useful guidelines on use, handling, storage and transportation of
compressed gas cylinders. The guidelines presented in this e- bulletin is expected to create awareness and
assist in decision-making while working with gas cylinders.

Editorial Team
Safety & Environment Department

S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.in
Introduction

Gases in their compressed state particularly compressed air are almost indispensable to modern life. They are used in in-
dustry for various applications such as manufacture of mineral waters, cooking, under water diving, in connection with
motor vehicles, medical purposes, etc. Compressed gases can get released suddenly in an uncontrolled manner . The dam-
aged cylinders can rocket or spin out of control causing significant injury and danger. A leak in a compressed gas cylinder
could displace air and cause people to suffocate. Gases especially, from a cylinder may be very cold and can cause frost-
bite, which can lead to serious permanent skin damage.

Therefore, familiarity with the chemical hazards of the gas is necessary. Most countries provide for a standard colour-
coding system whereby different coloured bands or labels are applied to the gas cylinders to indicate the type of hazard to
be expected, particularly toxic gases, such as hydrogen cyanide, are also given special markings. All compressed gas con-
tainers are so constructed that they are safe for the purpose for which they are intended when first put into service. How-
ever, serious accidents may result from their misuse, abuse or mishandling, and therefore greatest care should be exer-
cised in the handling of such cylinders or containers.

STATUTES IN INDIA
The following rules govern the handling of compressed gases in India.
(1) The Gas Cylinders Rules2004
(2) The Static and Mobile Pressure Vessels (unfired) Rules1981.
(3) Indian Standards.

The Gas Cylinders Rules

The scope of the Gas Cylinders Rules 2004 is to prescribe: (i) the requirement of a license for filling any cylinder with com-
pressed gas, or to possess a cylinder filled with compressed gas, (ii) the technical information to be furnished to the au-
thorities to enable them to issue the license, (iii) the validity period of license, and (iv) the conditions for renewal of license.
It also lists the safety features to be installed in the cylinder to be used, the safe practices to be adopted during filling,
transportation and use, etc.

The Static and Mobile Pressure Vessels (unfired ) Rules

The Static and Mobile Pressure Vessels (unfired) Rules 1981 prescribe: separate licences for storage and transportation of
compressed gases. It also list safety in the design, manufacture and location of pressure vessels, safety during filling and
during transportation, safety status of the vehicles transporting the vessels and certificate of safety etc.

Indian Standards
Bureau of Indian Standards has issued a number of standards pertaining to the design, transportation and handling of
compressed gases. The specifications of colour codes for industrial gas cylinders are dealt in IS4379. Specifications for
LPG are dealt in IS 4576. The test methods of LPG are dealt in IS 1448. The flameproof electrical fittings to be used in the
filling area is as per specification of IS 2148. The methods for Hydrostatic stress testing are dealt in IS 5844. Periodical in-
spection interval for gas cylinders in use are dealt in IS 8868. The colour specifications of selected industrial gas cylinders
(non-medical) as per IS-4379-1967.

Main Hazards Associated with Gas Cylinders

impact from the blast of a gas cylinder explosion or rapid release of compressed gas;

impact from parts of gas cylinders or valves that fail, or any flying debris;

contact with the released gas or fluid (such as chlorine);

fire resulting from the escape of flammable gases or fluids (such as liquefied petroleum gas);

impact from falling cylinders;

manual handling injuries;

S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.in
Use of Gas Cylinder Safely
Cylinder parts and markings
The main dangers in the use of compressed gases arise from their
pressure and from their toxic and/or flammable properties. The sali-
ent precautions are :-
To ensure that equipment is used only with those gases for which
it was designed, and that no compressed gases are used for any
purpose other than that for which their use has been authorized.
All hoses and other equipment should be of good quality and
should be examined frequently.
The use of non-return valves should be enforced wherever neces-
sary.
All hose connections should be in good condition and no joints
should be, made by forcing together threads that do not exactly
correspond.
In the case of acetylene and combustible gases, a red hose should
be used; for oxygen the hose should be black.
It is recommended that for all flammable gases, the connection-
screw thread shall be left-handed, and for all other gases, it shall
be right-handed.
Hoses should never be interchanged.
Oxygen and some anaesthetic gases are often transported in large
cylinders. The transfer of these compressed gases to small cylin-
ders is a hazardous operation, which should be done under com- Name Use
petent supervision, making use of the correct equipment in a cor- 1 Cylinder Protects the cylinder valve
rect installation. cap
2 Valve Used to open and close the cyl-
Compressed air is widely used in many branches of industry, and hand- inder valve.
care should be taken in the installation of pipelines and their pro- wheel
tection from damage. Hoses and fittings should be maintained in 3 The valve Contains a packing gland and
good condition and subjected to regular examinations. packing packing around the stem. It
nut should not be tampered with
Precautions should also be taken against all forms of irresponsi- when used in conjunction with
ble behaviour, which could result in a compressed air jet coming diaphragm-type valves.
in contact with any opening in the body the result of which can be 4 Pressure Permits gas to escape if in-
relief de- creased unsafe pressures are
fatal. A further hazard exists when compressed air jets are used
vice attained.
to clean machined components or workplaces: flying particles 5 Valve Various types of connections
have been known to cause injury or blindness, and precautions outlet are provided to prevent inter-
against such dangers should be enforced. connec- change of equipment for in-
tion compatible gases, usually
identified by CGA (Compressed
Gas Association) number; for
example, CGA No. 350 is used
for hydrogen service
6 Cylinder holds the cylinder cap at all
collar times, except when regulating
equipment is attached to the
cylinder valve
7 Valve Protects valve threads from
outlet damage and keeps the outlet
cap clean; it is not used universal-
ly.
8 Specifi- Signifies that the cylinder con-
cation forms to the specifications
number
9 Cylinder -
serial
number
10 Date initial hydrostatic testing

11 DOT -
specifica-
tions

S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.in
Safe Handling of Gas Cylinder
Incorrect handling of heavy, awkward cylinders can cause personal injury; particularly to the back, neck or arms. The
risks involved in moving cylinders will differ depending on the nature of the cellar.
Large cylinders should only be stored in underground cellars where there is suitable access and lifting equipment to
move or handle them safely.
Ensure that the current Material Safety Data Sheet (MSDS) is available and well understood.
Trolleys or other suitable devices should always be used to transport cylinders, even for short distances.
Ensure that the appropriate personal protective equipment (PPE) is worn e.g. stout gloves, protective footwear, safety
glasses.
Be aware of manual handling issues when moving cylinder e.g. trapping fingers between cylinders, use of correct lifting
posture.
Ensure that emergency management equipment is serviceable, regularly tested and maintained e.g. fire extinguishers,
breathing apparatus, absorption material.
All equipment should be compatible with the gas being used.
Equipment used when handling flammable gases must be earthed, flameproof, and free from ignition sources.
Keep supplied valve protection caps in place when the cylinder is not being filled or not connected for use.
Keep cylinder valve securely closed when not in use (unless connected to a device by permanent piping).
Precautions should be taken to prevent backflow of contaminants into the cylinder.
Do not use a cylinder that has become contaminated.
Use cylinders on a first-in-first-out (FIFO) basis.
Protect cylinders from any source of direct heat.
Carrying a cylinder close to the body reduces the stress on the back.

Manual handling is also involved in the movement of casks, kegs, crates, cases and other materials. It should be en-
sured that staff moving such objects are trained to:
1.use correct techniques for lifting heavy objects
2.consider the weight and balance of loads
3.reduce the size or weight of the load wherever possible for easier and safer handling

REMEMBER

ALWAYS use protective gloves and footwear when
handling cylinders
ALWAYS use suitable equipment such as a trolley or
mechanical lift for moving large cylinders
ALWAYS carry cylinders close to the body
ALWAYS secure cellar flaps during delivery of cylin-
NEVER lift a cylinder over 25kg in weight by yourself; this
can cause muscle strain or back injury.
NEVER lift cylinders above chest height
NEVER reach for and lift cylinders from behind stacks of
crates or kegs; this can cause strain or injury

S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.in
Storing Gas Cylinder Safely

In the cellar
The cellar, where cylinders are stored, handled or connected, should be checked periodically to make sure it is a safe
working environment.
Here are some of the safety precautions which should be observed to avoid risks to people working in the cellar:

Storing unused cylinders

ALWAYS store and secure the cylinder in an up- NEVER store cylinders where they may come into contact
right position with water

ALWAYS return all empties to the gas supplier you NEVER store next to a direct heat source; e.g. radiators, cool-
purchased them from ers etc.

ALWAYS store full cylinders in an area away from NEVER stack objects in front of cylinders. Reaching over ob-
cylinders in use jects to lift cylinders can cause back injury

Storing cylinders which are in use

ALWAYS secure cylinders in an upright position NEVER touch a frosted cylinder. Frosting usually indicates a
with a chain rapid release of gas

ALWAYS connect to a primary regulator valve, ei- NEVER try to unscrew the valve fittings on the cylinder
ther directly or through a high pressure hose

ALWAYS keep away from sources of heat

ALWAYS check the cylinder label before using it.

Ensure that the correct gas mixture is connected
to the line

Storage Requirements
All gas cylinders:

Shall not be stored in exits or egress routes.

Shall be stored within a well-ventilated area.
Shall not be stored in damp areas, near salt or corrosive chemicals, fumes, heat or where exposed to the weather.
Shall be stored in an upright position.
Shall be secured with a chain or appropriate belt above the midpoint, but below the shoulder. Laboratory cylinders less
than 18" tall may be secured by approved stands or wall brackets.
Shall be capped when not in use or attached to a system (if the cylinder will accept a cap).
Shall be kept at least 20 ft. away from all flammable, combustible or incompatible substances. Storage areas that have
a noncombustible wall at least 5 ft. in height and with a fire resistance rating of at least 30 minutes may be used to
segregate gases of different hazard classes in close proximity to each other.
Shall be stored so that cylinders are used in the order in which they are received.
Shall be stored so that gases with the same hazard class are stored in the same area. Inert gases are compatible with
all other gases and may be stored together.
Shall not be stored longer than one year without use.
Shall be stored so that full cylinders remain separate from empty cylinders.

S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.in
Transporting Gas Cylinder Safely
The recommended method to transport gas cylinders is by a professional gas transport company. Occasionally, there
might be a need to use other transport systems and it is then essential to follow safety instructions for full and empty cyl-
inders:

Secure all cylinders against moving during transport. Also consider the forces in a traffic accident.

Limit the number of cylinders to be transported.

Use open vehicles or trailers in preference to any enclosed vehicles or trailers. Do not cover with a tarpaulin.

Ensure that the contents label on the cylinder can be clearly read.

Never drop cylinders or subject them to shock. This is an extremely hazardous practice which may result in serious in-
jury.

Where possible, use mechanical lifting devices and trolleys to move cylinders.

Wear safety shoes or boots, safety glasses or goggles, and leather protective gloves when handling cylinders.

When handling oxidising or flammable gases, do not smoke or use a mobile phone.

Carry a fire extinguisher suitable for vehicle fires.

Before loading a cylinder into an enclosed vehicle:

Tighten (do not over-tighten) the cylinder valve and check that it is properly closed.

Use the valve outlet sealing nut when available.

Carefully check for gas leakage, (using approved leak detection fluid see your gas supplier).

Never transport a cylinder if a leak has been detected during loading.

Never transport cylinders with regulators or other equipment attached.

Do not remove any valve protection device (if fitted) during transport.

Conclusion

In addition to the knowledge of gas cylinder safety practices in the interest of personnel safety one must always famil-
iarize himself with the risks & hazards associated with the gas contained in the cylinder.

Most of the gases are invisible and their presence is not readily identifiable. They have the potential to asphyxiate,
burn or harm users. Therefore, copies of Material Safety Data Sheets (MSDSs) for each of the gases stored and used
must be collated and kept in a convenient location for quick reference in relation to: Storage, Handling, Transport is-
sues, Personal Protective Equipment, Incident response.

It is essential to handle the gases and gas cylinders with due safety precaution it demands failing which serious acci-
dents may occur leading to catastrophic situations.

S & E Department, Oil India Limited, Duliajan - 786602, Email id: safety@oilindia.in