Compressed Gas Cylinder Safety Program

Purpose

The purpose of this safety policy and procedure is to establish guidelines for the protection and safety of ([COMPANY]) employees who handle and use compressed gases. Compressed gases are typically stored under pressure in metal cylinders. These cylinders are designed and constructed to withstand high pressures. Improper handling and use of compressed gases can result in devastating consequences.

This safety policy and procedure provides guidelines for the safe handling and use of compressed gases. It includes provisions for training and presents safe handling guidelines. It also presents the types, uses, inspection, and marking requirements of compressed gas cylinders. Additionally, this safety policy and procedure presents transportation and storage requirements for compressed gas cylinders.

Responsibilities

• Managers/Unit Heads - Managers/Unit Heads are responsible for ensuring that adequate funds are available and budgeted for the purchase of compressed gas cylinder equipment and related supplies. They will also be responsible for identifying the employees affected by this safety policy and ensure required training is accomplished.
• Supervisors - Supervisors will not allow any employee who has not received the required training to handle any compressed gas cylinders. Supervisors will also note defective cylinders and tag them for repair.
• Employees - Employees shall comply with all applicable guidelines contained in this safety policy and procedure. They shall report any defective or damaged cylinders to their supervisor.
• Safety Department - Safety Department provide prompt assistance to managers/unit heads, supervisors, or others as applicable on any matter concerning this safety policy and procedure. Safety will assist in developing the required training. Safety will also work with Purchasing to ensure that all newly purchased compressed gas cylinders equipment and supplies comply with current safety regulations and this safety policy and procedure.

Training

Employees who use and handle compressed gas cylinders will be trained before initial job assignment and/or job reassignment. Employees will be trained in the safe use, inspection, handling, and storage of compressed gas cylinders. Refresher training shall be provided at the discretion of the supervisor.

Safe Handling Guidelines

Serious accidents can result from the misuse, abuse, or mishandling of compressed gas cylinders. Employees assigned to the handling of cylinders under pressure should follow general safe handling guidelines.
Serious accidents can result from the misuse, abuse, or mishandling of compressed gas cylinders. Employees assigned to the handling of cylinders under pressure should follow general safe handling guidelines. Compressed gas cylinders are used for a variety of gases in [COMPANY].
These gas cylinders fall into the following categories:
• Flammable
• Toxic and Poison
• Liquid

Use - Compressed gas cylinders are used for variety of purposes in [COMPANY]. Compressed gas cylinders in [COMPANY] are commonly used in metal cutting operations. Cylinders should be handled carefully and only used for their designated purpose. See the Welding Safety Program for additional related information.

Inspection - Compressed gas cylinders should be visually inspected daily for leaks, cracks, etc. This visual inspection will include the cylinder, safety relief devices, valves, protection caps and stems. If a cylinder is thought to be defective, it should be returned to the supplier for replacement. Under no circumstances should employees attempt to repair defective cylinders. Gages should be checked to ensure that the gas under pressure is not left in hoses when operations are completed.

Marking - For the purpose of identifying the gas content, compressed gas cylinders shall be legibly marked with either the chemical or trade name of the gas. Such marking shall be by means of stenciling, stamping, or labeling, and shall not be readily removable. Whenever practical, the marking shall be on the shoulder of the cylinder for easy identification.

Transportation - Transporting gas cylinders requires careful consideration and appropriate precautions. These considerations and precautions include:
• Motor vehicle transport of cylinders
• Flammable gas and oxidizer cylinders transpor
• Hand truck (dolly) transport of cylinders
• Cylinder transport precautions

Motor vehicle transport of cylinders shall only be done with vehicles equipped with racks or other means of securing the cylinders. Cylinders containing liquefied hydrogen or toxic gases shall be transported in open body vehicles.

Flammable gas and oxidizer cylinders transport must not be done together nor with poisons or corrosives. However, oxygen and acetylene cylinder joint transport is allowed if:
• The cylinders are transported in the rear truck bed below the cab level
• A roll bar is installed over the rear truck bed to prevent the cylinders from falling out of the truck bed in the event of the vehicle overturning

Red label, yellow label, white label, green label, or poison label materials are not to be transported on the same load. Poison label materials are not to be transported with food or other items intended for human consumption.

Hand truck (dolly) transport of cylinders shall be used for the transfer of compressed gas cylinders from loading area to shop or laboratory or other within-building transfers.

Cylinder transport precautions include:

• Cylinders having the valve protection cover in place while being transported (inter- and intra-building transport)
• Cylinders not being rolled or lifted by the valve or valve cap for moving
• Cylinder valves being shut off and valve caps in place during transit from location to location
• Cylinders that are dropped during transit being taken out of service and returned to the supplier for inspection
• Cylinders being securely supported at all times during transport
• Smoking being prohibited during loading, unloading, and hand transportation of flammable gas cylinders

Storage - The storage of compressed gas cylinders requires some basic precautions and guidelines. These include:
• General cylinder storage precautions
• Specific gas cylinder storage guidelines
• Cylinder storage room guidelines

General cylinder storage precautions include:

• Cylinders being secured in an upright position in a safe, dry, well-ventilated place prepared and reserved for the purpose
• Cylinders not being kept in unventilated enclosures such as lockers
• Cylinders not being stored in the same area as flammable substances, such as oil and volatile liquids or near sources of heat, such as radiators or furnaces
• Cylinders not being stored near elevators, gangways, stairwells, or other places where they can easily be knocked down or damaged
• Cylinders being stored on a level fireproof floor
• Cylinders stored in the open being protected from contact with the ground and against extremes of weather
• Cylinder storage being planned so that cylinders are used in the order that they are received from the supplier
• Empty and full cylinders being stored separately, with empty cylinders being plainly identified as such to avoid confusion
• Empty cylinders being grouped together that have held the same contents

Specific gas cylinder storage guidelines includes additional precautions and guidelines for oxygen, hydrogen, and acetylene and liquefied fuel gas cylinders.

Oxygen cylinders should not be stored within 20 feet (6 meters) of highly combustible materials, oil, grease, wood shavings, or cylinders containing flammable gases. (However, for [COMPANY] operations, oxygen and acetylene are typically paired on a common transfer cart for use.) If closer than 20 feet, cylinders should be separated by a wall with a fire-resistance rating of at least 30 minutes.

Hydrogen cylinders storage locations shall be permanently placarded as follows: “HYDROGEN-FLAMMABLE GAS-NO SMOKING-NO OPEN FLAMES,” or equivalent.

Acetylene and liquefied fuel gas cylinders should be stored with the valve end up. If storage is within 100 feet (30.5 meters) of each other and not protected by automatic sprinklers, the total capacity of acetylene cylinders stored and used inside the building should be limited to 2,500 cubic feet. Acetylene storage areas must be well ventilated and open flames must be prohibited. Acetylene storage rooms should have no other compressed gases.

Cylinder storage room guidelines include:

• Storage rooms for cylinders containing flammable gases being well ventilated to prevent the accumulation of explosive concentrations of gas
• No ignition sources being permitted
• Smoking

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