BEST PRACTICE GUIDE: HANDLING OF COMPRESSED

GAS CYLINDERS
Summary
This guide provides advice for the safe handling of compressed gas cylinders in a
laboratory environment. It summarizes the hazards presented when handling compressed
gas cylinders and the steps that should be taken to prevent injury to personnel during the
handling process from receipt at the loading dock through to preparing the depleted gas
cylinders for pick-up by the supplier after use. It includes recommendations for the safe
storage, transport and discharge of compressed gas cylinders.
Much of the information in the guide is based on documents published by the
Compressed Gas Association and suppliers of compressed gas products but also includes
experience gained from 25 years of safe operating experience in a laboratory
environment.
Table of Contents

Summary

Table of Contents

1. Introduction

2. Objectives and Scope

3. Compressed Gas Cylinder Handling Guidelines

3.1 Receiving
3.2 Transport
3.3 Securing
3.4 Storage
3.5 Discharging
3.6 Returning
1.0 Introduction
Compressed gas cylinders provide a convenient container for the handling of a wide
variety of compressed and liquefied gases. The size, shape and weight of compressed gas
cylinders varies widely but they are commonly found in the laboratory environment as
heavy-walled steel cylindrical vessels weighing in excess of 50 kg. They are heavy and
awkward to handle and can fall or be knocked over very easily with great potential for
serious injury and damage.
Some gas cylinders contain pressurized gas in excess of 17 MPa which creates a large
amount of potential energy stored in a relatively small volume. The cylinder may rupture
and explode from a fall sending metal shrapnel blasting through the area. In addition, a
fall may result in catastrophic failure of the cylinder valve causing the cylinder to become
a missile-like projectile with enough energy to penetrate cinder block walls.
The fluids contained within a compressed gas cylinder may be inert, flammable, toxic or
corrosive. An uncontrolled release of the contents of a cylinder can create an immediate
hazard to personnel in the form of asphyxiation, fire, explosion, poisoning or chemical
burns. Gases cannot be visually detected and many have no detectable odour. Cryogenic
liquids, also supplied in compressed gas cylinders, can rapidly freeze exposed human
tissue on contact. Compressed gas cylinders therefore present a unique combination of
physical, mechanical and chemical hazards.

2.0 Objectives and Scope

This document has been prepared to prevent injury to personnel responsible for handling
compressed gas cylinders by providing a summary of the necessary precautions to
eliminate the hazards associated with the handling, storage, use and disposal of
compressed gas cylinders. The scope of this document covers the period of time from
receipt of the fully charged compressed gas cylinder at the shipping/receiving loading
dock until it is depleted and prepared for pick-up by the supplier.

3.0 Compressed Gas Cylinder Handling Guidelines

These guidelines apply to all employees who store, use or otherwise handle compressed
or liquefied gas cylinders. Personnel handling compressed gas cylinders should be
properly trained in the handling of compressed and liquefied gases. Training should
include the associated hazards of the products, necessary safety precautions, personal
protective equipment and emergency response procedures. Material Safety Data Sheets
(MSDS) for the compressed gas cylinder products should be made accessible to
compressed gas users. Supplier compressed gas cylinders should not be used for any
other purpose than holding the product contents as received. They should not be used in
the laboratory for mixing gases.
CSA approved footwear is recommended for all personnel transporting compressed gas
cylinders weighing greater than 10 kg. Eye protection (safety glasses, goggles or face
shield) is recommended for personnel involved in the dispensing of compressed or
liquefied gases.
3.1 Receiving
Compressed gas cylinders delivered to the shipping/receiving loading dock should be
inspected before being accepted to ensure they have a content identification label and a
valve protection device (cap, ring or collar). Colour coding is not a reliable means of
identification as cylinder codes vary with the supplier. Content identification labels on
cylinder caps is not acceptable practice. If the labelling on the gas cylinder is unclear or
defaced so the contents cannot be identified, the cylinder should be rejected. Leaking
cylinders (odours, hissing, fuming), corroded cylinders and those in otherwise poor
physical condition should also be rejected.

3.2 Transport
Compressed gas cylinders should be transported with the valve protection device in place
and without a regulator (or any other dispensing equipment) connected to the cylinder
valve. A specially designed cylinder cart with securing chains (or straps) should be used
for the transport of compressed gas cylinders within the laboratory facility. The cylinders
can be moved a short distance (1 m) to the cart by rolling on their bottoms in a near
vertical position. Do not use the cylinder valve cover cap (if so equipped) to twist or spin
the cylinder while rolling in order to prevent inadvertent opening of the cylinder valve.
Ensure gas cylinders are not dropped, banged again each other or against hard surfaces
when being transported. They should not be dragged, physically carried or rolled on their
side
Special precautions should be taken to ensure compressed gas cylinders are not dropped
when being lifted. They should be lifted using only platforms, cradles or nets specially
designed for this purpose. They should not be lifted by the cap (or other valve protection
devices) or by using ropes, slings, chains or magnets. .

3.3 Securing
Compressed gas cylinders, whether empty or full, should be properly secured at all times
to prevent them from tipping and falling over. They should be secured in an upright
position with chains (or straps) firmly connected to a wall bracket or other fixed surface.
The chains should be located above the midpoint but below the shoulder of the cylinder.
A chain should not be used by itself to secure multiple cylinders.

3.4 Storage
The specific details regarding compressed gas cylinder storage are regulated by local
authorities who should be consulted to obtain information regarding requirements for
acceptable storage locations, gas storage amounts and segregation of compressed gas
hazard classes. The following information summarizes generally accepted practice for the
safe storage of compressed gas cylinders.
Compressed gas cylinders should be stored in an area away from personnel exit and
egress routes. They should not be stored where they will be exposed to weather,
dampness, corrosive chemicals or where they will be exposed to potential sources of
physical damage such as falling objects. The storage area should be between -29°C and
+52°C and be dry, well ventilated and away from direct sunlight, sources of ignition,
electrical circuits and direct sources of heat. Compressed gas cylinders should be stored
in a vertical position with a valve protection device installed (cap, ring or collar) and be
properly secured.
The contents of the cylinder should be identified with a label and cylinders of different
classes separated from each other in properly identified areas. Hazardous gases should be
stored in a separately ventilated areas approved for the hazard class. Oxidizing gases such
as oxygen and nitrous oxide should not be stored together with flammable gases such as
hydrogen and acetylene. Compressed gas cylinders in storage should be rotated when
new stock is received so that they will be used in the order received. Empty gas cylinders
should be stored separately from full cylinders.

3.4 Discharging
Compressed gas cylinders should be firmly secured at the point of use. If the cylinder is
fitted with a cylinder cap type of valve protection device, a cylinder cap hook can be used
to remove the cap, however, excessive force should not be used in an attempt to remove
rusted or otherwise overly tight caps. The cylinder should instead be returned to the
supplier. Ensure the cylinder valve is tightly closed and remove any cylinder valve outlet
plugs if so equipped. Inspect the condition of the cylinder valve and check the sealing
surface of the CGA connection for cleanliness. Do not attempt to clean the CGA
connection by partially opening the valve.
Select a regulator having materials compatible with the gas cylinder contents and having
the correct CGA connection. Inspect the condition of the regulator for physical damage
and cleanliness prior to installation. The inlet pressure rating of the regulator should be
checked to ensure it is capable of handling the full delivery pressure of the gas cylinder.
Connect the regulator inlet fitting directly to cylinder valve and securely tighten the CGA
gland using a 30 cm or longer wrench to minimize ergonomic strain. If the regulator
orientation needs to be adjusted, always loosen the gland first before adjusting the
regulator position to prevent inadvertent loosening of the CGA fitting on the regulator
body. CGA glands having a left-hand thread are identified with a "V" shaped notch cut
into the corners of the gland hex geometry. Adjustable wrenches are not recommended
for the tightening of CGA glands. Teflon tape, oil or grease should not be used on the
threads or sealing surfaces of any CGA fitting. Fitting adapters should not be used
between the cylinder valve CGA connection and the regulator to prevent the inadvertent
use of the incorrect gases.
Compressed gas cylinders containing hazardous gases should only be used in well
ventilated areas and in conjunction with the proper additional PPE such as self-contained
or supplied-air breathing apparatus and hazardous gas detection devices. For hazardous
gas applications, a regulator with a captured bonnet vent should be used to allow for
controlled venting away from personnel in the event of diaphragm failure. Pressure relief
devices installed on regulators handling hazardous gases should also have controlled
venting away from personnel. Inert gas regulators used in confined spaces should have
captured bonnet vents and pressure relief devices to prevent asphyxiation in the event of
regulator failure. A ground strap should be used on flammable gas cylinders isolated from
ground to minimize the risk of ignition from a static spark discharge in the event of a gas
leak.
Before opening the gas cylinder valve, ensure the regulator is closed by turning the
pressure adjusting knob fully counter-clockwise and closing the regulator outlet valve.
Wearing the appropriate eye PPE, stand to one side away from the regulator gauge faces
and slowly open the gas cylinder valve. If the valve is too tightly closed to open by hand,
a valve handle wrench can be used. If the valve cannot be opened using a valve handle
wrench, the cylinder should be returned to the supplier. Force in excess of that which can
be applied using a valve handle wrench should not be used.
Leak check the regulator by applying liquid leak detector solution to the high pressure
inlet port fittings. With the regulator outlet valve still closed, dial in the desired delivery
pressure on the regulator and leak check the low pressure ports and fittings on the
regulator. Do not attempt to re-tighten leaking fittings while still under pressure. If leaks
are found, close the cylinder valve and vent the system before correcting the problem. If
the regulator is found to be leaking, it should be returned to the manufacturer for repair.
The gas cylinder valve should be returned to the closed position when not in use.
Regulators and other equipment used for handling oxidizing gases such as oxygen and
nitrous oxide must be specially cleaned to ensure that it is free of oil and other organic
materials to prevent catastrophic combustion from adiabatic compression in the event of a
rapid pressure build-up. Equipment handling compressed air at pressures in excess of 14
MPa must also be specially cleaned in the same fashion.
The pressure relief devices installed in compressed or liquefied gas cylinders are
designed to prevent the catastrophic rupture of the cylinder in the event of inadvertent
over pressurization and should not be tampered with by the user. Cylinders containing
cryogenic liquids such as liquid nitrogen have a pressure relief valve which is set to allow
for periodic venting as the cryogenic liquids warm to prevent over pressurization. If these
valves are blocked, adjusted or otherwise tampered with, the resulting pressure build-up
may cause the cylinder to rupture. In addition, cryogenic liquids should not be used in
confined spaces due to the risk of asphyxiation from the large volumes of gas released as
the liquids evaporate.

3.5 Returning
When the gas cylinder is depleted, close the cylinder valve and vent the downstream
system manifold before removing the regulator from the cylinder. If the gas cylinder
contains a hazardous gas, the manifold should be designed to allow for purging with an
inert gas such as nitrogen before removing the regulator from the cylinder. The weight of
the regulator should be properly supported after removal to prevent undue strain on fitting
connections and should not be left hanging from a flexible delivery hose.
Install the cylinder valve plug and valve protection cap (if applicable) before transporting
the cylinder to shipping/receiving storage. The depleted cylinder should be stored in the
area designated for empty cylinders. Tagging of the cylinder to indicate that it is empty is
good practice to avoid potential confusion with full cylinders. The inadvertent connection
of an empty cylinder to a pressurized system could cause the reverse flow of
incompatible fluids into the cylinder.
 REFERENCES

Compressed Gas Association, Inc., Pamphlet P-1: Safe Handling of Compressed Gases,
1991

Braker, William and Mossman, Allen L., "Matheson Gas Data Book", The Safe Handling
of Compressed Gases in Laboratory and Plant, 1980.