This leaflet provides information on

the fire and explosion hazards in the

use of oxygen.

It is for anyone who uses oxygen

gas in cylinders.

HSE8(rev2)
TAKE CARE WITH OXYGEN
 TAKE CARE WITH OXYGEN

Hazards from oxygen

O xygen gas in cylinders is used by many people at work

and sometimes at home. It is used:

✴ in welding, flame cutting and other similar processes;

✴ for helping people with breathing difficulties;
✴ in hyperbaric chambers as a medical treatment;
✴ in decompression chambers for people who work in
compressed air or in deep-sea diving;

✴ for food preservation and packaging;

✴ in steelworks and chemical plants.

The air we breathe contains about 21% oxygen. Without

oxygen we would die in a matter of minutes. It may be hard
to believe, but oxygen can also be dangerous. The dangers
are fire and explosion.

Oxygen behaves differently to air, compressed air, nitrogen

and other inert gases. It is very reactive. Pure oxygen, at
high pressure, such as from a cylinder, can react violently
with common materials such as oil and grease. Other
materials may catch fire spontaneously. Nearly all materials
including textiles, rubber and even metals will burn vigorously
in oxygen.

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 TAKE CARE WITH OXYGEN

Even a small increase in the oxygen level in the air to 24%

can create a dangerous situation. It becomes easier to start
a fire, which will then burn hotter and more fiercely than in
normal air. It may be almost impossible to put the fire out. A
leaking valve or hose in a poorly ventilated room or confined
space can quickly increase the oxygen concentration to a
dangerous level.

The main causes of fires and explosions when using oxygen

are:

✴ oxygen enrichment from leaking equipment;

✴ use of materials not compatible with oxygen;
✴ use of oxygen in equipment not designed for oxygen
service;

✴ incorrect or careless operation of oxygen equipment.

Risk assessment

E mployers are legally required to assess the risks in the

workplace, and take all reasonably practicable
precautions to ensure the safety of workers and members of
the public.

A careful examination of the risks from using oxygen should

be included in the risk assessment.

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 TAKE CARE WITH OXYGEN

Beware of oxygen enrichment

O xygen enrichment is the term often used to describe

situations where the oxygen level is greater than in air.
Oxygen is colourless, odourless and tasteless. The presence
of an oxygen enriched atmosphere cannot be easily detected
by the human senses.

The main danger to people from an oxygen enriched

atmosphere is that clothing or hair can easily catch fire,
causing serious or even fatal burns. For example, people can
easily set their clothing and bedding on fire by smoking while
receiving oxygen treatment for breathing difficulties.

Smoking should be forbidden where oxygen is being used.

Oxygen enrichment is often the result of:

✴ leaks from damaged or poorly maintained hoses, pipes

and valves;

✴ leaks from poor connections;

✴ opening valves deliberately or accidentally;
✴ not closing valves properly after use;
✴ using an excess of oxygen in welding, flame cutting or
a similar process;

✴ poor ventilation where oxygen is being used.

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 TAKE CARE WITH OXYGEN

Consequently, the main ways to prevent oxygen enrichment

are to keep oxygen equipment in good condition and to take
care when using it. Good ventilation will also reduce the risk
of oxygen enrichment.

Oxygen enrichment can also result from the misuse of

oxygen. Never use oxygen for:

✴ cooling or refreshing the air in confined spaces;

✴ dusting benches, machinery or clothing.

If oxygen enrichment from an oxygen leak is suspected, the

oxygen supply should be turned off. Cigarettes and open
flames should be extinguished. The room should be well
ventilated and the source of the leak identified and repaired.
It is possible that oxygen may contaminate any clothing in
the area. If this is suspected, the clothing should preferably
be removed and taken outside for airing and ventilating.

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Confined spaces
Some of the most serious oxygen-related incidents have
involved damaged oxygen hoses leaking into confined spaces,
where welding and burning operations were taking place. The
workers’ oxygen enriched clothing caught fire, causing
serious or fatal injuries.

Gas cylinders should not be taken into confined spaces; the

gas can be fed in by using hoses. The hoses should be
removed from the confined space when work is finished or
suspended, such as at the end of each day. Where this is not
practicable, the hoses should be disconnected from the gas
supply at the cylinder or manifold.

Where the risk from oxygen enrichment is high, such as in a

confined space or a poorly ventilated room, the use of oxygen
monitoring equipment is advisable.

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 TAKE CARE WITH OXYGEN

Never use materials

incompatible with oxygen

S ome materials react explosively if they come into contact with

pure oxygen at high pressure. Other materials may catch fire
spontaneously. Such materials are incompatible with oxygen.

Equipment designed for oxygen service is made from materials and

components that have been tested and proved to be compatible, and are
safe for the purpose. The reasons for a particular design and choice of
material are not always obvious. Using substitute materials or
components, which appear to be similar but are not proven to be oxygen
compatible, is extremely dangerous and has caused many accidents.

You need to take care when replacing:

O-rings and gaskets

There are hundreds of different types of rubber and elastomer, and
most are not compatible with oxygen.

Metal components
Many metals and alloys are not suitable for use with oxygen.

Pressure regulators
You must ensure that the pressure rating of the regulator is not less
than the full cylinder supply pressure. Pressure regulators for gas
welding equipment should comply with BS EN ISO 2503 and for
medical gases with BS EN 738. Many existing regulators were made
to standards which have now been withdrawn such as BS 5741, BS
7650 and BS EN 585. These regulators may not be suitable for
pressures above 200 bar.
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 TAKE CARE WITH OXYGEN

If in doubt, check with the supplier or manufacturer.

Oxygen hoses
The flexible oxygen hose used for welding, etc, should comply
with BS EN 559 or BS EN 739.

Lubricants
As a rule, lubricants should be avoided. Only lubricants that
are made for oxygen service, and are specified by the
equipment supplier, should be used.

Tape
Tape should be avoided. Only tape that is marked as suitable
for oxygen service, and is specified by the equipment
supplier, should be used.

Other components
In some cases, the materials may appear to be compatible
but the shape and configuration of components may be
important in minimising the fire risk. Only components
approved by the manufacturer should be used when
maintaining oxygen equipment.

You should always ensure that high-pressure oxygen systems

are designed, constructed, installed and commissioned by
competent people who have specialised knowledge of the
subject. All oxygen apparatus and equipment must be
properly identified with the gas name and safe working
pressure.

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 TAKE CARE WITH OXYGEN

Never use oxygen in

equipment not designed for it

M any serious accidents have been caused by using

oxygen instead of other gases such as air, compressed
air or nitrogen. Oxygen can react explosively with oils and
greases. People have been injured or even killed when pumps,
engines, tyres and pressure equipment have been blown
apart by the explosion. Oxygen can also cause other
materials to ignite spontaneously. The resulting fire can
cause damage to equipment and injury to people.

You should never use oxygen for:

✴ driving pneumatic tools;

✴ inflating vehicle tyres;
✴ pressurising and purging systems;
✴ replacing air or inert gas;
✴ starting diesel engines.

Oxygen must not be introduced into any equipment unless it

has been designed for oxygen service by competent people
with specialist knowledge.

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 TAKE CARE WITH OXYGEN

Take care with

oxygen cylinders and equipment

I f oxygen cylinders and equipment are used carelessly or

incorrectly, then a fire may result. All users of oxygen
should know and understand the dangers, and should receive
training in the use of oxygen equipment.

There are a number of precautions to follow when using

oxygen equipment.

Oxygen cylinders
You should always:

✴ handle oxygen cylinders carefully. Use a purpose-built

trolley to move them;

✴ keep cylinders chained or clamped to prevent them from

falling over;

✴ store oxygen cylinders when not in use in a well-

ventilated storage area or compound, away from
combustible materials and separated from cylinders of
flammable gas.

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Oxygen equipment
You should always:

✴ open the valve slowly. Rapid opening, particularly of

cylinder valves, can result in momentarily high oxygen
velocities. Any particles will be pushed through the
system very quickly, causing frictional heat. Alternatively,
if the system has a dead end such as where a pressure
regulator is connected to an oxygen cylinder, heat can be
generated through compression of the oxygen. Both
cases can result in a fire;

✴ ensure that the pressure adjusting screw of the pressure

regulator is fully unwound, so that the regulator outlet
valve is closed before opening the oxygen cylinder valve,
particularly when opening the cylinder valve for the first
time after changing cylinders;

✴ ensure that cylinder valves are closed and piped supplies

isolated whenever work is stopped. Do not try to cut off
the supply of oxygen by nipping or kinking flexible hose
when changing equipment, eg blowpipes;

✴ maintain hoses and other equipment in good condition.

Leak tests can be carried out easily using a proprietary
spray or liquid solution that is certified for use on oxygen
systems. Soap or liquids that may contain grease should
not be used.

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 TAKE CARE WITH OXYGEN

Cleanliness
You should always:

✴ keep oxygen equipment clean. Contamination by

particulate matter, dust, sand, oils, greases or general
atmospheric debris is a potential fire hazard. Portable
equipment is particularly susceptible to contamination,
and precautions should be taken to keep it clean;

✴ use clean hands or gloves when assembling oxygen

equipment, eg attaching the pressure regulator, making
connections;

✴ wear suitable clean clothing, free from oil and easily

combustible contaminants.

General precautions
You should always:

✴ ensure that ventilation is adequate;

✴ check that fire extinguishers are in good condition and
ready for use;
✴ check that escape routes are clear.

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✔
Summary of advice

1 Be aware of the dangers of oxygen - if in doubt, ask. ✔

2 Prevent oxygen enrichment by ensuring that
equipment is leak-tight and in good working order. ✔
3 Check that ventilation is adequate. ✔
4 Always use oxygen cylinders and equipment carefully
and correctly. ✔
5 Always open oxygen cylinder valves slowly. ✔

✘
1 Do not smoke where oxygen is being used. ✘
2 Never use replacement parts which have not been
specifically approved for oxygen service. ✘
3 Never use oxygen equipment above the pressures
certified by the manufacturer. ✘
4 Never use oil or grease to lubricate oxygen
equipment. ✘
5 Never use oxygen in equipment which is not
designed for oxygen service. ✘

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 TAKE CARE WITH OXYGEN

References
Five steps to risk assessment INDG163 HSE Books 1998

BS EN ISO 2503: 1998 Gas welding equipment. Pressure

regulators for gas cylinders used in welding, cutting and allied
processes up to 300 bar

BS EN 738: 1997 Pressure regulators for use with medical gases

BS EN 559: 1994 Gas welding equipment. Rubber hoses for

welding, cutting and allied processes

BS EN 739: 1998 Low pressure hose assemblies for use with

medical gases

Safe work in confined spaces. Confined Spaces Regulations 1997.

Approved Code of Practice, regulations and guidance L101
HSE Books 1997 ISBN 0 7176 1405 0

The safe use of compressed gases in welding, flame cutting and

allied processes HSG139 HSE Books 1997 ISBN 0 7176 0680 5

Industrial gas cylinder manifolds and distribution

pipework/pipelines (excluding acetylene) 2nd edition Code of
practice CP4
British Compressed Gases Association 1998

The safe use of oxy-fuel gas equipment (individual portable or

mobile cylinder supply) 2nd edition Code of practice CP7 British
Compressed Gases Association 1996

Safe practice for the storage of gases in transportable cylinders

intended for industrial use 2nd edition Guidance note GN2
British Compressed Gases Association 1997

While every effort has been made to ensure the accuracy of the
references listed in this publication, their future availability cannot be
guaranteed.

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This leaflet contains notes on good practice which are not compulsory but which you may
find helpful in considering what you may need to do.

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Printed and published by the Health and Safety Executive HSE8(rev2) C150 4/00