35.

CYLINDERS AND COMPRESSED GASES

CYLINDERS AND COMPRESSED GASES

35.1 INTRODUCTION

This chapter contains guidelines and requirements for the safe use
of flammable and/or compressed gases. It covers the use of
flammable-gas piping systems, high-pressure gas cylinders,
manifolds and compressed air.

35.2 FIRE RISK

Fire requires three elements: fuel, oxygen, and ignition.

Non routine operation that places a flammable gas in the presence
of an oxidant (air, oxygen, etc.) and an ignition source (spark,
flame, high temperature, etc.) is extremely dangerous. To reduce
the risk of fire, eliminate two of these three elements when
possible.

Thus, when not using flammable gases for there intended use:
 Eliminate ignition sources.
 Prevent mixing of fuel with air or oxygen.
 Contain or isolate fuel.
35.3 Transporting, moving and storing

1915.55(a)

Transporting, moving and storing compressed gas cylinders.

1915.55(a)(1)

Valve protection caps shall be in place and secure. Oil shall not be used to lubricate protection caps.

1915.55(a)(2)

When cylinders are hoisted, they shall be secured on a cradle, sling board or pallet. They shall not be
hoisted by means of magnets or choker slings.

1915.55(a)(3)

Cylinders shall be moved by tilting and rolling them on their bottom edges. They shall not be
intentionally dropped, struck, or permitted to strike each other violently.

1915.55(a)(4)

When cylinders are transported by vehicle, they shall be secured in position.

1915.55(a)(5)

Valve protection caps shall not be used for lifting cylinders from one vertical position to another. Bars
shall not be used under valves or valve protection caps to pry cylinders loose when frozen. Warm, not
boiling, water may be used to thaw cylinder caps loose.

1915.55(a)(6)

Unless cylinders are firmly secured on a special carrier intended for this purpose, regulators shall be
removed and valve protection caps put in place before cylinders are moved.

1915.55(a)(7)

A suitable cylinder truck, chain, or other steadying device shall be used to keep cylinders from being
knocked over while in use.

1915.55(a)(8)
When work is finished, when cylinders are empty or when cylinders are moved at
any time, the cylinder valves shall be closed and capped.

1915.55(a)(9)

Acetylene cylinders shall be secured in an upright position at all times except, if

necessary, for short periods 1915.55(b)

35.4 Placing Cylinders

1915.55(b)(1)

Cylinders shall be kept far enough away from the actual welding or cutting operation so that sparks,
hot slag or flame will not reach them. When this is impractical, fire resistant shields shall be provided.

1915.55(b)(2)

Cylinders shall be placed where they cannot become part of an electrical circuit. Electrodes shall not
be struck against a cylinder to strike an arc.

1915.55(b)(3)

Fuel gas cylinders shall be placed with valve end up whenever they are in use. They shall not be
placed in a location where they would be subject to open flame, hot metal, or other sources of
artificial heat.

..1915.55(b)(4)

1915.55(b)(4)

Cylinders containing oxygen or acetylene or other fuel gas shall not be taken into confined spaces.

35.5 Treatment of cylinders.

1915.55(c)(1)

Cylinders, whether full or empty, shall not be used as rollers or supports.

1915.55(c)(2)

No person other than the gas supplier shall attempt to mix gases in a cylinder. No one except the
owner of the cylinder or person authorized by him shall refill a cylinder. No one shall use a cylinder's
contents for purposes other than those intended by the supplier. Only cylinders bearing Interstate
Commerce Commission identification and inspection markings shall be used.

1915.55(c)(3)

No damaged or defective cylinder shall be used.

1915.55(d)

Use of fuel gas. The employer shall thoroughly instruct employees in the safe use of fuel gas, as
follows:

1915.55(d)(1)

Before connecting a regulator to a cylinder valve, the valve shall be opened slightly and closed
immediately. (This action is generally termed "cracking" and is intended to clear the valve of dust or
dirt that might otherwise enter the regulator.) The person cracking the valve shall stand to one side of
the outlet, not in front of it. The valve of a fuel gas cylinder shall not be cracked where the gas would
reach welding work, sparks, flame or other possible sources of ignition.

..1915.55(d)(2)

1915.55(d)(2)

The cylinder valve shall always be opened slowly to prevent damage to the regulator. To permit quick
closing, valves on fuel gas cylinders shall not be opened more than 1 1/2 turns. When a special
wrench is required, it shall be left in position on the stem of the valve while the cylinder is in use so
that the fuel gas flow can be shut off quickly in case of an emergency. In the case of manifold or
coupled cylinders, at least one such wrench shall always be available for immediate use. Nothing shall
be placed on top of a fuel gas cylinder, when in use, which may damage the safety device or interfere
with the quick closing of the valve.

1915.55(d)(3)

Fuel gas shall not be used from cylinders through torches or other devices which are equipped with
shut-off valves without reducing the pressure through a suitable regulator attached to the cylinder
valve or manifold.

1915.55(d)(4)

Before a regulator is removed from a cylinder valve, the cylinder valve shall always be closed and the
gas released from the regulator.

1915.55(d)(5)

If, when the valve on a fuel gas cylinder is opened, there is found to be a leak around the valve stem,
the valve shall be closed and the gland nut tightened. If this action does not stop the leak, the use of
the cylinder shall be discontinued, and it shall be properly tagged and removed from the vessel. In the
event that fuel gas should leak from the cylinder valve rather than from the valve stem and the gas
cannot be shut off, the cylinder shall be properly tagged and removed from the vessel. If a regulator
attached to a cylinder valve will effectively stop a leak through the valve seat, the cylinder need not be
removed from the vessel.

1915.55(d)(6)
If a leak should develop at a fuse plug or other safety device, the cylinder shall be removed from the
vessel or shop.

35.6 Fuel gas and oxygen manifolds.

1915.55(e)(1)

Fuel gas and oxygen manifolds shall bear the name of the substance they contain in letters at least
one (1) inch high which shall be either painted on the manifold or on a sign permanently attached to
it.

1915.55(e)(2)

Fuel gas and oxygen manifolds shall be placed in safe and accessible locations in the open air. They
shall not be located within enclosed spaces.

1915.55(e)(3)

Manifold hose connections, including both ends of the supply hose that lead to the manifold, shall be
such that the hose cannot be interchanged between fuel gas and oxygen manifolds and supply header
connections. Adapters shall not be used to permit the interchange of hose. Hose connections shall be
kept free of grease and oil.

1915.55(e)(4)

When not in use, manifold and header hose connections shall be capped.

1915.55(e)(5)

Nothing shall be placed on top of a manifold, when in use, which will damage the manifold or interfere
with the quick closing of the valves.

35.7 Hoses

1915.55(f)(1)

Fuel gas hose and oxygen hose shall be easily distinguishable from each other. The contrast may be
made by different colors or by surface characteristics readily distinguishable by the sense of touch.
Oxygen and fuel gas hoses shall not be interchangeable. A single hose having more than one gas
passage, a wall failure of which would permit the flow of one gas into the other gas passage, shall not
be used.

1915.55(f)(2)

When parallel sections of oxygen and fuel gas hose are taped together not more than 4 inches out of
8 inches shall be covered by tape.

1915.55(f)(3)
All hose and connections carrying acetylene, oxygen, natural or manufactured fuel gas, or any gas or
substance which may ignite or enter into combustion or be in any way harmful to employees, shall be
inspected at the beginning of each shift. Defective hose shall be removed from service.

1915.55(f)(4)

Hose which has been subjected to flashback or which shows evidence of severe wear or damage shall
be tested to twice the normal pressure to which it is subject, but in no case less than two hundred
(200) psi. Defective hose or hose in doubtful condition shall not be used.

1915.55(f)(5)

Hose couplings shall be of the type that cannot be unlocked or disconnected by means of a straight
pull without rotary motion.

1915.55(f)(6)

Boxes used for the stowage of gas hose shall be ventilated.

35.8 Types of compressed gases used at Colonna’s

Flammables: Propylene, Acetylene, Natural Gas and Propane

Inert: Nitrogen, Argon (blends also), Carbon Dioxide (blends also) and Helium.
Oxidizers: Oxygen
Compressed Air
(Refer to Safety data sheets for information on gases listed above)

35.9 Training

Compressed gas handling, use and storage training is the

responsibility of the Structural shop supervisor as well as additional
training from the safety department weekly subjects. Gas cylinders
will only be accepted by approved vendors. Any questions about
the proper handling of a compressed gas cylinder or its contents,
consult your supervisor or the Safety department.

Compressed gas cylinders are dangerous when handled

incorrectly. Always assume that a cylinder is pressurized. Handle
it carefully. Never throw, bang, tilt, drag, slide, roll, or drop a
cylinder from a truck bed or other raised surface. If a cylinder must
be lifted manually, at least two people must do the lifting. Because
of their shape, smooth surface, and weight, gas cylinders are
difficult to move by hand. A truck or an approved cylinder handcart
must always be used to move a cylinder. Cylinders must be
fastened in metal cradles or skid boxes before they are raised
with cranes, forklifts, or hoists. Rope or chain lifting slings
alone must not be used.

Inspect cylinders for damaged before use. If the cylinder has deep
gouges, sever rusting, bent metal, pits, damaged mounting threads,
a regulator will not seat properly, cylinder valve does not operate
properly or any other signs of damage, notify your supervisor tag
and isolate cylinder so it may be sent back to the supplier. If a
cylinder is found leaking you need to notify a supervisor or
manager, identify what the product is and asses if can it be
approached safely to try to close the valve or isolate the cylinder.
Refer to the safety data sheet for the product leaking. Contact the
supplier of the gas cylinders for assistance. Keep people away from
the area. A cylinder can cause severe injuries, including lung
damage from inhalation of toxic contents and physical trauma from
explosion. A pressurized gas cylinder can become a dangerous
projectile if its valve is broken off or the cylinder is punctured.

When a cylinder is not connected to a pressure regulator or a

manifold, or is otherwise not in use, it is extremely important that
the cylinder valve be kept closed and the safety cap be kept in
place. The cap protects the cylinder valve (do not lift cylinders by
their caps).
 Cylinders containing compressed gases should not be subjected to
a temperature above 125O F. Flames, sparks, molten metal, slag or
direct sunlight. All gas cylinders are to be stored in their designated
storage areas. Empty cylinders must be marked as “MT” and stored
on the south side of shipping and receiving. Full cylinders are
stored in the Steel America steel yard. Oxygen cylinders may only
be stored with inert gas cylinders. No flammable gases may be
stored in the same location with oxygen cylinders unless separated
a minimum of twenty feet apart. (Storage sheds are labeled
flammable and the other shed oxygen/inert gases). All gas
cylinders must be capped, secured in an upright position when not
being used. When gas cylinders are stored inside a building they
shall be placed so not to block walkways or exits. They must be
secured in an upright position and capped when not in use. The
building must be well ventilated and separation of oxidizers and
flammables must be maintained at twenty feet when not in use. Do
not place cylinders where they might become part of an electric
circuit. Do not store cylinders where they are at risk of being
damaged. When cylinders are used in conjunction with electric
welding, ensure that the cylinders cannot be accidentally grounded
and burned by the electric welding arc.

Never attempt to repair, alter, or tamper with cylinders, valves, or

safety relief devices. Only transport capped cylinders with the
proper hand truck with the bottle securely fastened in a vertical
position or in an approved bottle rack.

Compressed gas safety training is conducted and completed at

OSHA 10 hour training and annually for employees.

35.10 Safety Rules

1. All portable cylinders used for the storage and shipment of
compressed gases shall be constructed and maintained in
accordance with DOT regulations.

2. Compressed gas cylinders shall be equipped with

connections complying with ANSI B57.1-1965. "Compressed
Gas Cylinder Valve Outlet and Inlet Connections".

3. All cylinders with a water weight capacity of over 30 pounds

shall be equipped with means of connecting a valve
protection device or with a collar or recess to protect the
valve.

4. Compressed gas cylinders shall be legibly marked, for the

purpose of identifying the gas content, with either the
chemical or the trade name of the gas. Such markings shall
be by means of stenciling, stamping, or labeling, and are not
readily removable. Whenever practical, the markings will be
located on the shoulder of the cylinder.

5. Compressed air not to exceed 30 psi or other compressed

gases will not be used to blow dirt, chips, or dust from
clothing or machinery.

6. Compressed air or gases shall not be used to empty

containers of liquids.

7. The use of compressed air will be so controlled, and proper

personal protective equipment or safeguards utilized, as to
 protect against the possibility of eye or body injury to the
operator or other workers.

8. Abrasive blast cleaning nozzles shall be equipped with an

operating valve that must be held open manually. A support
will be provided on which the nozzle may be mounted when
it is not in use.

9. Compressed gases shall not be used to elevate or otherwise

transfer any hazardous substance from one container to
another

10. Always identify the contents of a gas cylinder before using it.
If a cylinder is not clearly labeled, return it to the vendor.

11. Before using a cylinder, be sure it is properly supported with

a metal chain or the equivalent to prevent it from falling.
Contamination of compressed gas cylinders by feedback of
process materials must always be prevented by installation
of suitable traps or check valves.

12. When a cylinder cap cannot be removed by hand, cylinder

shall be tagged "Do Not Use" and returned to the designated
storage area for return to vendor.

13. Suitable pressure-regulating devices and relief devices must

always be used when gas is admitted to systems having
pressure limitations lower than the cylinder pressure.

14. Gas cylinder valves can be "cracked” (opened slightly)

momentarily before regulators are attached to blow dirt off
 the valve seats, but the valve outlet should always be
pointed away from people or equipment. (Cracking the valve
is not recommended with hydrogen because it can be ignited
by static charge or friction.)

15. Before the regulator is attached to the cylinder valve

inspect the regulator for signs of damage such as damage
to the threads, valves, coupling, the housing and gas
compatibility. User must ensure that no oil, grease or dirt is
on the regulator or the cylinder. Fully release (turn
counterclockwise) the pressure-adjusting screw of the
regulator before opening the cylinder valve.

16. Open gas cylinder high-pressure valves slowly, this gives

compression heat, time to dissipate and prevents “bumping”
the gauges.

17. Cylinders are equipped with either a hand wheel or stem

valve. For cylinders equipped with a stem valve, the valve
spindle key should remain on the stem while the cylinder is
in service. Only wrenches or tools provided by the cylinder
supplier should be used to open or close a valve. At no time
should pliers be used to open a cylinder valve.

18. Keep removable keys or handles on valve spindles or stems

while cylinders are in service.

19. Never leave pressure in a system that is not being used.

20. To shut down a system, close the cylinder valve and vent the
pressure from the entire system.

21. Equipment must not be disassembled while it is under

pressure.

22. Be aware that any isolated portion of the system may still be
under pressure. Bleed the hose, line, or vessel before
disassembly to ensure that there is not enough pressure
energy stored in the trapped gas or in piping distortion to
propel loose objects.

23. Connections to piping, regulators and other appliances

should always be kept tight to prevent leakage.

24. Where a hose is used, it must be kept in good condition.

25. Manifold pigtails should not be left disconnected for more

than a few minutes.
26. Never use compressed gas to dust off clothing. This may
cause serious injury or create a fire hazard.

27. About 30-psi gauge pressure (0.2 MPa) must be left in

"empty" cylinders to prevent air from entering the cylinder
and contaminating it. Air contamination in a hydrogen
cylinder is extremely dangerous.

28. Before a regulator is removed from a cylinder, close the

cylinder valve and release all pressure from the regulator.
 29. Chicago type fittings will have safety pins or wires to prevent
accidental disconnection.

30. No smoking or open lights are allowed in the cylinder

storage area or when hooking up any compressed gas
cylinders. Disciplinary action will be taken for any
violations.

Before returning an empty cylinder, close the valve and replace the cylinder-
valve protective cap and outlet cap or plug, if used.