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  • OSHA, CGA, and the DOT all have regulations for dealing with the special hazards associated with compressed gases in cylinders.
  • In general, compressed gas cylinders must be handled gently, kept away from temperature extremes and electricity, and closed when not in use.

Compressed gases in cylinders present special hazards that include the possibility of oxygen displacement and toxic effects from the gas itself, as well as fire and explosion risks due to the high pressure. Thus, gas cylinders may only be handled and used by trained workers.

The Occupational Safety & Health Administration (OSHA) addresses compressed gases in general at 1910.101, which adopts by reference some regulations from the Compressed Gas Association (CGA).

Marking gas cylinders

Cylinders, containers, pipes, etc., must be clearly marked so that the gas can be easily identified. Labels should not be defaced or removed. Containers whose content labels are not legible should be returned unused to the supplier. Containers should not be repainted, and container color should not be used to identify the cylinder content.

All gas lines leading from a compressed gas supply should be clearly labeled or identified. Some states require specific labeling of cylinders, containers, and pipes.

Inspecting gas cylinders

Employers must visually inspect compressed gas cylinders to determine that they are in safe condition under 1910.101.

Visual inspections must be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR Parts 171–179 and 14 CFR Part 103) when applicable. Otherwise, they must be conducted in accordance with CGA Pamphlet C-6-1968.

In general, all parts of a cylinder (valves, neck rings, hoses, manifold, regulator, etc.) should be inspected for:

  • Corrosion or pitting;
  • Cracks;
  • Denting or bulging;
  • Gouges;
  • Leaks; and
  • Oil, grease, and other foreign material.

Storing gas cylinders

Proper storage of gas cylinders is crucial for maintaining a safe workplace. According to CGA P-1, storage areas must:

  • Allow containers to be grouped by hazard using spacing or partitions;
  • Separate full and empty containers;
  • Be dry, well-drained, ventilated, and fire-resistant;
  • Not exceed 125�F; and
  • Not expose the cylinders to tampering by unauthorized persons.

Containers must be:

  • Wearing their valve protection caps (if provided);
  • Adequately separated from corrosive chemicals or fumes, readily ignitable substances, and combustibles;
  • Stored on well-drained, paved surfaces to prevent bottom corrosion/rusting;
  • Clear of walkways, elevators, stairs, unprotected platform edges, and possible falling objects;
  • Protected from cuts, punctures, and other abrasions; and
  • Secured with brackets, chains, or straps.

Moving gas cylinders

Safe handling of gas cylinders includes moving them carefully, both within and between facilities.

Practices to avoid include:

  • Dragging or sliding cylinders,
  • Lifting cylinders by their caps,
  • Using lifting magnets, and
  • Using cylinders (full or empty) as rollers or supports.

Protective caps and outlet caps or plugs should be replaced before empty cylinders are returned to the supplier.

OSHA states that compressed gas cylinders that are not secured to a “special truck” must have their regulators removed and valve-protection caps installed. A special truck is a vehicle or cart that provides stable support of vertical standing Department of Transportation portable gas cylinders during movement and at various work locations. It must include protection of cylinder valves and regulators. CGA Pamphlet P-1 allows for a “suitable hand truck, forklift truck, or similar material handling device,” as long as cylinders are properly secured to it by a chain or other comparable method.

Using gas cylinders

When using any compressed gas (i.e., cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks), employers must comply with the provisions outlined in CGA Pamphlet P-1-1965, which is incorporated by reference in the OSHA standard.

When handling compressed gas cylinders, workers should always follow these procedures:

  • General handling:
    • Do not subject cylinders to artificially low temperatures or temperatures above 125�F.
    • Keep cylinders away from heat sources and flames.
    • Keep cylinders away from places where they could become part of an electric current, and never use them as a ground.
    • Never drop cylinders or strike them against one another or other surfaces.
    • Never attempt to transfer compressed gases from one container to another. (This must only be performed by the gas supplier or by personnel familiar with the hazards.)
    • Keep cylinders far enough away from welding or cutting projects so that sparks, hot slag, or flames do not reach them. When this is impractical, use fire shields.
  • Valves:
    • Never tamper with or alter cylinders, valves, or safety-related devices.
    • Leave valve protection caps in place and hand-tightened until cylinders are secured and ready to be connected.
    • For gas cylinders with valve outlet caps and plugs that form a gas-tight seal, keep these devices on the valve except when containers are secured and connected.
    • Keep cylinder valves closed except when the cylinder is being used.
    • When opening a valve, stand to one side of the regulator and open it slowly.
    • Do not tighten connections or leaking fittings or attempt other repairs while the system is under pressure.
    • Before connecting a regulator to the cylinder valve, open the valve slightly for an instant and then close it.
    • Do not use oxygen from a cylinder without first attaching an oxygen regulator to the cylinder valve, unless the cylinder is connected to a manifold.