Compressed Gas Cylinders- Storage & Handling

Some of the most dangerous devices may be found on your jobsites and in your shop. Compressed gas cylinders of all types have a tremendous capacity for injury from mistreatment or mishandling.

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The sheer energy storage that is contained in a cylinder (especially Oxygen) makes this equivalent to storing and handling a bomb. Oxygen cylinders are typically pressurized to 2,000 P.S.I, and acetylene cylinders are typically pressurized to 250 P.S.I. The following will cover the common high-pressure oxygen/ acetylene cylinder regulations outlined by OSHA in Subpart J "Welding & Cutting", and should be a part of your safety program. Most of the handling techniques addressed here will apply to CO2, LP, and other similar gas cylinders.

Storage Regulations/ Techniques:

All high pressure gas cylinders need to comply with certain regulations. The following are highlights of the more common requirements for storage.

Outside storage areas selected should be dry, well-ventilated, protected, and not subject to continuous exposure to sunlight, moisture, salts, corrosives, or extreme weather. The areas should have a definitive designation for cylinder storage, and not be subject to damage, falling, or from tampering. Outside storage areas require a minimum of a 20-B fire extinguisher located from 25 ft. to 75 ft. away from the storage area.

Inside storage areas selected should be dry, well-ventilated, protected, and away from high traffic areas such as gangways, elevators, and stairs. The areas should have a definitive designation for cylinder storage, and not be subject to damage, falling, or from tampering. Areas should be located away from salts, corrosives, or sources of heat. Inside storage rooms with more than 60 gallons of flammable or combustible liquids shall have a minimum of a 20-B fire extinguisher located within 10 ft. of the storage room door. Inside storage areas are limited to 2,000 cubic ft. gas capacities, or 300 lbs. of LPG. Larger amounts would require a separate storage room.

When cylinders are stored, or transported, the protective caps are required to be screwed on. Caps may be screwed on hand tight. Caps should be removed only when the cylinders are in use- which is when the regulators are installed. Cylinders may be moved without protective caps (and with regulators installed) only in carts designed for the purpose, with the cylinders secured. Protective caps cannot be used to hook onto for hoisting. When removing caps, do not apply leverage to the valves. According to OSHA, when caps are frozen, warm water may be used to thaw cap threads.

Cylinder valves shall be closed at all times, except when in use. Empty cylinders are also required to have valves closed. Cylinders should not be emptied completely, but retain approximately 30 P.S.I. to prevent contamination. Oxygen cylinders not in use are required to be separated from fuel-gas cylinders, oils, grease, and other combustibles by at least 20 ft. In lieu of this requirement, you may store oxygen cylinders closer (adjacent) if separated by at least a 5 ft. high 1/2 hr. fire-rated partition.

Cylinders shall always be stored upright in a vertical position. In the case of acetylene, if a cylinder is found lying down, it must be set upright for at least one half hour before use to allow the acetone component in the cylinder to settle.

Usage and Handling Regulations/ Techniques:

All high pressure gas cylinders need to comply with certain regulations. The following are highlights of the more common requirements for usage and handling.

Gas cylinders are made to be slightly tilted and rolled along their base. However, they shall not be dropped, dragged, or allowed to strike each other, or surrounding surfaces.
Moving cylinders may also be done by hand trucks, or cylinder hand carts. Lifting by hand typically takes two people. When lifting by cranes, hoists or forklifts a metal cradle or skid box shall be used- no rope or chain slings. When moving cylinders, always assume they are pressurized.

Gas cylinders are required to be secured in a vertical position when transported, or used. Cylinders in use shall be placed to avoid sparks, slag, or flames from reaching the tanks. Cylinders shall be placed where they cannot become part of an electrical circuit, or in the case of arc welding, be far enough away to prevent an arc from striking the cylinder. Cylinders shall not be placed, or used in any confined space. Cylinders (even empty ones) can never be used as rollers, or supports for any equipment or materials.

Fuel-gas valves shall be opened slightly, then closed (called cracking) before connecting the regulator to clear the valve of any dirt or dust first. The valve should be clear of any source of ignition, and the worker cracking the valve should stand to one side. When a regulator is placed on a gas valve, the valve should be turned open slowly to prevent regulator damage, and not opened more than 1-1/2 turns to permit quick closing. If a special wrench is used to operate the valve, it shall be left in place to permit quick closing of the valve. Any gases must be released from the regulator before disconnecting a regulator from the gas valve. Cylinders shall not become greasy or oily through use. Any grease or oil can become a fire hazard if oxygen is accidentally released. Clean off any grease or oils frequently.

An OSHA safety course and safety training for your construction site can help keep you from having to deal with issues like compressed gas cylinder explosions. Contact us today for a safety manual for your jobsite.