General Assist Safety Reference
BOC Guidelines for Gas Cylinder Safety
Safe handling, transport, storage, use and emergency response
For workplaces using compressed, liquefied, oxidising, flammable, inert or refrigerant gas cylinders
Purpose: This guide summarises essential precautions for handling, transporting, storing and using compressed gas cylinders. It supports safe work practices but does not replace training, the applicable Safety Data Sheet (SDS), site risk assessments, legislation, codes of practice or Australian Standards.
High-pressure hazard: Treat every cylinder as full and pressurised. Cylinders must only be handled or connected by trained and authorised personnel. Never tamper with a cylinder valve, fitting, pressure relief device or identification marking.
1. General safety principles
| 1 | Treat every cylinder as full, even when it is believed to be empty. |
| 2 | Confirm the gas from the cylinder label before acceptance, storage or connection. Colour is only a secondary means of identification. |
| 3 | Do not use a cylinder with a missing, damaged or illegible label. Isolate it and arrange return to the supplier. |
| 4 | Review the current SDS and equipment instructions before handling or using the gas. |
| 5 | Keep cylinders upright and secured where practicable, with clear access to the valve and regulator. |
Typical gas hazards: Cylinders may contain flammable, oxidising, toxic, corrosive or asphyxiant gases. Some gases can collect in drains or low-lying areas, while lighter gases may accumulate at high level. A gas leak may not be visible or detectable by smell.
2. Cylinder handling
- Use a purpose-designed cylinder trolley or mechanical aid. Do not drag, slide or roll cylinders horizontally.
- Close the cylinder valve before moving the cylinder.
- Remove regulators and ancillary equipment before movement unless the cylinder is secured on a purpose-designed trolley or carrier.
- Refit supplied valve protection caps or outlet caps before transport or relocation.
- Never lift a cylinder by its valve, handwheel or regulator.
- Do not use chains, magnets or unsuitable slings around an individual cylinder.
- Do not try to catch a falling cylinder. Move clear of its direction of travel.
- Wear suitable PPE, including safety footwear, eye protection and protective gloves appropriate to the task and gas.
Oxygen equipment: Hands, gloves, fittings and tools must be clean, dry and free from oil or grease. Oil or grease in contact with high-pressure oxygen can ignite violently.
3. Transporting cylinders
Professional gas delivery is the preferred transport method. Where workplace transport is necessary, comply with dangerous-goods requirements and the applicable vehicle and load-restraint rules.
| Do | Do not |
|---|---|
| Secure cylinders against movement and consider the forces that may occur during emergency braking or a collision. | Do not transport unsecured or loose cylinders. |
| Use an open vehicle or ventilated, segregated load compartment wherever possible. | Do not transport flammable or toxic gases in an enclosed passenger compartment. |
| Keep acetylene and LPG cylinders upright with valves uppermost. | Do not transport cylinders with regulators or equipment attached. |
| Leak-check the cylinder and ensure the valve is closed before loading. | Do not leave cylinders in a vehicle for extended periods or overnight. |
| Unload cylinders promptly on arrival. | Do not smoke or use ignition sources while handling flammable or oxidising gas loads. |
4. Storage safety
- Store cylinders in a secure, well-ventilated and well-drained location, preferably outdoors with weather protection.
- Keep the area away from heat, flames, ignition sources, combustible material, corrosive liquids and heavy traffic.
- Secure cylinders vertically using suitable chains, brackets, racks or approved storage systems.
- Separate full and empty cylinders and segregate different gas classes.
- Store oxygen and other oxidising gases at least 3 metres from fuel gases, unless an appropriately fire-rated barrier provides the required separation.
- Keep toxic gases separate and replace the valve outlet cap or plug whenever the cylinder is not connected.
- Display required dangerous-goods, HAZCHEM, no-smoking and no-naked-flame signage.
- Maintain clear access for emergency response and cylinder delivery or removal.
- Do not store cylinders in confined spaces or below ground unless a specific risk assessment and controls address gas accumulation.
Temperature: Keep cylinders away from direct heat and do not expose them to temperatures above 65°C. Never direct a flame, hot slag, welding arc or other heat source toward a cylinder.
5. Connecting and using cylinders
- Verify the cylinder label and confirm the gas is suitable for the intended application.
- Inspect the cylinder, valve outlet, regulator, seals, hoses and fittings for damage or contamination.
- Use only a regulator and fittings designed for the gas and cylinder valve connection. Never force a mismatched connection or use an improvised adaptor.
- Back off the regulator adjusting knob before connecting the regulator.
- Secure the cylinder before connecting equipment.
- Open the cylinder valve slowly using moderate force. Once fully open, turn it back approximately half a turn to reduce the risk of seizure.
- Leak-check joints using an approved leak-detection fluid or a suitable ammonia-free soapy-water solution. Wipe the area dry after testing.
- Close the cylinder valve whenever the equipment is unattended, during breaks and at the end of work.
Leak testing: Bubbling or foaming indicates a leak. Depressurise the equipment and arrange corrective action. Never test for leaks with a flame and never tighten fittings while the system is under pressure.
Equipment requirements
- Do not apply oil, grease, PTFE tape or unauthorised sealants to cylinder valves or regulator connections.
- Use gas-specific hoses and connections that comply with the applicable standard.
- Fit flashback arrestors where required for oxy-fuel systems and have them tested at the prescribed interval.
- Replace damaged regulators, gauges, hoses or fittings. Do not repair or modify them unless authorised and competent to do so.
- Take precautions to prevent backflow, contamination and the entry of moisture into cylinders.
6. Inspection and cylinder condition
- Regularly inspect cylinders for dents, gouges, corrosion, fire or heat damage, damaged valves, contamination and illegible labels.
- Do not use a cylinder that is damaged, leaking, heat affected, out of test or unable to be positively identified.
- Isolate and clearly identify defective cylinders, then contact the cylinder supplier for collection, exchange or assessment.
- Never repaint, relabel, alter, refill, transfer gas between cylinders, mix gases or scrap a cylinder unless authorised by the cylinder owner and applicable standards.
7. Emergency procedures
In an emergency: Raise the alarm, evacuate people from the affected area, eliminate ignition sources only where this can be done safely, call Emergency Services on 000, and provide details of the gases and cylinder locations. Do not enter a suspected oxygen-deficient, toxic or flammable atmosphere without appropriate monitoring and respiratory protection.
| Situation | Immediate response |
|---|---|
| Gas leak | Do not attempt repairs while pressurised. Close the valve only where safe. Evacuate, isolate ignition sources and ventilate naturally where appropriate. Keep clear of the direction of escaping gas. |
| Cylinder in a fire | Evacuate at least 100 metres and call the fire brigade. Do not approach or move a heated cylinder. From a protected position, trained responders may cool it with copious water until emergency services arrive. |
| Heat-exposed cylinder | Withdraw it from service, clearly identify it and advise the cylinder supplier. Never clean, repaint, repair or reuse it before formal assessment. |
| Transport incident | Stop in a safe location away from people and traffic where practicable, leave the vehicle and contact emergency services and the gas supplier. |
BOC Emergency Response Line: The source guideline lists 1800 653 572. As the source document is the 2008 Australian edition, confirm current emergency and supplier contact details within your workplace emergency plan.
8. Key prohibitions
| ! | Never use oil or grease on any cylinder valve, regulator or fitting, particularly oxygen equipment. |
| ! | Never repair, modify, repaint, relabel, refill, mix or transfer gas between cylinders. |
| ! | Never expose a cylinder to flame, excessive heat, electrical arcs, molten metal or uncontrolled electrical current. |
| ! | Never use a cylinder as a roller, work support, structural support or receiver for waste gas or liquid. |
| ! | Never use gas equipment in a confined space without an appropriate risk assessment, ventilation, atmospheric monitoring and permit controls. |
9. Safety summary
Safe cylinder management depends on five controls: positive identification, correct handling and restraint, compliant segregation and ventilation, fit-for-purpose equipment, and a clear emergency response plan. Stop work and seek competent advice whenever a cylinder, connection or operating condition is uncertain.
Source: BOC, Guidelines for Gas Cylinder Safety, 2008 Australian Edition. This article is a practical summary and must be read alongside current SDS information, workplace procedures and applicable legal requirements.