GAS -The Safe Use of Gas Cylinder - HSE UK

8/6/2019 GAS -The Safe Use of Gas Cylinder - HSE UK

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The safe use of

gas cylinders

HSEHealth & Safety

Executive


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1

Accidents involving gas cylind ers can cause serious injury or even

death. This leaflet provid es simple practical advice on eliminating or

redu cing the risks associated with using gas cylinders.

The leaflet is aimed at anyon e wh o manufactures, owns, fills, repairs

or uses gas cylind ers at work. The legal term for gas cylinders is

transportable pressure receptacles or transportable pressure

vessels. The advice will be useful for those who own or man agesmall businesses.

Gas cylind ers used in adverse or extreme cond itions, such as u nd er

water, may require special precautions. Although the ad vice in this

leaflet is valid for all uses of gas cylinders, these extra p recautions

are not covered.

As an emp loyer or self-employed p erson, you have a du ty to providea safe workp lace and safe work equ ipment. Designers, inspectors,

man ufacturers, supp liers, users and owners also have du ties.

Employers have a further d uty to consult any safety or emp loyee

representatives on health and safety matters. Where none are

app ointed, employers should consult the workforce directly.

Uses of gas cylinders

Gas cylind ers are a convenient way to transport and store gases

under p ressure. These gases are used for man y different pu rposes

including:

q chemical p rocesses;

q soldering, welding and flame cutting;

INTRODUCTION


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2

q breath ing (eg diving, emergency rescue);

q med ical and laboratory uses;

q dispensing beverages;

q fuel for vehicles (eg fork-lift tru cks);

q extingu ishing fires;

q heating and cooking;

q water treatment.

The main hazards are:

q impact from the blast of a gas cylind er explosion or rap id

release of compressed gas;

q impact from parts of gas cylinders that fail, or any flying debris;

q contact with the released gas or fluid (such as chlorine);

q fire resu lting from the escape of flamm able gases or

fluid s (such as liquefied p etroleum gas);q impact from falling cylinders;

q man ual handling injuries.

The main causes of accidents are:

q inadequate training and su pervision;

q poor installation;

q poor examination and maintenance;q faulty equipm ent and / or design (eg badly fitted valves

and regulators);

q poor hand ling;

q poor storage;

q inadequately ventilated working conditions;

q incorrect filling procedures;

q hidden damage.


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All gas cylind ers must be designed an d m anu factured to an

app roved specification to withstand everyday u se and to prevent

danger (see Legislation, page 10). They m ust be periodically

examined at approp riate intervals to ensure that they rem ain safe in

service. To reduce the risks of failure you need to know, and act on,

the following precautions.

Training

Anyon e who examines, refurbishes, fills or uses a gas cylinder

should be suitably trained and have the necessary skills to carry out

their job safely. They should un derstand the risks associated with the

gas cylinder and its contents.

In particular:

q new employees should receive

training and be sup ervised closely;

q users should be able to carry ou t

an external visual inspection of

the gas cylind er, and an y

attachments (eg valves,

flashback arresters,

and regulators),to determine

whether they

are dam aged.

Visible indicators

may includ e dents,

bulges, evidence of fire

dam age (scorch marks) and

severe grind ing marks, etc.

3

HOW TO REDUCE THE RISKS


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Manufacture and initial examination

The law requ ires that gas cylinders are:

q man ufactured to the design standards and specifications of the

relevant legislation (see Table 1 on p ages 12/ 13);

q examined by a relevant insp ection bod y (see Table 1) to verify

that the cylinders are manufactured correctly.

Owners and fillers should satisfy themselves that the m anufacturing

requirements have been carried out by examining either:

q the written certificate which accompanies the gas

cylinder; or

q the stamp or m ark of the relevant inspection

body on the gas cylind er itself (see Table 1).

Periodic examination

If you own or fill gas cylind ers, you mu st ensure

that they have been examined a t the appropriate

intervals to make sure that they are safe for

continued use.

The law requ ires that all gas cylinders are:

q examined and tested by the relevant

inspection body, in accord ance with

relevant regulations and at the app ropr iate

intervals (see Table 1); and

q perm anently marked by a relevant inspection

body to show the d ate of the last periodic examination.

4


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Repair

The law p rohibits mod ifications (with the exception of neck thread

cutting) or major repairs to the body of seamless gas cylinders or

cylind ers that h ave contained acetylene. However, the law d oes

allow for mod ification and major repair (ie hot work), by an

approved person only, of other typ es of cylinders, subject to certain

conditions. These include that a relevan t inspection body (seeTable 1) marks or certifies the cylind er as being fit for use.

Where there is minor d amage only, refurbishm ent work w hich d oes

not affect the integrity of the cylind er can be und ertaken by a p erson

comp etent to do so.

Filling

Anyon e carrying out the filling of gas cylinders shou ld wear suitable

personal protective equipm ent as app ropr iate. This may includ e

safety shoes, protective overalls, gloves, and ear and eye protection.

Before filling a gas cylinder check that:

q from the m arkings on the cylind er, it has been p roperly

examined by a relevant inspection body and is still within its

du e test date;

q it shows no sign of damage, external corrosion, falsification

(defacing) of markings or illicit rep airs that may affect integrity;

If it is necessary to alter some cylinder markings, eg because

of a change in tare w eight, it is preferable that this i s done by

overstamping the old markings with XXX, not by grinding

them off . Grinding can reduce cylinder wall thickness to

unsafe levels and shorten cylinder life.

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q it is suitable for the gas/ fluid with which it is to be filled;

q from the m arkings on the cylinder , the safe operating limits are

established;

q valves, fittings and regu lators (where fitted) are:

- correctly fitted and not leaking;

- not damaged and in good working condition;

- su itable for their in tended purpose;

- not contaminated, eg with incompatible lubricants.

If any of the above conditions are not met, then the cylinder must

not be filled.

After filling a gas cylind er check that:

q it is within its safe operating limits;

q it is not overfilled oroverpressurised. In the event

of inad vertent overfilling,

any excess gas mu st be

removed in a safe man ner

and the cylinder checked for

further fitness for service;

q the cylinders valves, fittings

and regulators are notleaking, for example by

using special equipm ent,

such as sniffers or m anom eters.

If app ropriate, the simp le method

of using a soapy w ater solution can be

adopted.

6


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Handling and use

q Use gas cylinders in a vertical position, unless specifically

designed to be used otherw ise.

q Securely restrain cylind ers to prevent them falling over .

q Always double check that the cylinder/ gas is the right one for

the intend ed use.

q Before connecting a gascylind er to equipm ent or

pipework make sure

that the regulator and

pipew ork are suitable

for the type of gas and

pressure being used.

q When required, wear

suitable safety shoesand other personal

protective equipm ent

when h andling gas

cylinders.

q Do not use gas cylind ers for any oth er

pu rpose than the transp ort and storage of gas.

q Do not drop, roll or d rag gas cylinders.

q Close the cylind er valve and replace du st caps, wh ere provided ,wh en a gas cylinder is not in use.

q Where approp riate, fit cylinders w ith residu al pressure valves

(non-return valves) to reduce the risk of back flow of water or

other materials into the cylinder d uring u se that might corrode it

(eg beer forced into an empty gas cylind er d uring cylind er

change-over).

7

x


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Lifting

q Use suitable crad les, slings, clamps or other effective m eans

when lifting cylind ers with a hoist or crane.

q Do not use valves, shroud s and caps for lifting cylinders un less

they have been designed and m anufactured for this pu rpose.

q Gas cylinders should not be raised or lowered on the forks of lift

trucks unless adequate precautions are taken to prevent themfrom falling.

Transport

q Fit suitable protective valve caps and covers to cylinders, when

necessary, before transporting. Caps and covers help prevent

moisture and dirt from gathering in the valve of

the cylinder, in addition to providingprotection during transport.

q Securely stow gas cylind ers

to prevent them from

moving or falling. This is

norm ally in the vert ical

position, unless instru ctions

for tran sport state otherw ise.

q Disconnect regulators and hosesfrom cylinders whenever practicable.

q Do not let gas cylinders project beyond the

sides or end of vehicles (eg fork-lift tru cks).

q Ensure gas cylinders are clearly marked to show their contents

(includ ing their UN num ber) and the d anger signs associated

with their contents.

q It may be necessary to take special measures with certain types

and quan tities of comp ressed gases and fluids in order to ensu re

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9

their safe carriage. If you have any dou bts seek furth er gu idance

(see Furth er ad vice, page 15).

q The transport of gas cylinders is subject to carriage

requirements. For example, that:

- the vehicle is suitable for the purpose;

- the vehicle is suitably marked to show that it is carrying

dangerous goods;

- the dr iver is su itably trained; and- the driver carries the appropriate documentation about the

natu re of the gases being carried.

Storage

q Store gas cylind ers in a d ry, safe place on a flat surface in the

open air. If this is not reasonably practicable, store in an

adequately ventilated building or part of a building specificallyreserved for this pu rpose.

q Gas cylinders containing flamm able gas shou ld not be stored in

part of a building used for other pu rposes.

q Protect gas cylinders from external heat sources that m ay

adversely affect their mechan ical integrity.

q Gas cylinders shou ld be stored aw ay from sources of ignition

and other flamm able materials.

q Avoid storing gas cylinders so that th ey stand or lie in w ater.q Ensure the valve is kept shu t on empty cylind ers to prevent

contaminants getting in.

q Store gas cylind ers securely when they are not in use. They

should be p roperly restrained, unless designed to be freestand ing.

q Gas cylind ers mu st be clearly marked to show what they contain

and the hazards associated with their contents.

q Store cylinders w here they are not vu lnerable to hazards caused

by imp act, eg from vehicles such as fork-lift tru cks.


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LEGISLATION

10

The five m ain sets of Regulations covering gas cylind ers are:

q The Transportable Pressure Vessels Regulations 2001 (SI

2001/ 1426) (TPV Regulations) came fu lly into force on 1 Ju ly

2001. They allow for the free movement and use of transp ortable

pressure vessels (ie gas cylinders which are d esigned,

man ufactured and examined to the requirements of the TPV

Regulations) across the European Union (EU) and GreatBrita in (GB).

q The Carr iage of Dangerous Goods (Classification, Packaging

and Labelling) and Use of Transportable Pressure Receptacles

Regulations 1996 (SI 1996/ 2092), as am end ed (CDGCPL2

Regulations) cover the d esign, manufacture and examination

of gas cylinders which are only for the dom estic market in GB.

q The Gas Cylind ers (Pattern Ap proval) Regulations 1987

(SI 1987/ 116) (Pattern Approval Regulations) for EEC-typecylind ers cover the design and man ufacture of EEC-type

cylind ers (under Europ ean Directives 84/ 525/ EEC, 84/ 526/ EEC

and 84/ 527/ EEC) for both the dom estic and EU markets.

q The Pressure Vessels (Verification) Regulations 1998 (SI

1988/ 896) (Verification Regulations) cover th e initial

examination an d verification of EEC-type cylinders (un der

European Directives 84/ 525/ EEC, 84/ 526/ EEC and

84/ 527/ EEC) for both the d omestic and the EU markets.q The Pressu re Equipm ent Regu lations 1999 (SI 1999/ 2001) (PE

Regulations) cover w ithin th eir scope the d esign, man ufacture

and initial integrity of cylinders used in breath ing app liances

and portable fire extingu ishers, together w ith valves and other

accessories used w ith these gas cylinders which have a direct

safety fun ction. For period ic examination th ese cylinders are

governed by the requirem ents of the CDGCPL2 Regulations.


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The TPV Regulations do not apply to the gas cylinders used in

breathing appliances (including diving cylinders) or portable fire

extinguishers. Manufacturers, suppliers, users and owners of

diving cylinders are required to comply with the requirements of

either the CDGCPL2 Regulations, the Pattern Approval

Regulations or the PE Regulations.

The first four sets of Regulations allow owners of cylindersmanu factured before 1 July 2003 a number of choices.

For new cylinders, either:

q continue to comp ly with the requ irements of the CDGCPL2

Regulations if the cylind ers are for use only in GB; or

q continue to comp ly with the Pattern App roval and Verification

Regulations if they are EEC-type cylind ers; orq comply with the requirements of the TPV Regulations, if the

cylind ers are for use throu ghout the EU and GB.

For existing cylinders, either:

q continue to comp ly with the requ irements of the CDGCPL2

Regulations if the cylind ers are for use only in GB; or

q have the cylinders reassessed in accordan ce with the TPVRegulations if they are to be used throughout th e EU. However,

in the case of EEC-type cylinders, reassessment u nd er the TPV

Regulations is not needed . These cylinders may be given a p i-

mark (-mark) at their first periodic inspection after the TPV

Regulations come into force.

Additional ad vice and guidance is listed at the end of this leaflet.


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Sum

maryofthelaw

Regulations

Relevantinspectionbodies

Manufacturing

Cylindermarkings

andscope

Initial

Reassessment

Periodic

anddesign

Initial

Reassessment

Periodic

ofapplication

examination

examinatio

n

standards

examination

examination

andverificat

ion

andverification

TPVRegulations

Notifiedor

Notifiedor

Notifiedor

Schedule2of

Domestic

market:

EU

and

EU

an

d

(EU

andGB)

approvedbo

dy

approvedbody

approvedb

ody1

TPVRegulations

ID

numbe

rof

domestic

domestic

appointedby

appointedby

appointedb

y

orstandard

notifiedo

r

market:

marke

t:

theHealthan

d

theHealthand

theHealthand

approvedby

approved

body3

a-mark

and

theda

teofthe

Safety

Safety

Safety

HSE2

ID

numberof

examination

Executive

Executive

Executive

EU

market:

notifiedor

andID

(HSE)

(HSE)

(HSE)

a-mark

and

approvedbody

numberof

ID

numbe

rofa

undercertain

notifiedor

notifiedb

ody

conditions4

approvedbody

CDGCPL2

HSEapprove

d

-

Competent

Standard

Verification

-

Dateo

fthe

Regulations(GB)

person5

person6

approvedbyHSE

mark

examination

12

Table1


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PatternApproval

Inspection

-

Competent

Patternapproval

Patterna

pproval

-

Dateo

fthe

andVerification

body7

person6

issuedunderEU

andEEC

examination

Regulations

Directives,

verificatio

nmark

(EU

andGB)

84/525/EEC,

symbols

and

84/526/EEC

and

eandth

emark

84/527/EEC

oftheins

pection

body

PERegulations

Notifiedbody

-

Competent

Essentialsafety

CEmark

and

-

Dateo

fthe

(EU

andGB)

oruser

person6

requirementsof

ID

numbe

rof

examination

inspectorate

s8

PERegulations

notifiedb

odyor

appointedby

orharmonised

userinsp

ectorate

theSecretary

of

standards

StateforTrad

e

andIndustry

13

3


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Notes

1 Examination and testing to be carried out in accordance with Chapter 6.2 of

the European agreement concerning the international carriage of dangerou s

goods by road (ADR 2001) and at the intervals specified in the relevant

packing instruction (P200 or P203 in 4.1.4.1 of ADR 2001).

2 HSE will charge an app licant or body a fee for the approv al of a new stand ard

which meets the relevan t requ iremen ts of [chap ter 6.2] of ADR 2001.

3 Until 30 Jun e 2003, man ufacturers of new TPVs wh ich are for use only in the

domestic market in GB may have their TPVs initially examined an d verified

by either a notified or app roved body u nd er the TPV Regulations or by a HSE

app roved person u nd er the CDGCPL2 Regulations.

4 Ow ners of existing gas cylinders manu factur ed before 1 July 2003 in

accordance with the CDGCPL2 Regulations but which meet the requirem ents

of the TPV Regulations may h ave their cylind ers reassessed by a notified or

approved body and be -marked to allow th e free movemen t of such gas

cylinders throu ghou t the EU. Periodic examinat ion of these cylinders w ould

then be carried ou t by a n otified or ap proved body.

5 New cylinders man ufactured in accorda nce with the CDGCPL2 Regu lations

mu st be initially examined by a HSE app roved p erson.

6 Periodic examination of cylinders man ufactured in accordance with the

CDGCPL2, Pattern Appr oval, Verification an d PE Regulations m ust be carried

out by a competent person. A comp etent p erson is an ind ividu al person or

body who has the necessary skills, know ledge of the law, experience and

expertise to carry out a thorou gh examination an d test of a gas cylinder to

determine wh ether it is safe for continued use.

7 EEC-type cylinders are required to have an initial examination and verification

by an insp ection body app ointed by th e HSE un der th e Verification

Regulations. The insp ection body w ill carry out an examination, affix EEC

verification marks to the cylinders and issue EEC verification certificates.

8 Gas cylinders designed and manu factured und er the PE Regulations are

required to have their initial examination an d verification carried out by a

notified bod y app ointed by th e Secretary of State for Trade and Indu stry.

Lists of HSE notified and app roved bod ies and standard s app roved by H SE

are available on the HSE website at ww w.hse.gov.uk/ signp ost/ index.htm

un der the entry for transportable pressure equipment.


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FURTHER ADVICE

Contact the following:

q Your local HSE office - the num ber can be obtained from

directory enqu iries or the phone book u nd er Health and Safety

Executive or from HSEs website.

q Information on H SE approved standards can be obtained from

HSE Technology Division 5, Magdalen H ouse, Stanley Precinct,

Bootle, Merseyside L20 3QZ, Tel: 0151 951 4514 or from HSEswebsite at www .hse.gov.uk/ signpost/ index.htm.

q For prem ises covered by the local authority eg offices, shops and

pu blic hou ses, contact the Local Authority Unit enquiry point:

Tel: 020 7717 6442, Fax: 020 7717 6418.

q The United Kingd om Accred itation Service (UKAS) can advise

on comp etent persons and notified and app roved bod ies. UKAS

can be contacted at 21-47 High Street, Feltham , Midd lesex

TW13 4UN, Tel: 020 8917 8435, Fax: 020 8917 8499, or from theirwebsite at ww w.ukas.com.

Related Regulations, guidance and further information

This leaflet tells you about th e main d angers of gas cylinders and of

some of your legal responsibilities. For more d etail you shou ld

refer to:

The Transportable Pressu re Vessels Regulations 2001 SI 2001/ 1426

The Stationery Office 2001 ISBN 0 11 029347 9

The Carriage of Dangerous Goods (Classification, Packaging and

Labelling) and Use of Transportable Pressure Receptacles

Regulat ions 1996 SI 1996/ 2092 (as amend ed) The Stationery Office

1996 ISBN 0 11 062923 X


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The Gas Cylinders (Pattern Approval) Regulations 1987 SI 1987/ 116


The Pressure Vessels (Verification) Regulat ions 1988 SI 1988/ 896

The Stationery Office 1988 ISBN 0 11 086896 X

The Pressu re Equ ipm ent Regulations 1999 SI 1999/ 2001


European Agreement concerning the international carriage of

dangerous goods by road (ADR) and protocol of signature d one at

Geneva on 30 Septem ber 1957

Guidelines on the appointment of conformity assessment bodies for

transportable pressure vessels in Great Britain. Transportable Pressure

Vessels Regulations 2001 (copies available from HSE at 020 7717 6695

or from HSEs w ebsite at ww w.hse.gov.uk/ signpost/ index.htm)

The Highly Flamm able Liquids and Liquefied Petroleum Gases

Regulat ions 1972 SI 1972/ 917 The Stationery Office

ISBN 0 11 880382 4

Manual Handling: Manual Handling Operations Regulations 1992

Guidance on Regulations L23 HSE Books 1998 ISBN 0 7176 2415 3

Safe use of lifting equipment: Lifting Operations and Lifting Equipment

Regulations 1998 A pproved Code of Practice and Guidance L113 HSEBooks 1998 ISBN 0 7176 1628 2

Chemical warehousing: The storage of packaged dangerous substances

HSG71 HSE Books 1998 ISBN 0 7176 1484 0

The carriage of dangerous goods explained. Part 2. Guidance for road

vehicle operators and others involved in the carriage of dangerous goods by

roadHSG161 HSE Books 1996 ISBN 0 7176 1253 8

16


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

processes HSG139 1997 ISBN 0 7176 0680 5

Cylinder retest stations IGC Doc 79/ 01/ E EIGA.

Available on their w ebsite: www.eiga.org

The Storage of Full and Empty LPG Cylinders and Cartridges. LP Gas

Association Code of Practice No 7. Available from the LP Gas

Association, add ress given below.

While every effort has been m ade to ensu re the accuracy of the references and

websites listed in this p ublication, their futu re availability cannot be

guaranteed.

Regulations are available from:

The Stationery Office (formerly HMSO), The Pu blications Cen tre,

PO Box 276, London SW8 5DT, Tel: 0870 600 5522, Fax: 0870 600 5533

Further guidance may be obtained from:

The British Compressed Gases Association, 14 Tollgate, Eastleigh,

Ham pshire SO53 3TG, Tel: 01703 641488

The LP Gas Association, Pavilion 16, Head land s Business Park,

Salisbury Road, Ringwood , Ham pshire BH24 3PB, Tel: 01425 461162

For fur ther gu idance on d iving cylinders contact:

ASSET, 12 Cou lston Road , Lancaster, Tel: 01524 381831

IDEST, Scuba Industry Trad e Association admin office,

29 Ravenswood Avenu e, West Wickham , Kent BR4 0AN,

Tel: 020 8777 6740.


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HSE priced and free publications are available by mail order from

HSE Books, PO Box 1999, Sudbu ry, Suffolk CO10 2WA

Tel: 01787 881165 Fax: 01787 313995 Website: w ww.hsebooks.co.uk

(HSE pr iced p ublications are also available from bookshops.)

For information abou t health an d safety ring H SE's InfoLine

Tel: 08701 545500 Fax: 02920 859260 e-mail:

hseinformationservices@natbr it.com or write to HSE InformationServices, Caerphilly Business Park, Caerphilly CF83 3GG. You can

also visit HSEs w ebsite: www.hse.gov.uk

18

This leaflet contains notes on good p ractice which are not

comp ulsory but w hich you may find h elpful in considering

wh at you need to do.

This leaflet is available in pr iced packs of 10 from HSE Books,

ISBN 0 7176 2332 7. Single free cop ies are also available fromHSE Books.

This pu blication may be freely reproduced except for advertising,

endorsement or comm ercial purp oses. First published 4/ 02. Please

acknowledge the source as HSE.

Printed and pu blished by the Health and Safety Executive

INDG308(rev1) 4/02 C250

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GAS -The Safe Use of Gas Cylinder - HSE UK

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