Handling and Storage of Gas
Cylinders
Guide
All guides are intended to give further details to information contained in a particular piece of legislation, policy,
code, agreement or procedure and must therefore be read in conjunction with them.
INTRODUCTION
To meet the requirements of the NT Workplace Health & Safety (National Uniform Legislation) Act 2011 and
Regulations and the CDU Work Health & Safety (WHS) Policy, CDU has produced this Handling and
Storage of Gas Cylinders Guide.
PURPOSE
This document is an advisory text which sets out a general guide for the safe handling and storage of gas
cylinders. Gas cylinders are used in many University work areas and the following recommended methods
of handling, storage and transport will ensure the safety of workers, students and visitors.
Handling and Storage of Gas Cylinders Guide
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1.
Abbreviations................................................................................................................................... 2
2.
Relevant Definitions ........................................................................................................................ 2
3.
Health and Safety Responsibilities ................................................................................................. 3
4.
3.1
How to manage work health and safety risks ......................................................................... 3
3.2
Duty of Care ............................................................................................................................ 3
Gas Cylinders Guide ....................................................................................................................... 4
4.1
General ................................................................................................................................... 4
4.2
Know your gases ..................................................................................................................... 4
4.3
Classification of gases ............................................................................................................. 5
4.4
Cylinder design and construction ........................................................................................... 6
4.5
Valves, valve guards and protection caps ............................................................................... 6
4.6
Regulators ............................................................................................................................... 6
4.7
Flashback Arresters ................................................................................................................. 6
4.8
Maintenance and servicing ..................................................................................................... 6
5.
Handling and use of gas cylinders .................................................................................................. 7
6.
Storage of gas cylinders .................................................................................................................. 7
7.
Transporting of gas cylinders .......................................................................................................... 8
8.
Signage and placarding .................................................................................................................. 8
9.
Essential Supporting Information .................................................................................................... 8
1. Abbreviations
AS/NZS
CDU
LPG
NUL
PCBU
PPE
SDS
WHS
Australian/New Zealand Standard
Charles Darwin University
Liquefied Petroleum Gas
National Uniform Legislation
Persons Conducting a Business or Undertaking
Personal Protective Equipment
Safety Data Sheet
Work Health and Safety
2. Relevant Definitions
In the context of this document:
Chemical is defined as any element, chemical compound or mixture of elements and/or compounds
where chemical(s) are distributed. Chemicals may be in solid, liquid, gas or plasma.
Competent person means a person who has acquired through training, qualification or experience
the knowledge and skills to carry out the task.
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Flashback Arrester is a safety device designed to stop a flashback (flame re-entering the mixing
chamber) and is for use on equipment where fuel gas and oxygen/compressed air are being used in
combination.
Hazard means a situation or thing that has the potential to harm a person. Hazards at work may
include: noisy machinery, a moving forklift, chemicals, electricity, working at heights, a repetitive job,
bullying and violence at the workplace.
Plant relates to and includes any machinery, equipment, appliance, container, implement or tool,
including any component or anything fitted or connected to any of those items. Plant includes items as
diverse as hoists, cranes, computers, machinery, vehicles, power tools, etc. (as per Code of Practice
– Managing risks of plant in the workplace).
Risk is the possibility that death, injury or illness might occur when exposed to a hazard.
Safety Data Sheet (SDS) is a document prepared by the vendor
(manufacturer/importer/supplier) of a chemical which describes uses, chemical and physical
properties, hazard information, precautions for use, safe handling and emergency information. It
is a legislative requirement for the vendor to supply a copy of the SDS for each chemical to the
end user.
Student is a person enrolled at Charles Darwin University in a course of study or instruction.
Worker means any person who carries out work in any capacity for the University, including but not
limited to, University’s staff members, contractors, subcontractors and their employees, apprentices or
trainees, students gaining work experience, and volunteers;
Workplace means any area or place, including vehicle or vessel, where a worker goes or is expected to
be, while performing a business or undertaking for the University.
3. Health and Safety Responsibilities
3.1
How to manage work health and safety risks
It is the responsibility of all workers to identify any hazards and ensure they are reported to
supervisors or management so that effective controls can be implemented. Employees are
encouraged to attend WHS Risk Management Training and to read the CDU Risk Management
Policy. http://www.cdu.edu.au/governance/policies/pol-036.pdf
This document will provide information relating to:
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3.2
Duty of Care
Duty to identify hazards
Managing risks to health and safety
Hierarchy of control measures
Maintenance of control measures
Review of control measures
Duty of Care
Primary duty of care – Persons conducting a business or undertaking (PCBU) must ensure, so far
as reasonably practicable the health and safety of all persons engaged or influenced by the persons
activities, by eliminating or minimising the exposure to hazards and risks.
Workers and others – While at work, a worker must take reasonable care for their own health and
safety whilst also taking all reasonable measures to ensure that their acts or omissions do not
adversely affect the health and safety of other persons. The worker must comply and cooperate with
any reasonable policy or procedure relating to health or safety at the workplace.
Work Health and Safety Policy http://www.cdu.edu.au/governance/policies/pol-044.pdf
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Risk management is about exercising responsibility to ensure workers and the public are properly
protected. The Risk Assessment Form allows you to identify the hazard, then identify and control the
associated risk.
Risk Assessment Form
4. Gas Cylinders Guide
4.1 General
Compressed, dissolved and liquefiable gases contained within gas cylinders are under very high
pressures, and new developments in cylinder technology over the past decade have enabled cylinder
pressures to be significantly increased.
There are many commonly used industrial gases stored and used throughout the University. It is for
this reason is it important that workers are familiar with the types of gases available, and the hazards
associated with their use.
4.2 Know your gases
Since gases are invisible their presence is not readily identifiable and they have the potential to
asphyxiate, burn or harm users. To avoid potential incidents and in the interest of personal
safety, users must be able to identify gases by their hazard classification and be familiar with the
precautions required when handling cylinders.
The label is the primary means of identification of the cylinder contents. As per example below:
If labels are illegible or missing from cylinders, DO NOT use the cylinder. Return the cylinder to
the supplier for a satisfactory replacement.
Cylinder colour is the secondary means of identification of the nature of the cylinder contents
and the hazards associated with the gas contained within the cylinder. Examples of the more
commonly used gases around the University are below:
Gas
Type
Air
Body
Pewter
Band
Black
Nitrogen
Pewter
Oxygen
Black
Argon
Peacock
Blue
Carbon
Dioxide
Green
Grey
Acetylene
Claret
LPG
Galvanise
or silver
grey
Refrigerant
Galvanised
or white
Aqua
Further examples of cylinder colour identification can be obtained from manufacturers or
suppliers.
Never repaint a cylinder.
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4.3 Classification of gases
Classification is a process used to determine if a chemical can cause harm to human health and
safety. It involves the identification and evaluation of the physical properties of a chemical, along with
the health effects. It is the classification of a hazardous chemical that determines what information is
communicated on the label and SDS. An important part of the label is the class diamond, which
represents the characteristic of the gas.
Until the 31st December 2016, chemical classification is in a transitional stage where it is moving from
the Hazardous Substances and Dangerous Goods classification to a new Globally Harmonised
System (GHS) introduced by Work Health and Safety (WHS) Regulations. During this period you may
encounter pictograms from either of the classification systems. Further information on this is available
in Section 13 of the CDU Chemical Management Guide.
http://www.cdu.edu.au/ohrs/policies/health-safety.html
Examples of pictograms from both the Australian Dangerous Goods (ADG) and the Globally
Harmonised System have been provided.
ADG Class Diamonds - gases
GHS classification pictograms - gases
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4.4 Cylinder design and construction
Gas cylinders are designed and construction to comply with AS 2469 – 2005 Steel cylinders for
compressed gases – Welded two-piece construction – 0.1 kg to 150 kg. There is a wide range of
single high pressure cylinders suitable for small volumes of gas, which are available in various sizes
and pressures. Sizes are denoted by a letter code which is permanently marked on the cylinder.
Cylinders are usually used individually, but collectively grouped cylinders interconnected by a
manifold (Manifolded Cylinder Packs (Pack or Bundle) are available for purposes where larger
quantities of gas is required.
4.5 Valves, valve guards and protection caps
Cylinders containing gas under pressure are fitted with a cylinder valve which must not be tampered
with at any time, as this will compromise the safety of the cylinder. Each valve is specially threaded to
receive commercially available pressure regulators. For safety reasons, the cylinder valve outlets for
flammable gases (left hand thread/counter-clockwise) and non-flammable (right hand
thread/clockwise) are threaded opposite direction to prevent connection of the incorrect regulators.
Some cylinders are fitted with valve guards or protection caps to prevent the valves from being
damaged.
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DO NOT damage the threaded portions by connecting an incorrect regulator.
DO NOT over – tighten or use excessive force to connect equipment.
DO NOT remove valve guards.
DO NOT lubricate valves or fittings
DO refit the protection caps whenever the cylinder is not secure or not in use.
4.6 Regulators
Regulators are used to control the pressure from the cylinder to the required piece of equipment at
the end of the hose or manifold. The regulator has two pressure gauges, one indicating cylinder
pressure, and the other indicating hose pressure. Most regulators have two stages:
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First stage is a fixed-pressure regulator with the function of releasing the gas from the cylinder
at a constant intermediate pressure, despite the pressure within the cylinder falling as the
amount of gas within the cylinder is used.
The adjustable second stage of the regulator controls the pressure reduction from
intermediate pressure to the lower pressure required at the outlet.
4.7 Flashback Arresters
It is important for the manufacturer, testing facilities and the user of the safety devices to appreciate
that the devices are only effective for their designed purpose if they continue to perform within their
design specifications.
Flashback arresters to be connected to regulators, welding hose and blowpipes shall have end
connections in accordance with AS 4267 and AS 1335 to prevent interchangeability.
Testing on flashback arresters in service shall be carried out at a minimum interval of 12 months by
an independent third party to determine the suitability for continued use of the safety device.
4.8 Maintenance and servicing
Most cylinders are owned by gas companies and it is the responsibility of the supplier to ensure
that cylinders are properly maintained, serviced and tested. It is suggested by WHS that annual
checks of cylinders be conducted, to ensure that the cylinders in storage are still in good order
and within the due test date.
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Keep cylinder valves clean.
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Never attempt to repair a cylinder.
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Never disguise damage to cylinders.
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Never mix gases.
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Never transfer gas to another cylinder.
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Never scrap a cylinder. Have it returned to or picked up by the supplier to condemn and
dispose of.
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Ensure annual inspections of manifold systems are performed.
5. Handling and use of gas cylinders
Musculoskeletal or crush injuries are just a couple of examples of risks associated with the moving
and handling of gas cylinders. Therefore, for general personal safety it is recommended that:
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Mechanical aids (trolleys, forklifts, etc.) should be used wherever possible to move cylinders
(especially cylinders >12kg).
Disconnect any attached equipment prior to moving a cylinder.
Ensure that cylinders are safely secured to the lifting device prior to moving.
Observe safe lifting techniques where manually handling of cylinders is required.
Use suitable personal protective equipment (PPE).
In case of a leak or suspected leak, close the cylinder valve tightly before attempting to
find a leak or to replace components.
DO NOT roll cylinders other than on their bottom edge.
NEVER lift cylinders by the valves.
6. Storage of gas cylinders
Storage of gas cylinders must be in accordance with AS 4332:2004 – The storage and handling
of gases in cylinders. Where one of the below gases is kept or stored, the appropriate standard
listed applies in lieu of AS 4332:2004.
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AS/NZS 2022:2003 Anhydrous ammonia – storage and handling
AS 1894:1997 The storage and handling of non-flammable cryogenic and refrigerated
liquids
AS/NZS 2927:2001The storage and handling of liquefied chlorine gas
AS 3961:2005 The storage and handling of liquefied natural gas
AS/NZS 1596:2014 The storage and handling of liquefied petroleum gas (LPG)
Whilst minimal quantities of gas may be stored indoors, it is preferred that indoor storage of gas
cylinders shall be avoided wherever possible.
Cylinder storage facilities shall:
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Be located on the ground floor and not less than 1 meter from any door, window, air vent
or duct.
Have a level base constructed of non-combustible materials.
Have adequate drainage.
Be well ventilated.
Have substantial racks or other rigid supports where cylinders can be securely attached
to prevent them from falling
Storage arrangements should allow for easy accessibility and rotation (turnover) of stock.
Be free from artificial sources of heat and clear of combustible materials.
Be secure to prevent unauthorised access.
All cylinders should be considered as full and handled with corresponding care. When empty,
the valves should be closed and the cylinders marked as empty.
Full cylinders must be stored separately from empty cylinders. Cylinders of different gases,
whether full or empty, must be segregated from each other. Example: where oxidising gases and
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flammable gases are being stored within the same storage area, they must be stored at least 3m
apart or separated by a firewall.
7. Transporting of gas cylinders
This section gives information to the requirements associated with transporting gas cylinders safely. It
is highly recommended that wherever possible,
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Avoid having to transport gas cylinders in cars and vans.
Arrange to have gas cylinders transported to and from the work site by the supplier.
If no other options are available other than using a van, utility or car, the following is recommended:
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The vehicle must be suitable for the size and type of load.
Use open vehicles or trailers in preference to enclosed vehicles or trailers.
The load must be correctly positioned and secured on the vehicle to maintain its stability.
Acetylene and LPG cylinders must always be in an upright position.
Cylinder storage area of the vehicle is well ventilated.
Remove regulators or attachments prior to transporting.
Ensure cylinder valves are closed.
8. Signage and placarding
Storage areas must clearly show signage in accordance with State Work Health and Safety and
Dangerous Goods regulations.
This includes:
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Class Diamonds and pictograms
Hazchem
No smoking and naked flame warning signs
Authorised access only
9. Essential Supporting Information
CDU Policies, Procedures and Guides
Work Health and Safety Policy
Emergency Management Plan
Risk Assessment Form
Risk Management Policy
Procurement of Goods and Services Procedures
Personal Protective Equipment (PPE) Guide
Safety Signage Guide
Workshop Safety Guide
Chemical Management Guide
Acts & Regulations
Work Health and Safety (National Uniform Legislation) Act 2011
Work Health and Safety (National Uniform Legislation) Regulations
Codes of Practice
How to Manage Work Health and Safety Risks
Managing the Work Environment and Facilities
Managing the Risks of Plant in the Workplace
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Australian and New Zealand Standards
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AS/NZS 1319:1994 – Safety signs for the occupational environment
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AS/NZS 31000:2009 – Risk management – Principals and guidelines
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AS/NZS 1596:2008 – The storage and handling of LP gas
•
AS 2030.1:2009 – Gas cylinders – General Requirements
•
AS 4267:1995 – Pressure regulators for use with industrial compressed gas cylinders
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AS 4289:1995 – Oxygen and acetylene gas reticulation systems
•
AS4326:2008 – The storage and handling of oxidizing agents
•
AS 4332:2004 – The storage and handling of gases in cylinders
•
AS4484:2004 – Gas cylinders for industrial, scientific, medical and refrigerant use –
Labelling and colour coding
•
AS4603:1999 – Flashback arresters – Safety devices for use with fuel gases and oxygen or
compressed air
•
AS 4839:2001 – The safe use of portable and mobile oxy-fuel gas systems for welding,
cutting, heating and allied processes
•
AS 5034:2005 – Installation and use of inert gases for beverage dispensing
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