INTER PLANT STANDARD – STEEL INDUSTRY

SAFETY STANDARD ON STORAGE,

HANDLING & USE OF GAS IPSS: 1-11-029-17
CYLINDERS IN STEEL INDUSTRY
IPSS

Corresponding IS does not exist

0. FOREWORD

0.1 This Inter Plant Standard prepared by Standards Committee on Safety

Appliances and Procedures, IPSS 1:11, with the active participation of the
representatives of all the steel plants was adopted in January 2017.

0.2 Objective of this Standard is to provide a safety guideline for storing, handling
and use of gas cylinders. However, medical gas cylinders are not in the scope
of this standard.

1.0 SCOPE

1.1 To provide a safety guideline for storing, handling and use of gas cylinders.
However, medical gas cylinders are not in the scope of this standard.

1.2 Responsibility for implementation of this standard lies with all executing
departments like Engg. & Projects, Engg. Services, Maintenance Departments
and Contractors,

2.0 Associated Hazards:

2.1 Fire / Explosion / Gas Leak / Bursting of Gas Cylinders/ hit by cylinders.

3.0 License requirement as per Statutory provisions

3.1 The license in Form-F under Gas Cylinder Rules 2004 is required for storage
i.e., possession of cylinders filled with compressed gas. The license in Form-F
is granted by respective Circle offices of the Department of Explosives. But
when storage shed of cylinders is attached to the gas filling plant, the license is
granted for storage of cylinder in the filling plant along with license for filling by
the Chief Controller of Explosives, Nagpur.

3.2 No license needed for possession in certain cases as per Rule-52 of Gas
Cylinder Rules, 2004.

3.2.1 possession of any cylinder filled with a compressed gas by a carrier or other
person for the purpose of transport in accordance with the provisions of these
rules;

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3.2.2 Possession of cylinders filled with –

 Liquefied petroleum gas when the total quantity of gas does not exceed
100 kg at a time;
 Any other flammable but non-toxic gas when the total number of cylinders
containing such gas does not exceed 25 or the total weight of gas does
not exceed 200 kg., whichever is less, at a time;
 Any non-flammable non-toxic gas when the total number of such
cylinders does not exceed 200 at a time;
 Any toxic gas when the total quantity of such cylinders does not exceed 5
at a time;

4.0 General safety precautions for storage of cylinders.

 The gas cylinder storage shed must be located in an isolated area, as far
as practicable.
 The gas cylinder storage shed shall have roofing to protect from direct
sunlight and have adequate ventilation.
 Gas cylinders shall not be stored in exits or egress routes.
 Gas cylinders shall not be stored in damp areas, near salt or corrosive
chemicals, fumes, heat or in areas exposure to the weather.
 The gas cylinder storage shed shall not be located close to any
inflammable chemicals / fuel storage area / source of combustion
activities / open flames / steam pipes.
 Full and empty cylinders are to be stored separately.
 The gas cylinders shall be stored in segregated manner, considering
incompatibility (example bulk DA & bulk Oxygen; bulk Hydrogen & bulk
Oxygen, bulk LPG & bulk Oxygen, toxic and flammable gas cylinders).
Incompatible gas cylinders must be stored at least at a gap of 3 meters.
 Incompatible gas cylinders must not be transported together.
 The store in-charge / supervisor shall maintain the up-to-date inventory of
Gas cylinders.

 Other than notified gas cylinders, no other material of any kind shall be
stored inside the area.

 All the gas cylinders shall be kept in upright position with chaining to
prevent accidental fall.

 A system of marking of gas cylinders for their individual identification &

record of their hydrostatic test to be maintained by custodian deptt.

 All gas cylinders shall be capped when not in use.

 All gas cylinders shall be stored so that cylinders are used in the

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order in which they are received.

 The gas cylinder storage area shall not have any loose electrical cables,
wires or lines in the vicinity.

 Do not keep cylinders in battery room or oil storage room.

 Adequate warning signs / labeling / no smoking caution / safety

instructions shall be displayed in the gas cylinder storage area in legible
manner.

 Display of material safety data sheet (MSDS) of the stored gas at

appropriate place in legible & in local language/ English.
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5.0 Handling and Usage

 Gas Cylinders shall be handled only by properly trained persons. Training

must include the contents of this guideline as well as any specific
information relevant to the gas being used. While handling cylinders, the
cylinder shall not be dragged or rolled.

 Instructions shall be issued to all suppliers for mandatory affixing of cap

guards, providing color coding and warning sticker as per Gas Cylinder
Rules, 1981. In addition, supplier shall issue Test and Inspection
Certificates.

 Do not issue a cylinder unless contents are clearly identified.

 Do not alter the color coding and marking of Gas Cylinders, as given below.
Type of Gas Cylinder Color Coding
Non-flammable & non-toxic --
Non-flammable but toxic Yellow
Flammable but non-toxic other than LPG Red
Flammable and toxic Red and Yellow

 Do not use cylinders as rollers, work supports or jacks (sliding, dropping or

playing with cylinders shall be strictly prohibited.)
 Prevent damage to cylinders. Locate cylinders where they will be protected
from physical damage by striking or falling objects, corrosion or damage
from public tampering.
 Containers shall not be used for any other purpose than holding the
contents as received.
 Damaged or leaking cylinders must be reported immediately for proper
disposal. Cylinders shall not be picked up by pulling the cap.
 Magnets shall not be used for lifting cylinders.

 Lowering & lifting of cylinders shall not be done manually. It shall be done
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by mechanized means (using winch, telfer, crane etc.) with proper cage for
holding the cylinders.
 Where appropriate lifting attachments have not been provided on the
cylinder/container, suitable cradles or platforms to hold the containers shall
be used for lifting.
 Do not use welded cylinders
 Leaking, defective, fire burned and corroded containers shall not be used.
 Do not use chain slings for lifting cylinders; only fiber sling should be used.
 Do not allow cylinders to come in contact with electrical apparatus or live
wires.
 Do not lay gas cylinders on wet soil.
 Do not lubricate cylinders valve threads.
 Do not handle cylinders or valve assemblies with greasy hands or oil rags
 Oil or grease shall not come in contact with the cylinder valve assembly or
the regulator fittings.
 Use red hose for acetylene and other fuel gases and black / green hose for
oxygen. Never interchange hoses.
[

 To train workmen to handle and store dangerous cylinders properly and in

case of any problem, it has to be capped and sent back to the supplier.
 Nozzle tips shall be always kept clean to prevent back fire.
 Use hoses of equal length and do not coil the hoses around regulator or
cylinder.
 Ensure that regulator pressure control valve is relieved (i.e., closed) before
attaching to tanks.
 Close valves on gas cylinders when a system is not in use.
 Remove all pressure from regulators not currently used (by opening
equipment valves downstream after the regulators are closed).
 Shut-off valves must not be installed between pressure relief devices and
the equipment they are to protect.
 Use pressure relief valves in downstream lines to prevent high pressure
buildup in the event that a regulator valve does not seat properly and a
tank valve is left on.
 Relief valves should be vented to prevent potential buildup of explosive or
toxic gases.
 Never allow flames or concentrated heat sources to come in contact with a
gas cylinder.
 Never allow a gas cylinder to become part of an electrical circuit.
 Never partially open a tank valve to remove dust or debris from the
cylinder inlet.
 Never use cylinder gas as compressed air.
 Pressurize the regulators slowly and ensure that valve outlets and
regulators are pointed away from all personnel when cylinder valves are

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opened.
 Cylinders which require a wrench to open the main valve shall have the
wrench left in place on the cylinder valve while it is open. Use adequately
sized wrenches (12” long) to minimize ergonomic stress when turning tight
tank valves. Never apply excessive force when trying to open the valves.
Cylinders with “stuck” valves should be returned to suppliers to have
valves repaired.
 Do not attempt to open a corroded valve; it may be impossible to reseal.
 Valves should only be opened to the point where gas can flow into the
system at the necessary pressure. This will allow for quicker shutoff in the
event of a failure or emergency.
 Use a cylinder cap hook to loosen tight cylinder caps. Never apply
excessive force or pry off caps. Return to supplier to remove “stuck” caps.
 Keep piping, regulators and other apparatus gas tight to prevent gas
leakage.
 Confirm gas tightness by using compatible leak test solutions (e.g., soap
and water) or leak test instruments.
 Release pressure from systems before connections are tightened or
loosened and before any repairs.
 Never use adapters or exchange fittings between tanks and regulators.

 Ensure flash arrestor for cutting purpose.

5.1 Manifolds, Valves and Regulators

The following information applies to the use of manifolds, valves and/or

regulators:
 Where compressed gas containers are connected to a manifold, the
manifold and its related equipment, such as regulators, shall be of proper
design for the product(s) they are to contain at the appropriate
temperatures, pressures and flows.

 Use only approved valves, regulators, manifolds, piping and other

associated equipment in any system that requires compressed gas. Care
must be taken to ensure that pressure gauges on regulators are correct for
the pressure of the gas cylinder used.

 Valves and regulators should undergo periodic maintenance and repair. A

visual inspection should be performed before each usage to detect any
damage, cracks, corrosion or other defects. Long term maintenance or
replacement periods vary with the types of gases used, the length of use,
and conditions of usage.

 Valves and regulator maintenance histories should be known before

usage. Valves that pass visual inspection are still subject to failure,

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therefore it is critical that toxic or poisonous gases are used in ventilated
enclosures and have local exhaust ventilation in place for downstream
pressure relief valves, etc.

 Valves and regulators should only be repaired by qualified individuals

 Display the license no. if the number of industrial LPG cylinders stored is
more than five.
5.2 Gases with specific hazard classes

The following information regarding specific classes of gases is offered as

additional guidance to be used in conjunction with the general usage
requirements listed previously:

5.2.1 Flammable Gases

 Flammable gases, except for protected fuel gases, shall not be used near
ignition sources. Ignition sources include open flames and sparks, sources
of heat, oxidizing agents and ungrounded or non-intrinsically safe
electrical or electronic equipment.
 Portable fire extinguishers shall be available for fire emergencies. The fire
extinguisher must be compatible with the apparatus and the materials in
use.
 Flames shall not be used for detecting leaks. A compatible leak detection
solution shall be used for leak detection.
 Spark proof tools shall be used when working with or on a flammable
compressed gas cylinder or system.
 Access doors to areas which use or store flammable gases shall be
posted "No Open Flames."

5.2.2 Fuel, High Pressure and Oxidizing Gases

 Oxidizing gases are non-flammable gases (e.g., oxygen), but in the

presence of an ignition source and fuel can support and vigorously
accelerate combustion. Do not use oil in any apparatus where oxygen will
be used.

5.2.3 Toxic and Highly Toxic Gases

 Unless otherwise indicated, all gases must be stored in a continuously

mechanically ventilated gas cabinet, fume hood or other enclosure.

5.3 Handling leaks and emergencies

5.3.1 Preplanning
Despite strict adherence to safety practices, accidents involving gases may
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occur. Users of compressed gas cylinders must be familiar with necessary
safety precautions. Standard Operating Procedures for using compressed
gases shall include a discussion of possible accident scenarios, appropriate
employee responses and should take into account the following factors:

 The nature of the operation (e.g., equipment used and type of injury that
might be inflicted).

 The quantities of material that might be released and the type of

containment (i.e., compressed gas tank size, manifold systems, etc.).

 The chemical and physical properties of the compressed gas

 The hazardous properties of the compressed gas (e.g., its toxicity,

corrosivity and flammability).

 The availability and locations of emergency supplies and equipment.

 A contingency plan which identifies building evacuation routes, emergency

telephone numbers, chemical containment procedures, fire extinguisher
usage, etc., should be posted at the site

5.3.2 Minor Leaks

Occasionally a gas cylinder or one of its component parts may develop a

leak. Most of these leaks occur at the top of the cylinder in areas such as
the valve threads, pressure safety device, valve stem and valve outlet. The
following information applies to the remediation of minor leaks:

 If possible, verify suspected leaks using a flammable gas detector or

soapy water solution (a flame should not be used for detection). If the leak
cannot be stopped by tightening a valve gland or packing nut, emergency
action procedures should be initiated and concerned person should be
notified.

 For flammable, inert or oxidizing gases, the cylinder shall be moved to an

isolated & well-ventilated area away from combustible materials. Post
signs that describe the hazard.
 For corrosive and toxic gases, the cylinder shall be moved to an isolated,
well-ventilated area and use suitable means to direct the gas into an
appropriate chemical neutralizer if possible.

 If it is necessary to move a leaking cylinder through populated portions of

the building, place a plastic bag, rubber shroud or similar device over the
top and tape it (duct tape preferred) to the cylinder to confine the leaking
gas.

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5.3.3 Major Leaks

 In the event of a large gas release or if an accident takes place in which

readily available personal protective equipment (PPE) is inadequate to
ensure worker safety, activate the following Emergency Procedures:

 Immediately call Fire Brigade and report the incident.

 Activate building and area fire alarms.

 Evacuate the area, securing entrances and providing assistance to others

on the way out.

 Provide emergency response officials with details of the problem upon

their arrival.

5.3.4 Accidents Involving Personnel Injury

Assist persons involved and administer immediate first aid which may
include:

 Washing under a safety shower (in case of burning clothing or chemical

exposures).

 Removing contaminated clothing.

 Wash the eyes properly at eyewash station.

 Administering artificial respiration.

 Notify personnel in adjacent areas of any potential hazards (e.g., activate

building or area alarms).

 Move injured personnel only if necessary to prevent their exposure to

further harm.

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