How Can We Improve Our SOP for Storing and Handling Compressed Gas Cylinders?

I am attaching the Standard Operating Procedure (SOP) for storing and handling compressed gas cylinders. Please review and suggest any changes if necessary.

Regards,
Sudhir

Thank you for sharing the attachment with us. It's a good document, no doubt, but not perfect. Can you help me in bringing clarity to the following:

Distance Requirements for Oxygen and Fuel Gas

How much distance should be maintained while transporting and in use between oxygen and fuel gas (LPG or DA)? If you can provide a reference to any act or rule, it would be very helpful to me. Also, may I suggest adding this to your procedure?

Thank you.

To the best of my knowledge, the Acts or Rules such as the Factories Act and the Compressed Cylinder Rules are silent on the distance to be kept between the oxygen and fuel gas. However, good engineering practices would recommend using a combined trolley for transportation. You have to ensure that the LPG or DA does not leak and that the hoses are free from cracks. The red hose should be used for fuel gas, and the black hose for oxygen. If you have any different views, please share.

Regards,
Sudhir

Dear Sudhir,
Thanks for your feedback. Go through the attachment. In this accident, three people died. In almost 99% of places in India, gas cylinders are being shifted in such types of vehicles, and in the same, both fuel and oxygen cylinders are mixed up.

Safety Concerns in Cylinder Transportation

In my opinion, the industry-wide practice of transporting both oxygen and fuel gas in one trolley is also not safe. If they are transported in one trolley, they will be kept together in the cylinder even while in use.

I request all members to go through the attachment and comment on safe transportation (1. In Site (Internal) and 2. from Supplier to Site) and the safe distance to be kept while the cylinders are in use.

Thank you.
Regards

This refers to the earlier post. I was thinking about transportation within the factory premises, which is usually done on a manual trolley. Thank you very much for the pictures; they will be good for training.

Fire Chemistry

As per fire chemistry, a fire will occur only if the following three elements combine together:

1. Oxygen
2. Fuel
3. Spark

I feel in the above incident, while the oxygen cylinders were being unloaded, one must have rolled over an LPG cylinder, causing friction and thereby generating a spark. Probably, the LPG was leaking, which caught fire and exploded. Please refer to photograph no. 2 on page no. 1 of your PDF file.

Observations

According to me:

1. The LPG cylinder looks to be expired.
2. The cylinder valve is not proper.
3. The valve safety ring is not visible in photograph no. 2.
4. There is every possibility that the cylinder was leaking.

After the expiry of cylinders, these are taken out of circulation and sent to an authorized agency for inspection and hydro pressure testing. If found OK, they can be reused. Such agencies have very strict rules and regulations. I have audited one such party; these parties take care of all the tests and have perfect records.

Please find attached herewith the abstract of Gas Cylinder Rules and refer to rule 35 on page no. 17. It is clearly mentioned that fuel gas cylinders should not be transported together with any other gas. Therefore, your question of "how much distance to be kept while transportation" is answered.

We will have to train the procurement engineers to make a purchase order clause that "fuel gas cylinders shall be supplied separately," although at slightly extra freight. Your pictures would help convince procurement engineers. Thanks again.

Best Regards,
Sudhir

Thank you for your feedback and for attaching the abstract of the gas cylinder rules. I have attached a photograph of the gas cylinder trolley that is mostly used by us. Please review it and provide your comments on the following:

1. Is this internal transportation safe?
2. If both cylinders are placed on this trolley during use, is it safe? If not, what is the recommended distance between them?

Thank you in advance for your insights and for sharing your expertise with us.

Regards

Dear Sir,

Asudhir17, in your document, you mentioned:

"Empty and full cylinders should be stored in separate areas."

Why should empty and full cylinders be stored separately? I know it is easier for identification during transportation. Is there any other reason?

Thank you.