Gas cylinder blast controls for safety purpose.

Safety precautions for gas blast

1.   Gas cylinder blast case- 2025 Blast in Oxygen plant. 2 fatalities, Multiple injured, Property loss. Mohali- Aug 2025

2.   Gas cylinder blast cases- Possible reasons and controls 1) Cylinder fitness: Cause: Full cylinder unable to hold pressure > Improper Hydro static testing or due for Hydro testing > Failure in pre fill inspection in plant. Effect: Cylinder can’t hold pressure and can blast anywhere from filling point to consumption point at customer location. Control: Genuine hydro static testing in test shop, If cylinder testing done out side - verification of test certificates. Effective pre fill inspection. 2) Physical Damage or Corrosion Cause : Dropping, impact, rusting, or structural fatigue over time. Effect : Compromises the cylinder strength, increasing the chance of rupture. Control: Vertical transportation, Storage and securement of cylinders, customer awareness, Training to cylinder handlers. 3) Overpressure/ Over filling. Cause : Filling the cylinder beyond its rated capacity or pressure rating. Effect : Structural failure due to excess internal pressure. Control: Effective pre fill inspection , Engineering controls to avoid over pressure or over filling ( CO2, N2O etc) , maintaining good health of cylinders and avoid un approved and uncertified cylinders.

3.   4) Valve or Regulator or adapters Failure Cause : Defective or damaged valves, regulators, or pressure relief devices. Effect : Uncontrolled gas release, which can ignite or increase internal pressure dangerously. Control: Use tested and approved equipment only in plant and on cylinders also, insist customers to comply for the same. Engineering controls to Avoid adapters wherever possible and use suitable end connections. 5) Exposure to High Temperatures or Fire Cause : Cylinders exposed to fire, direct sunlight for long durations, or hot industrial processes. Effect : Internal pressure builds up; relief devices may fail, leading to explosion. Control: Engineering controls like RD fixed valves on liquid filled product cylinders ( CO2,N2O) , Effective planning in logistics for day time supplies in summer, Sufficient infrastructure, Customer awareness. 6) Gas Leaks & Ignition Cause : Faulty seals, connections, or cracked hoses. Effect : Leaked flammable gases (like Silane, Ethylene, acetylene, propane, hydrogen etc ) can form an explosive mixture with air. Control: Engineering controls like approved hoses, compatible materials usage shall be mandatory and purchase shall be from approved vendor only, Detectors/ sensors mandatory in calibrated well maintained in plant as well as at customer locations. Gas cylinder blast cases- Possible reasons and controls

4.   6) Mixing Incompatible Gases Cause : Accidental or careless mixing of gases (e.g., oxidizers and fuels). Effect : Spontaneous combustion or violent reaction inside or near the cylinder. Control: New product approval controls. MOC, Awareness to plant (Operations) and sales team. 7) Using the Wrong Type of Cylinder for a Gas Cause : Using a cylinder not rated for a specific type of gas. Effect : Material incompatibility can weaken the cylinder or corrode internal components. Control : New product purchase approval controls. MOC, Awareness to plant people. 8) Manufacturing Defect Cause : Defects in material or construction during cylinder manufacturing. Effect : Can lead to unexpected structural failure under normal use. Control: Engineering controls like approved equipment only allowed. Control on procurement from approved suppliers and approved vendors for service related . Gas cylinder blast cases- Possible reasons and controls

5.   9) Improper Storage Cause : Storing cylinders in unsafe environments—poor ventilation, heat sources, or unstable positions. Effect : Increases risk of leaks, overheating, or toppling. Control: Engineering controls for storage and protection, Awareness for all cylinder handlers including customers on distance to be maintained between non compatible gases. Protection barriers requirement etc. 10) Tampering or Unauthorized Modifications Cause : Unqualified individuals attempting repairs, refills, or alterations. Effect : Critical safety systems may be bypassed or damaged. Control: Critical operating parameters ( COP) and operational safety standards (OSS) Shall be known to all. Engineering controls with regular calibration requirements/ preventive maintenance shall be defined to all critical equipment. All tasks shall be through approved vendors/ approved work force in plants. Gas cylinder blast cases- Possible reasons and controls

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