A gas cylinder according the WHS Regulations, means a rigid vessel:

  1. that does not exceed 3 000 litres water capacity and is without openings or integral attachments on the shell other than at the ends; and
  2. that is designed for the storage and transport of gas under pressure; and
  3. that is covered by AS 2030.1: (Gas cylinders—General requirements)

Typically made of steel or aluminium, these cylindrical bottles hold gas such as propane, butane, oxygen, or nitrogen in compressed, liquefied, or dissolved states for applications like home heating and BBQ cooking (LPG), industrial use (Acetylene), cryogenic (liquid Nitrogen) and medical (Oxygen).

Hazards

As compressed gas cylinders contain gas stored under high pressure, and the gases are often flammable, toxic or corrosive they present a significant hazard in the workplace. Some hazard examples include:

  • fire or explosion from the release of flammable gases near ignition sources (e.g. acetylene or liquid petroleum gas) which can lead to a catastrophic rupture resulting in a rapid and large release of gas and flying shrapnel.
  • spontaneous combustion from oxidising gases (e.g. oxygen or nitrous oxide)
  • oxidizing gases such as oxygen have the additional hazard of increasing the propensity for things to burn and increase the intensity of a fire.
  • exposure to toxic or corrosive gases (e.g. anhydrous ammonia)
  • asphyxiation from some non-toxic, non-flammable gases by displacement of oxygen (e.g. nitrogen, carbon dioxide or argon).
  • low boiling point, cryogenic or liquefied gases (e.g. oxygen, nitrogen) present thermal hazards where frostbite may occur with skin contact.
  • some gases are also denser than air (e.g. LPG, carbon dioxide). On release, these gases will tend to collect in low lying areas such as pits, depressions and basements. Depending on the chemical properties of the heavier than air gas, people working in low lying areas may be exposed to the risk of fire or explosion, asphyxiation, or exposure to toxic or corrosive gases.
  • large gas cylinders (e.g. G or F sized cylinders) can also be bulky, heavy, awkward objects that could cause severe strain and sprain injuries from inappropriate handling practices.

Hazard levels are rated from A through to E, with A being the most hazardous and E the least hazardous. These hazard levels are calculated using Australian Standard - AS 4343 Pressure Equipment - Hazard Levels. The Hazard Level assessment is normally the responsibility of the designer, manufacturer, importer, or supplier.

There are several factors that contribute to the hazard level including: volume, pressure, temperature, location, usage and contents type.

Safety requirements

Risk controls for storing cylinders

  • store cylinders in cool areas away from sources of radiant heat (e.g. boilers, hot surfaces, and internal combustion engines). Where possible, store cylinders in the shade to avoid exposing cylinders to direct sunlight.
  • do not store flammable gas cylinders near sources of ignition such as naked lights or cigarette smoking.
  • where flammable gas is used, erect appropriate signs stating, 'No smoking', 'No naked lights' to prevent ignition sources in these areas.
  • wherever flammable gases are used, stored and handled, fire and explosion risks such as naked lights and ignition sources must be safely managed.
  • store gas cylinders separately from other hazardous chemicals by at least 5m or by using appropriate fire-rated barriers.
  • do not store gas cylinders in areas or structures constructed of combustible materials.
  • locate gas stores on the ground floor away from other dangerous goods (e.g. Class 3, 4, 5, 6.1, 7, 8 or 9, etc.) and combustible liquids (e.g. diesel fuel) stores by at least 5 m or more.
  • avoid storing below ground level especially if flammable, toxic or asphyxiant gases are present.
  • store heavier than air gases with caution to avoid storing where these gases can collect in low lying areas.
  • avoid storing gas cylinders in significant quantities near to or inside protected places where members of the public may assemble (e.g. places of worship, theatres, age care facilities, schools, hospitals, property boundaries).

Risk controls when gas cylinders are stored indoors:

  • store gas cylinders in well-ventilated areas to prevent build-up of escaped gases.
  • store gases outside in a cage where possible.
  • where gases are stored inside a building, a mechanical ventilation system may be required if the natural ventilation is inadequate. Expert advice should be obtained if unsure.
  • design the mechanical ventilation system to capture escaped gases, not ignite flammable gases. Ensure workers are not placed at risk of asphyxiation or exposed to gases above the relevant National Exposure Standard (NES). National standards are those stated in the Workplace Exposure Standard (WES) as specified in Workplace exposure standards for airborne contaminants published by Safe Work Australia.

Other risk controls

  • avoid ignition and electrostatic shock hazards arising from static electricity.
  • control hot work.
  • control ignition sources particularly from electrical installations or equipment.
  • they require regular inspection, including testing for valid 10-year stamps, and must always be transported/stored upright.
  • check for damage and ensure the valve is securely closed after use.
  • always transport in an upright position and check for leaks using soapy water

Safety Data Sheets

  • obtain SDSs from the supplier for each gas cylinder and keep in a register.
  • locate each SDS close to workers who may be potentially affected by the gas and ensure it is readily accessible. Also ensure that emergency responders have access to this information if required during an incident.
  • read the SDS to identify:
    • chemical and physical hazards from each gas cylinder
    • appropriate safe storage and handling practices
    • the need for additional control measures
    • first aid measures
    • firefighting and emergency information.
  • conduct and record a risk assessment to identify hazards and the need for any additional control measures.
  • provide workers with information, training and effective supervision, about the hazards from gas cylinders, safe storage and handling information and what to do in an emergency.
  • document procedures to inform workers about how to store and handle gas cylinders safely.

Safe handling practices

  • store cylinders in the upright position. Some gases (e.g. LPG and acetylene) contain a gaseous and liquid phase. Some flammable gas cylinders contain a pressure relief valve that must be in contact with the vapour phase if the cylinder is to function properly during an emergency.
  • ensure cylinders are prevented from falling or being knocked over by securing them using a racking system or using a non-abrasive, coated chain that will not scratch the cylinder markings and paint work.
  • avoid knocking cylinders about. Prevent damage to cylinders caused by impact from other objects (e.g. crashing into other cylinders). Some cylinders (e.g. acetylene) may react violently after being excessively shaken, heated, or knocked.
  • do not use cylinders as rollers to move other objects.
  • when moving cylinders, avoid rolling them. Ensure that an appropriate mechanical handling device (e.g. cylinder trolley with a restraining strap) is used. More information on manual handling of gas cylinders is available in the Victorian Government publication, Delivering large gas cylinders - A guide to manual handling.
  • wear eye protection, safety shoes and gloves in gas cylinder storage and handling areas.

Storage and ventilation

Gas cylinders should be stored outdoors, preferably in a secure, cage that's protected from sunlight. Storage indoors is not recommended unless the building has been designed for that purpose with appropriate fire-rated walls and ventilation.

Some general principles apply:

  • do not store gas cylinders in areas or structures constructed of combustible materials.
  • locate gas stores on the ground floor away from other dangerous goods (e.g. Class 3, 4, 5, 6.1, 7, 8 or 9, etc.) and combustible liquids (e.g. diesel fuel) stores by at least 5 m or more.
  • avoid storing below ground level especially if flammable, toxic or asphyxiant gases are present.
  • store heavier than air gases with caution to avoid storing where these gases can collect in low lying areas.
  • avoid storing gas cylinders in significant quantities near to or inside protected places where members of the public may assemble (e.g. places of worship, theatres, age care facilities, schools, hospitals, property boundaries).
  • store gas cylinders in well-ventilated areas to prevent build-up of escaped gases.
  • store gases outside in a cage where possible.

Heat and ignition sources

  • store cylinders in cool areas away from sources of radiant heat (e.g. boilers, hot surfaces, and internal combustion engines). Where possible, store cylinders in the shade to avoid exposing cylinders to direct sunlight.
  • do not store flammable gas cylinders near sources of ignition such as naked lights or cigarette smoking.
  • where flammable gas is used, erect appropriate signs stating 'No smoking', 'No naked lights' to prevent ignition sources in these areas.
  • wherever flammable gases are used, stored and handled, fire and explosion risks must be safely managed.

Segregate incompatible gases and hazardous chemicals

Store gas cylinders separately from other hazardous chemicals by at least 5 m or by using appropriate fire-rated barriers as:

  • corrosive liquids can damage gas cylinders on contact
  • flammable liquids can spread a fire across a workplace floor and allow flames to come into contact with gas cylinders
  • other hazardous chemicals may also be adversely affected by gas cylinders in an emergency.

Segregation of incompatible goods also allows fire fighters to safely use appropriate firefighting media for each type of goods present.

Gas cylinders must also be segregated from other incompatible gases by at least 3 m or more. The following is recommended:

  • store class 2.3 Toxic gas and corrosive gases (those with a subsidiary risk of class 8 Corrosive) away from all other gas cylinders.
  • segregate class 2.1 Flammable gas during storage from all oxidising gases.

Mutually compatible gases (e.g. Class 2.2, without subsidiary risk) may be used between incompatible gases.

Housekeeping

  • do not store objects on top of gas cylinders.
  • store full and empty cylinders separately, in clearly marked areas.
  • rotate stock, ensuring a first-in-first-out process.
  • ensure gas cylinders are stored at least 3 m away from combustible materials and debris (e.g. timber, cardboard, packaging materials).
  • do not locate gas cylinders where they may block stairs, exits, ladders or walkways.
  • keep an up-to-date and accurate inventory.
  • keep inventory quantities as low as possible.

Emergency planning

Emergency plans must be developed wherever hazardous chemicals (including gases) are used, stored and handled. Possible hazards, incidents and emergency situations should be considered, including:

  • likely types of emergencies (e.g. fires, gas leaks for each type of gas, explosion)
  • the adequacy of firefighting systems
  • access to and from the site
  • a safe evacuation area
  • the need to notify neighbours
  • providing and testing alarms
  • carrying out regular emergency drills.

Refer to the general guidance on emergency planning for hazardous chemicals.

If gas products classified as hazardous chemicals are used, stored or handled in excess of the prescribed manifest quantities in column 4 of schedule 12 of the Work Health and Safety Regulation 2011, an emergency services manifest is required at the workplace. The manifest must contain an up-to-date inventory of hazardous chemicals used, stored and handled at the workplace, including the quantity and location of each gas storage area. Schedule 12 of prescribes the information to be included in the manifest and site plan. The manifest and site plan should be kept in a red weatherproof container at the main entrance to the workplace.

Notification

If gas products classified as hazardous chemicals are used, stored or handled in excess of the manifest quantity, then notify SafeWork SA.

Placarding storage areas

Where gases are stored in excess of the prescribed placarding quantities shown in column 4 of schedule 11 in the Work Health and Safety Regulation, placarding must be erected at the following locations:

  • the main point of entry into a building
  • at either the main point of entry to a room or enclosure or other area
  • adjacent to the where the gas cylinders are being stored.

Where the prescribed placarding quantities are exceeded at a workplace, an outer warning placard stating 'HAZCHEM' must be visible from every entrance to the premises.

High Risk Work Licence

You need a High Risk Work Licence to operate specific pressure equipment.

Registration

Gas cylinders require design registration but not require plant registration.

Registration costs can be found at Registration Fees.

Design registration

Plant design registration – Guidance notes

To register or alter the design of plant:

Plant design - New or alteration to design

According to WHS Regulation 243, you must register new designs and alteration to designs covered by Section 1 of AS 2030.1: Gas cylinders - General requirements which have a calculated Hazard Level of A, B, C or D when assessed in accordance with AS 4343: Pressure equipment – hazard levels.

The pressure equipment can be designed to any internationally recognised published technical standard with the following documents being required for the registration of the plant design:

  • each model must have a separate design registration application form.
  • statement signed by the designer of the plant stating:
  • the designer has complied with their obligations under section 22 of the WHS Act.
  • the published technical standards and engineering principles used in the design.
  • design calculations and drawing(s) in English, as referenced in the designer's statement
  • an independent design verification statement.
  • payment of the fee which lasts for the life of the design (payable on completion of the online application).

Note:

  • design registration applies to all plant items manufactured to the same design.
  • design registration is valid for the life of the plant.
  • manufacturers, importers, and suppliers of plant are prohibited from supplying plant unless the design of that plant is registered.
  • design registration in SA is not required if the plant design is registered in another state under a corresponding WHS law (WHS Act 2012 (SA)).
  • any alteration to the design of registered plant that may affect health, and safety requires an alteration to its design registration.

Change of details

You must provide us with written notice within 14 days if:

  • you change your name or address, or any other information stated on your application for registration.
  • the plant design has been altered to an extent where it is subject to new control measures.

Inspection and maintenance

According to WHS Regulation 213 - Maintenance and Inspection of Plant, the person with management or control of plant at a workplace must ensure that the maintenance, inspection and, if necessary, testing of the plant is carried out by a competent person. In addition, the maintenance, inspection and testing must be carried out:

  1. in accordance with the manufacturer's recommendations, if any; or
  2. if there are no manufacturer's recommendations, in accordance with the ;recommendations of a competent person; or
  3. in relation to inspection, if it is not reasonably practicable to comply with paragraph (a) or (b), annually.
  4. According to WHS Regulation 224 – Pressure Equipment, the person with management or control of plant at a workplace must ensure that:
  5. the equipment is inspected on a regular basis by a competent person; and
  6. any gas cylinder that is inspected is marked with a current inspection mark showing the date of the most recent inspection.

The inspection must also be in accordance with AS/NZS 3788: In-service Inspection of Pressure Equipment, which outlines the responsibilities for both the inspector and the owner of the pressure equipment. The Standard incorporates a table that details the periods between routine inspections as well as information that leads the inspector through the inspection process for the various types of pressure equipment.

On completion of the inspection, the inspector will provide you with a Certificate of Inspection and a Report. The certificate must include a statement from the inspector indicating that they have conducted the inspection in accordance with AS/NZS 3788 and that the equipment is 'Safe to operate' (where this is found to be the case).

Record keeping

According to AS 2030.1, pressure receptacles shall be subjected to periodic inspection and testing by a test station which conforms to Clause 6.1 – Initial test station inspection and marking. Periodic inspection and testing shall be performed in accordance with both AS 2030 series, and AS 2337, where relevant.

A record (e.g. logbook) of the service and maintenance history of the plant needs to be kept and made readily available and be written in easy to understand English.

Refer to WHS Regulation 237.

Contact us

Visit: safework.sa.gov.au

Call: SafeWork Licensing Unit on 1300 365 255

Email: licensing.safework@sa.gov.au

Further information

SafeWork SA

Resources

Legislation

  • WHS Act 22 - Duties of PCBUs that design plant, substances or structures
  • WHS Regulation 213 – Maintenance and inspection of plant
  • WHS Regulation 224 – Inspection and management of pressure equipment
  • WHS Regulation 237 – Records of plant
  • WHS Regulation 244 – Altered plant designs to be registered

Australian Standards

Codes of Practice

FAQ - Frequently asked questions

Q1. What should a purchaser ask a supplier before purchasing a gas cylinder?

  • can they provide a copy of the design registration?
  • what is the after sales service arrangement?
  • who takes responsibility for the item of plant registration process?
  • what are the safety features?
  • for used plant, can they provide a copy of the inspection(s)?

Q2. What are the registration requirements?

Gas cylinders require design registration but not require plant registration.

They require design registration if they have a calculated Hazard Level of A, B, C or D according to AS 4343: Pressure equipment – hazard levels.

The gas cylinder supplier (who may also be the importer) has the legal duty to ensure that the gas cylinder is design registered, and that they hold a copy of the design registration certificate prior to any distribution and sale.

The design registration number issued by SafeWork SA or an interstate regulator is unique to that model and must be permanently marked on the gas cylinder.

The owner or person with management control of the gas cylinder is responsible for the item of plant registration. They will need copies of the design registration certificate, “Safe to Operate” certificate and commissioning report. They can then attach all the supporting documentation to a completed application form and send it to SafeWork SA along with payment of the fee.

Q3. Are there any registration fees?

Gas cylinders incur a fee when they are first design registered which is valid for the life of the plant.

A design registration fee applies only once for the initial application because upon issue there is no expiry date.

Q4. Who can apply for design registration?

  • a person conducting a business or undertaking (PCBU) that designs an item of plant may apply to the regulator for the registration of the design of that item of plant.
  • a person with management or control of an item of plant at a workplace may apply to the regulator for the registration of the design of that item of plant.

Q5. Duties of the Designer and Design Verifier.

The designer must undertake a design risk assessment and be satisfied through engineering calculations that the glass cylinder is at the appropriate level of safety in accordance with the published technical standards and/or engineering principles being used. The designer must declare that they “have complied with the designer’s obligations under Section 22 of the WHS Act in respect to the design of the plant.”

For design verification under regulation 252, a Design Verifier is a person who has the skills, qualifications, competence and experience to design the plant or verify the design

The Design Verifier has the important role of determining through their own independent assessment that the design satisfactorily complies with design intent published technical standards, and/or engineering principles. They must also declare that “they were not involved in the production of the design; and that the design was produced in accordance with the published technical standards and/or engineering principles specified by the designer’s statement and documents.”

The glass cylinder original design can be to any internationally recognised published technical standard including calculations and drawings. However, Design verification must declare full compliance with the applicable Australian Standards.

Q6. Can the Designer and/or Design Verifier be located overseas?

Yes. There is no requirement for the Designer and/or Design Verifier to be located in Australia. They must however fully understand their duties under South Australian WHS Legislation. Penalties apply for provision of false or misleading information.

Q7. Can a Designer and Design Verifier be employed by the same business?

Yes, the Designer and Design Verifier can be employed by the same organisation, but the Design Verifier must not have been involved in the production of the design. The design verification process must be independent of the Designer.

Q8. Does each gas cylinder require individual design registration?

No, once the design is registered, there is no restriction on the number of gas cylinders that can be supplied, provided they comply with the registered design. The registration holder must ensure the design registration number is provided with each gas cylinder that is supplied.

Q9. Is interstate design registration recognised in South Australia?

Yes, interstate design registrations issued under a corresponding WHS law (i.e. a law of another Australian jurisdiction corresponding, or substantially corresponding, to the WHS Act 2012 (SA)) are recognised in South Australia. However, it is important to ensure the gas cylinder design also complies with relevant South Australian Approved Codes of Practice.

There may be Australian States or Territories who have introduced specific variations to the WHS model legislation and while the design may comply with the legislation in those jurisdictions, it may no longer fully comply with South Australian requirements. If this is the case, item of plant registration may be refused (i.e. design registration may not be recognised) because the design does not fully comply through a corresponding WHS law equivalent to that in South Australia.

Q10. Are overseas design registrations recognised?

Every gas cylinder installed in South Australia must have an Australian design registration.

Q11. When is an Application for Alteration to a Design of a gas cylinder required?

The WHS Regulations state that “In this regulation a reference to the alteration of a design is a reference to an alteration that may affect health or safety.”

What does that mean?

'Alter' in relation to any plant means to change the design of, add to or take away from the plant where the change may affect health or safety, but does not include routine maintenance, repairs or replacements.

When a gas cylinder is first design registered, the design is based on certain criteria and specifications that set a minimum level of safety. If that level of safety is altered (i.e. structural integrity, capacity, safe operating limits) then an application for the alteration must be submitted to SafeWork SA.

Note: alterations must be compliant to the latest legislative requirements.

Q12. What happens after I submit an application for registration?

After SafeWork SA receives an application and fee payment has been receipted:

  1. SafeWork SA will check each section of application form and supporting documentation. It is important that correct information is provided.
  2. If any information is missing, SafeWork SA will contact the applicant. This may cause delays in processing.
  3. Once details are checked and any amended documents received the application will be registered.
  4. A design registration certificate will be sent to the applicant following approval. The certificate will contain information as submitted in the application form, the applicant details and design registration number.
  5. The design registration is valid for the life of the plant.

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