Gas cylinders are used in an enormous range of activities; from industrial welding to deep sea diving,

from the production of semiconductors to patient care in hospitals, from heating factories and

warehouses to calibrating police intoximeters. Industrial gas companies are involved in supplying all

of these applications and take great care to ensure that the cylinders you receive are suitable and

safe, and will meet your requirements. It is important, however, that you understand the hazards

associated with them and the steps to be taken to use them correctly and, therefore, safely. This

booklet is intended to cover the basic considerations in this respect and point the way towards the

safe and effective use of gas cylinders so as to protect you and your workforce.

The following text will concentrate on the commonly encountered gases in the party industry – Helium

and Nitrogen. Gases for more specialised applications including toxic and highly toxic gases and gas

mixtures are not covered in this booklet. Information on these can be obtained on request from your

Industrial gas supplier.

Over the next few pages guidance will firstly be given on how to identify the common gas cylinders.

This will be followed by consideration of hazards common to all gases in cylinders and then specific

types of hazards. A description of the properties of certain gases will then be given, together with the

specific precautions to be taken in each case. The text will then move on to describe the safe

methods of handling cylinders, followed by recommendations for storage and a brief overview of

transport considerations. A summary of precautions is then given and finally, details on where to

obtain further information. A certain amount of detailed information is included in the appendices for

completeness.

Gas cylinders are engineered and prepared to provide useful quantities of Helium gas for a wide range

of applications. Used correctly they are quite safe, with a safety record that is the envy of many

industries. Industrial gas companies are committed to ensuring that this situation continues. Please

read this booklet and apply it to your workplace - it is important.

In 1868, during observations of a solar eclipse in India, French astronomer, Pierre-Jules-César

Janssen first obtained evidence of the existence of the gas when he detected a new yellow line in the

solar spectrum. Sir Norman Lockyer, an English astronomer, recognised that no known element at

that time gave this line and named the element helium after helios, the Greek word for the sun. It was

not until 1895 that Sir William Ramsay isolated helium after treating cleveite, a uranium bearing

mineral, with mineral acids. Ramsey subsequently sent samples to Sir William Crookes and Sir

Norman Lockyer who finally identified the gas as helium.

Although it is found in trace quantities in the atmosphere it would be far too expensive to remove.

Your helium comes from natural gas wells in the USA or North Africa where it is separated from the

natural gas, collected and liquefied for transport to the UK in specially constructed road tankers. The

liquefied helium is then converted back into gas and pumped into cylinders.

Yes, helium is used for balloons. From latex and

mylar foil balloons for messages, decorating and

balloon releases, to larger meteorological

balloons carrying analytical equipment high

above the earth for weather forecasting purposes.

Airships are increasing in numbers around the

world. Their uses include advertising, TV

platforms, surveillance, military and passenger

pleasure flights. This increasing market requires

helium both for initial inflation of the aircraft and

top up volumes. Airships vary in size from

2,000m³ to 7,000m³ helium capacity.

The latest use for helium in the lighter than air category is tethered

passenger balloons. Tethered balloons can carry up to 30 people to a

height of 150 metres, each balloon requires 6,500m³ for initial inflation

and top up volumes of 140m³ per month.

1 cubic metre of helium will provide 1.02 kilograms of lift.

As a guide 1 cubic metre of helium will inflate approximately 88 x 11"

latex and 65 x 18" foil balloons.

There is only one certain way of identifying the contents of a gas

cylinder. That is by the label located on the the shoulder of the cylinder. Along with most of the

existing industrial gas cylinder colours, the colour of Helium cylinders is in the process of changing,.

Therefore, the colour of the cylinder cannot be used as a reliable means of identification.

In some cases there may also be stencilling or a composition label on the body of the cylinder. This is

merely a further means of identification which is used for some applications and differs from the

labelling or colour dose as there is no standard or legal requirement for this method.

The labels on the shoulder of the cylinder give detailed information on the gas that is contained within.

The provision of this information is a legal requirement under EU chemical labelling and classification

regulations and the requirement of UK and European regulations for the transport of dangerous

goods. Details will be given such as the name of the gas and the the chemical formula. There will

also be brief information about the hazards and necessary precautions and what are known as risk

and safety phrases to indicate precautions for the safe handling and use of the gas.

Professional users of gases must also aquaint themselves with the contents of the appropriate

Material safety data Sheet (MSDS) as this document will give all the information needed to make

ensure the safe use of the gas and advice for emergency situations. You can obtain a copy of the

MSDS free of charge from your gas supplier. Very often they can be downloaded from the company

web site.

The cylinder label will also have what is known as a “UN number” This is a number given to some

chemicals by a committee of experts at the United Natuons so potentially hazardous chemicals can be

quickly identied without the need to translate product names into an understandable language.

Helium UN number is 1046 Class 2.2.

If you know the UN number for a chemical you can very quickly obtain the product or chemical name

and establish what hazards it may present and what precautions you need to take to make sure that

you stay safe. The other useful piece of information is the “Class”. Helium is Class 2.2 which

immediately indictes the gas is non-flammable and non-toxic. Other gases will be classed as 2.1 or

2.3 indicating the gas is flammable (2.1) or toxic (2.3). Since the colour bands on the cylinder

shoulder do not specify this, as above, the UN number provides a useful means of determining the

overall properties of the mixture. To reiterate, this label is the primary means of identification and

should be read and acted upon. If the cylinder is not labelled, the contents are uknown and the

cylinder must not be used or transported. It should be set aside and the gas supplier informed.

Currently, industrial gas cylinders in Britain are colour coded according to the requirements of British

Standard BS 349, and the actual colours used are specified in British Standard BS 381. These

standards lay down specific colours for the various common gases, together with a protocol for colour

coding gas mixtures. There is a general rule that red is used to denote flammability, whereas yellow is

used to denote toxicity. Like most things in life, however, this is not an absolute rule and there are

exceptions. All Helium supplied in the UK are currently colour coded Brown.

BALLOON GAS - Facts, Figures, Safe Handling & Legislation

Helium is a noble gas, it is inert, colourless,

odourless, non-toxic, non-flammable, nonexplosive

and non-radioactive. It will not

combine chemically with any other element.

Helium is unique in that it combines, inertness,

high thermal conductivity, low boiling point,

lightness and small molecular size, properties

that are normally associated with many

industrial gases. Because of this its uses and

applications are many. Helium is the lightest

of the inert or noble gases.

Helium also has the lowest boiling point, 4.2°K

(-268.8°C) of any element. This property

makes liquid helium useful as a cryogenic

refrigerant and essential in superconductivity

applications.

Molecular Symbol He

Molecular Weight 4.0026

Boiling Point (1 atm) 4.2°K (-268.8°C)

Boiling Point

0.125 g/cm³

124.9 g/l

Gas Density at Normal

Boiling Point

0.01689 g/cm³

16.89 g/l

Gas Density at NTP (1 atm &

70°F)

0.1657 g/l

Gas Density at STP (1 atm & 0°C) 0.1785 g/l

Latent Heat of Vaporisation at

Normal Boiling Point

4.88 cul/g

20.4 joules/g

609 cul/l

8.78 Btu/lb

2.42 Btu/l

Thermal conductivity of gas at

NTP

Thermal conductivity of gas at

STP

Volume expansion, Liquid at NBP

to Gas at NTP

753.8 to 1

Volume expansion, Liquid at NBP

to gas at STP

699.7 to 1

By way of introduction into the hazards of specific gases, it is useful to review some general properties of

any gas which might lead to injury to anyone coming into contact with them. These properties include

the pressure of the gas inside the cylinders and its ability to expand quickly to very large volumes.

Firstly, to be of any practical use cylinders need to contain a significant quantity of gas compressed to

as high a pressure as possbile. By simple laws of physics, the higher the pressure the smaller the

volume occupied by the gas, hence the smaller and more manageable the cylinder can be made. In

the last twenty years there has been an increase of approximately 60 per cent in the amount of gas

put into cylinders. Stored pressures of 300 bar (over 4,500 psi) are now becoming commonplace.

There is thus a great deal of stored energy inside the thick walls of the gas cylinder - energy which is

very useful to the operator, but needs to be controlled to prevent it causing harm. In particular, gases

released from a cylinder whether by controlled opening of the valve, shearing of the valve or through a

leak, can have a very high velocity. It is estimated, for example, that should the gas be released

suddenly from a modern high pressure cylinder, the resulting force would be sufficient to accelerate

the cylinder to a speed of 35 miles per hour in a tenth of a second! It is also possible that dust

particles or debris from the working area, may become entrained in the gas flow and cause injury to

the eyes, face or other parts of the body.

Secondly the volume of gas stored under pressure within a cylinder will occupy much larger volumes

when expanded to atmospheric pressure. It is important to realise the potential this volume of gas

might have for displacing breathable air, or creating an explosive atmosphere at the work place. The

majority of gas companies fill cylinders to 200-300 bar. The gas contained in a 50 litre cylinder

compressed to 200 bar will fill a space 8.5 cubic metres in volume if it were all released to

atmosphere.

Finally, when gas under pressure in a small volume expands rapidly to a lower pressure, it takes in

heat energy from the surroundings. This principle is used very effectively in refrigeration systems.

Although it makes for a very interesting scientific experiment, it can lead to serious problems for the

unwary user, since in some circumstances the heat drawn from the metal in valves and regulators can

cause them to freeze and frost up. If these metal parts are then touched, frostbite and cold burns can

be caused which are very painful and difficult to treat. This sort of situation can occur if a valve is left

cracked open or a valve failure develops. Anyone who has filled a gas-fuelled cigarette lighter can

attest to the cooling effect of gas expansion!

BALLOON GAS - Facts, Figures, Safe Handling & Legislation

Armed with the information given earlier, it is essential that all users of gases identify the contents of

cylinders before attempting to use them and have ready the label to familiarise themselves with the

hazards and precautions necessary.

It is also essential that users understand how to operate cylinder valves, pressure regulators and any

other equipment supplied for use with the cylinder. This may sound simple but it is amazing how

many incidents result from a lack of understanding of how to shut off a valve or close down a

regulator.

All British cylinder valves are closed by turning the valve clockwise and are opened by turning it anticlockwise.

Regulators are shut off by screwing them out (that is anti-clockwise). Screwing them in (that is

clockwise) raises the pressure.

Valves should never be closed with such force that they require undue leverage to open. If a valve is

difficult to seat adequately without applying a high torque, set the cylinder aside, mark clearly "DO

NOT USE" and notify the gas supplier.

As well as understanding the properties and characteristics of the gas being used, how to get the gas

out of the cylinder safely (and how to keep it in when necessary), users must have a good knowedge

of the application itself. Although many DIY enthusiasts are casual users of the gases, they use them

at their own peril if they do not carefully study the available data and safety sheets for the gases and

the instruction manual supplied with the equipment. All gas and equipment suppliers should provide

literature and suitable training material for operators and there are many Industry and Government

sponsored courses available for a range of applications.

Every gas has to be supplied with a Material Safety Data Sheet which details the chemical and

physical properties and characteristics of the gas; as well as providing advice on use, handling,

storage and transport. Any limits for safe use are also detailed. All users must ensure that they are

familiar with the information contained in these sheets for the gases they are using.

The most likely cause of a sudden release of gas at high pressure from a cylinder is the valve

shearing off as a result of impact, since the valve is the most vulnerable part of the cylinder. It is for

this reason that the majority of cylinders supplied by gas companies are fitted with valve protection

guards, which must be in place before attempting to handle and move the cylinders.

In order to protect against two of the general characteristics mentioned earlier, namely high pressure

and possible low temperature created by escaping gas, users should always wear some sort of

personal protection when handling or using gases.

Safety glasses or goggles, approved to BS 2092 should be used to protect the eyes from high velocity

gases or particles carried in the gas stream. Gloves or gauntlets should be worn to proect the hands

from cold burns and other injuries. Protective footwear should be worn to avoid injury from falling

cylinders. Clothing should be made from highly combustible materials particularly when using Oxygen

or fuel gases. Additional protective clothing may be required in awkward work locations.

Helium is odourless, colourless, is non-toxic and is much lighter than air. It is inert and will not burn or

support combustion. It is however, a simple asphyxiant and in high concentrations it will displace the

oxgen in the air when it will give rise to a risk of asphyxiation. Under no circumstances should Helium

be inhaled.

Helium cylinders are currently colour coded BROWN.

Throughout industry manual handling accounts for over a third of reported accidents. Common

injuries experienced include slipped discs and other back injuries such as sciatica, strained muscles

and torn ligaments as well as associated types of injuries as a result of contact with the materials

being handled.

BALLOON GAS - Facts, Figures, Safe Handling & Legislation

It was in an attempt to combat this trend that the Manual Handling Operations Regulations 1992 were

brought into effect. These regulations oblige employers to remove or at least reduce the necessity for

manual handling, or if this is not possible, to assess the risks and implement suitable safety measures. The

HSE subsequently produced guidance on the regulations.

Users of industrial gases face particular issues in this respect. A large cylinder (50 litre water capacity) can

weigh anything between 60 and 100 kilograms, and is a relatively unstable mass of metal. They are designed

for a particular task - containing the maximum amount of gas in the smallest practical package. Given this

primary purpose they are not the easiest of objects to handle or move. Many injuries have followed from poor

methods of handling and the misuse of cylinders has caused injury and damage to property.

The easiest, safest and therefore the best way to handle and move gas cylinders is with the help of

mechanical aids. These range from specially designed vehicles for transporting them, through fork lift trucks

for loading and unloading them, to cylinder trolleys for moving them around. The use of these devices is in

line with the requirements of the regulations to 'automate' handling if the need for it cannot be removed.

In the case of single cylinders, it is often more appropriate to use devices such as tail lifts, whereby cylinders

can be churned onto the platform and lowered to the ground. Manually dropping cylinders onto the ground, or

the reverse action of attempting to manually lift cylinders onto the deck of a vehicle are to be avoided at all

costs. Such actions can result in serious strains and sprains, or damage to the cylinders with consequent

risks.

The last, but not least, mechanical aid to mention is the cylinder trolley. This again is a purpose designed

device which usually holds one cylinder at a time, secured by a chain to prevent it from falling out. It

provides the safest method of moving cylinders around premises, in particular where the user is

inexperienced in handling cylinders or where the ground is uneven.

During the handling of cylinders it is almost inevitable that at some point the cylinder will have to be

moved by hand. This could be when moving it around a room, moving it into position on equipment or

where a cylinder trolley is not available. This is an acquired art but some guidelines can be given here.

Churning cylinders requires the use of both hands. One hand holds the top of the cylinder on the valve

guard to steady and support it, whilst the other imparts a rotary motion to the body of the cylinder, thereby

spinning it along the ground on its axis. It is important to lean the cylinder over from the vertical by just the

right amount while doing this. Leaning it over too far can result in the cylinder spinning out of control, while

not leaning it over far enough will make it difficult to make any progress. It is recommended that protective

footwear (with steel toe-caps) and suitable gloves are worn whilst doing this to protect against impact on

the feet from the cylinder and trapping fingers respectively. The distance that cylinders are churned should

be kept to a bare minimum.

One of the hazards of handling cylinders concerns the risk of injury should the cylinder fall or be knocked

over. Care should be taken to prevent this from happening, but the general advice here is that if a cylinder

does start to fall over, do not try to catch it. Stand clear and let it fall. Serious back injuries have resulted

from attempting to catch falling cylinders, the weight of which can be equivalent to that of a large person.

Under the vast majority of conditions, it is unlikely that the cylinder will come to any harm and the valve

should be protected from shearing off by the valve guard.

If a cylinder has fallen over there is a safe method for picking it up, especially in the case of the largest

cylinders. Approach the cylinder and crouch at the top (valve end) of the cylinder, facing down the cylinder

body. Adopting a balanced posture, check that the valve is closed and the valve guard is securely

attached. Grasping the valve guard, straighten the back, lift up and at the same time slowly rise from the

crouching position and walk forward until the cylinder has been raised to the vertical. Steady the cylinder

and ensure that it is stable before leaving it.

From the above, it is clear that only one cylinder at a time should ever be churned. It is impossible to

properly control more than one cylinder at a time, however impressive it may look. If a cylinder has to be

lifted a small amount, e.g. onto a pallet, it is recommended that a suitable mechanical aid or, failing this, a

short ramp is used, rather than trying to pick up the cylinder.

Cylinders should never be deliberately dropped or hit sharply. They should also never be used for any

other purpose, e.g. as supports or rollers. They should never be rolled horizontally along the ground

as damage can be caused and the cylinder markings obliterated. They should also never be allowed

to come into contact with an electrical supply or electrical equipment. Direct heat or flames should

never be used on them and they should be adequately protected from these at all times. Finally,

cylinders should never be hoisted by the valve guard - this is designed to protect the valve not as a

lifting handle.

BALLOON GAS - Facts, Figures, Safe Handling & Legislation

This is a potentially complex subject, given the variations in types of premises and the mix of gases

being stored. Without full details on these issues, only the sort of matters that need to be covered can

be addressed. Any further guidance would have to be on an individual basis.

The chief concerns of any facility for storing gases relate to the control or elimination of the hazards

presented by flammable, oxidising, asphyxiating and toxic gases.

The storage facility should be in the open wherever possible. Storage inside buildings presents many

potential problems relating to ventilation, flammable zone ratings etc, most of which can be avoided by

storing the gases in the open air.

The facility should be secure, sufficient to prevent unauthorised access as far as practicable. Where

possible a perimeter fence to a height of 1.8m is recommended. For fenced compounds adequate

means of access and escape should be provided, usually entailing the provision of two exits, with any

gates opening outwards. The cylinders should be stored on a flat, firm surface, preferably concrete as

an impermeable medium. This surface should be adequately maintained so as to provide a stable

base for the cylinders. The storage surface should be adequately drained to avoid the cylinders

standing in water which would lead to corrosion of the cylinder bases. If stored adjacent to buildings

avoid proximity with doors and gangways and especially in the case of lighter than air gases -

windows and other openings.

.

Good housekeeping is important. Separate full cylinders from empty and avoid the accumulation of

rubbish etc, particularly combustible materials.

Individual gases have individual storage requirements, which are mentioned below.

.

.

These are classed as inert, or relatively inert gases and so can be stored adjacent to most other gases

if required. The main hazard presented by these is as an asphyxiant due to their ability to displace

breathable air in an enclosed space.

There is a plethora of legislation covering the transportation of gases, much of which is common to all

products classed as hazardous. Such legislation specifies the method of transportation, the safety

requirements for various quantities and the information that must accompany the load. Some of the

basic requirements will be covered here.

In the UK, the road transport of dangerous goods in governed by an EU wide standard known as the

ADR. This 1200 page document covers all the legal requirements that must be observed by the

carrier of dangerous goods.

The good news is that for most helium users, because the quantity of gas being carried is very small,

the journey will be exempted from the regulations under clause 1.1.3.6 in ADR. This is usually called

“the thousand points rule”. Basically, this states that if the quantity of goods carried is below a certain

threshold, apart from taking reasonable care to ensure the load is secure, the need to show orange

plates or green hazard diamonds on your vehicle, carry TREMCARDS, etc., etc. does not apply.

In effect, you are allowed to carry 1000 litres of helium, or any non-flammable, non toxic gas, before

the rules apply. That means you would need to have over 20 cylinders of 50 litre capacity, on board

your vehicle.

It may be “good practice” to put a green diamond on the back of your vehicle to advise the emergency

services in the event of an accident, but remember to remove it when you are not carrying any

cylinders.

When you are carrying cylinders, please follow these simple but important guidelines.

BALLOON GAS - Facts, Figures, Safe Handling & Legislation

If you want to know more about the ADR regulations, please follow this link:

www.hse.gov.uk/pubns/cdg.pdf

More details can be found in the BCGA bulletin included in the appendices.

The responsibility for supplying information where required rests with the supplier or 'consignor' of the

gases. This could be the original gas producer or an agent if cylinders are being sold on. The

responsibility for complying with the requirements imposed according to the quantity being transported

rests with the carrier, although the gas companies are always willing to supply advice.

The primary sources of further information about the storage, handling and use of gases are the

Codes of Practice published by the British Compressed Gases Association (BCGA). Their address is

as follows: British Compressed Gases Association, 14 Tollgate, Eastleigh, Hampshire SO5 3TG Tel:

01703 641488

Also of note are similar Codes of Practice from the European Compressed Gases Association (EIGA).

Specific information on the hazards and precautions for particular gases appear on the Material Safety

Data Sheets supplied with each product. It is a legal requirement for suppliers to provide their

customers with copies of these on the first purchase of each gas and to supply any updates if the

customer has purchased the gas in the previous twelve months.

TREMCARDS carried with the gases during transportation provide emergency advice.

The Health and Safety Executive publish various documents, some of which are relevant to the area

of gases. Of particular note is HS(G) 71 which deals with 'Packaged Goods'.

Last but not least, in terms of information sources is the supplier. The gas company will always

endeavour to provide specific information and answer any queries the customer may have to promote

the safe and effective use of industrial gases.