High-Pressure Gas Safety Information

Audience: Field workers handling high-pressure gas equipment

Purpose: Quick reference for safe operation and incident prevention

⚠ CRITICAL SAFETY NOTICE Accidents have occurred due to aging equipment. Please schedule regular overhauls in addition to daily inspections, based on usage and annual inspections.

Daily Checks Are Important for Safety

PRECAUTIONS INFORMATION

Safety Information Necessary for Preventing Disasters Caused by High-Pressure Gases

Distributed in 2024, intended for users of high-pressure gases for welding and cutting (such as acetylene, liquefied petroleum gas, and oxygen for Welding or Thermal Cutting).

About High-Pressure Gas Cylinders

Not all high-pressure gas cylinders can hold high-pressure gas indefinitely. Make a written agreement with your distributor regarding how long cylinders may remain at the point of use, considering the properties of the gas and usage conditions.

This document is issued to high-pressure gas consumers at the time of contract signing and every transaction after one year from the announcement, based on Article 20-5, Paragraph 1 (Duty of Adequate Information, etc.) of the High-Pressure Gas Safety Law.

Important: To ensure the accurate conveyance of the contents of this document, please refrain from redistributing, publishing, or partially quoting it in any manner other than handing it over in a condition in which it can be explained.

INDEX

1. Equipment Adaptability

Basic information on the adaptability of the consuming equipment used to high-pressure gas

2. Management, Operation and Inspection

Basic points to be observed with regard to the operation, management and inspection of consuming equipment

3. Environment of Use

Basic information about the environment where the consumable is used

4-1. Equipment Repair and Disposal

Basic points to consider when replacing consumable equipment

4-2. Transporting Cylinders

Basic points to be observed when changing consumption facilities

5. Accident Response

Emergency measures to be taken by consumers in the event of a disaster

6. Other

Other matters necessary for the prevention of disasters caused by high-pressure gas

1. Equipment Adaptability

Regarding the handling of equipment and apparatus, obey the laws and regulations, thoroughly check the instruction manuals and warning signs, etc., and use the equipment and apparatus correctly.

Management and Handling of High-Pressure Gas Cylinders

Storage of cylinders for long periods of time is a very dangerous situation that can easily lead to unmanaged cylinders in a facility. Check cylinders currently in use or stored. Cylinders that are not expected to be used for some time should not be allowed to sit idle, whether or not there is residual gas.

Important: The storage of cylinders with more than a certain amount of gas, regardless of the amount of gas remaining, is subject to either notification or licensing requirements, including the need to maintain a storage facility that meets certain requirements and to keep records in a transfer logbook.

*Calculations are based on the fully charged volume and, as a general rule, the total volume of cylinders within 22.5 meters is combined, even if they are not connected by piping.

To use high-pressure gas in cylinders, please appoint a person responsible for cylinder management and ensure thorough control of the location of cylinders in terms of storage, transfer and removal from the premises, as well as the prompt return of used cylinders.

⚠ Lost or stolen cylinders are an easy source of secondary damage.

In order to deter terrorism and criminal use, please prevent theft of cylinders, and in particular, thoroughly manage the receipt and delivery of cylinders to be taken out of business, which can easily become unmanageable or lost.

Even if cylinders are not used daily, check their location before and after each workday.Use the cylinder inventory or storage records provided by your distributor to confirm their presence and condition.Do not allow cylinders to remain without a designated responsible person within the workplace.

Cylinder Protection Requirements:

  • Protect from direct sunlight
  • Keep temperature below 40°C (104°F) at all times
  • Protect from shock from falling or tipping over
  • Prevent damage to valves
  • Avoid corrosion by chemicals, water droplets, moisture, etc.

Leaving valves in a state where they are easily corroded or handling roughly is considered an illegal act.

2. Management, Operation and Inspection

Inspection and Maintenance

Regular inspections and maintenance are crucial for safe operation. Establish a comprehensive inspection schedule that includes:

  • Daily pre-operation checks
  • Regular maintenance based on usage frequency
  • Annual comprehensive inspections
  • Scheduled overhauls for aging equipment

Operation Guidelines

When operating high-pressure gas equipment:

  • Follow manufacturer's instructions precisely
  • Ensure proper training for all operators
  • Maintain accurate operation logs
  • Report any abnormalities immediately
  • Never attempt unauthorized modifications

3. Environment of Use

The environment where high-pressure gas equipment is used must meet specific safety requirements to prevent accidents and ensure proper operation.

Environmental Requirements:

  • Adequate ventilation at all times
  • Temperature control (below 40°C/104°F)
  • Protection from direct sunlight
  • Dry, moisture-free conditions
  • Clear of flammable materials (minimum 2 meters)
  • Proper fire prevention measures in place

4-1. Equipment Repair and Disposal

Equipment Replacement

When replacing or disposing of consumable equipment, several critical points must be considered to ensure safety and legal compliance.

  • Contact authorized distributors for equipment disposal
  • Never attempt unauthorized repairs or modifications
  • Ensure proper depressurization before disposal
  • Follow manufacturer's guidelines for replacement parts
  • Maintain records of all equipment changes

4-2. Transporting Cylinders

Transportation Safety Requirements

Required Materials and Tools for Transport:

  • Red signal light or flashlight (must work reliably)
  • Red flag
  • Leather gloves
  • Wheel stoppers (2 or more)
  • Megaphone
  • Leak detection fluid
  • Cylinder valve open/close handle
  • Cylinder valve gland wrench or monkey wrench
  • Rope (two or more ropes of 15 m or longer)

*However, these are not necessary if only cylinders with a capacity of 25 liters or less are loaded with a total volume of 50 liters or less. (Required if the cylinder is larger than 7m³ of oxygen or 6 kg of acetylene)

⚠ CRITICAL WARNING

Wagons and cars are not suitable for transporting high-pressure gases. If they are unavoidably used, they must be well ventilated at all times to prevent stagnation even in the event of a leak.

It is prohibited to leave loaded cylinders in a parked vehicle for extended periods of time (generally 2 hours or more). This is a violation of storage standards and is subject to more severe penalties.

Parking Regulations

When parking during transport, avoid places where 'safety-related facilities' are densely packed, except for loading and unloading cylinders, and choose a safe place with little traffic. The driver must stay with the vehicle. Exceptions may apply.

Safety-Related Facilities Include:

  • Schools and kindergartens
  • Hospitals
  • Theaters and cinemas
  • Performance halls
  • Public halls (capacity 300+ people)
  • Welfare facilities
  • Nursing homes (capacity 20+ people)
  • Cultural properties and historic sites
  • Natural monuments
  • Museums
  • Major stations (20,000+ daily passengers)
  • Department stores and markets
  • Hotels and inns
  • Large public buildings (1,000+ m² floor area)
  • Residential buildings

For large quantities of gas (300 cubic meters or more of flammable gas or oxygen), additional legal requirements apply, including the appointment of a movement monitor.Please contact your distributor for details.

🚨 5. Accident Response - EMERGENCY!

Please thoroughly discuss emergency response with suppliers and ensure that appropriate measures, responses and communications are in place, such as posting emergency contact information.

Emergency Preparedness

In preparation for emergencies such as earthquakes and disasters, establish a clear "emergency response system" and determine the roles of contact persons, etc., and establish the necessary systems.

Be aware of owning high-pressure gas, anticipate natural disasters and secondary disasters, and follow rules such as shutting off the main gas valve before evacuating to work diligently on disaster mitigation.

In addition to posting contact information, prepare for emergencies by regularly briefing employees on emergency procedures, reviewing their roles and emergency equipment, and conducting communications drills.

Cylinder Gas Leaks and Emergency Response

If a gas leak alarm is triggered or a gas leak is detected during work:

  1. Stop work immediately
  2. Close combustion equipment and cylinder valves
  3. Repair the leaking area
  4. Open doors and windows fully for ventilation
  5. Confirm no gas leaks before resuming use

If gas leaks from the valve handle or spindle, close the valve if it is safe to do so.Then move the cylinder to a fire-free area and contact your distributor immediately.

What to Do in the Event of a Fire Caused by Flammable Gas

  1. First turn off the gas and extinguish the fire
  2. Cool the cylinder by pouring a large amount of water into it
  3. Flames in equipment or hoses will be suppressed by closing the cylinder valve
  4. Continue to cool and pour water even after fire is extinguished
  5. Provide forced ventilation to avoid re-ignition

⚠ CRITICAL: Even after the fire is extinguished, if there is a gas leak, there is a possibility of re-ignition or explosion. Continue thorough cooling and forced ventilation.

Legal Reporting of Accidents and Notification to Your Distributor

Accidents involving high-pressure gas, such as fire or rupture of a safety valve, must be reported to the prefectural government (or the municipal fire department if the authority has been transferred to the municipality). Failure to do so is a violation of the law.

In the event of theft or loss, the responsible person must contact the prefectural government or the police.

In the event of any accident, including theft or loss, the designated responsible person must notify your distributor.

Please note that it may be required by law to preserve the current condition of the accident.

6. Other Important Information

Compliance with Laws and Regulations and Voluntary Safety

Regulations under the Safety Law are the minimum rules to be followed. In addition, accident prevention through self-safety is essential (Article 1 of The High Pressure Gas Safety).

  • Attend safety training sessions held by high-pressure gas industry associations
  • Collect and stay updated on safety information
  • Cooperate in updating safety records as required by law
  • Disseminate safety information within your business premises
  • Implement improvements when problems are pointed out
  • Wear necessary protective equipment: helmets, safety shoes, protective gloves, and safety glasses

Cylinder Storage - Ensure the Safety of the Cylinder Storage Area

Storage Requirements:

  • Store cylinders upright in designated storage area
  • Adequately protect valves
  • Prevent tipping, considering all foreseeable disasters
  • Keep out of direct sunlight
  • The area must maintain ventilation conditions that prevent gas accumulation
  • Maintain temperature below 40°C at all times
  • Keep oxygen and combustible gas cylinders separate
  • Segregate full cylinders from residual gas cylinders
  • Provide fire extinguishers
  • Post "No Fire" signs
  • No fire or flammable materials within 2 meters of cylinders

⚠ Storage of more than 40 kg of acetylene or 300 kg of LP gas must be notified in advance to the fire department in accordance with the Fire Code. (Other notifications may be required according to ordinances, so please consult your distributor.)

About Gases

Be familiar with the safety and hazardous properties of gases used for welding and cutting.

Important Gas Properties:

Oxygen: High concentrations of oxygen have the property of igniting even difficult-to-ignite materials and causing them to burn explosively if an ignition source is present.

Flammable Gases: All flammable gases except oxygen are highly flammable and will mix with air (oxygen) to form explosive gas mixtures.

Use extreme caution when handling these high-pressure gases and avoid gas leaks.

Gas for cooking or heating must be supplied in accordance with the Liquefied Petroleum Gas Act of Japan.

Prohibited Actions (Unauthorized and Unreported Manufacturing and Sales)

⚠ STRICTLY PROHIBITED

Manufacturing activities that do not meet the standards for high-pressure gas manufacturing are extremely dangerous and are prohibited by law.

All high-pressure gas manufacturing businesses must notify the prefectural governor, etc. (or the mayor or other designated address if authority has been transferred to the municipality) or apply for a license.

Violations will be severely punished.

  • Transferring and filling a cylinder is also a manufacturing act
  • Avoid operations where air is compressed with acetylene (dangerous)
  • Cylinders may not be owned without proper ownership identification (stamping and proper labeling)
  • Consumer-owned cylinders should be subject to a contract for outsourced cylinder management services
  • Unregistered sales are illegal and strictly prohibited

Failure to comply is punishable by law and may result in imprisonment, fines, or both.For further information, contact your distributor.

Definitions

Consumption means reducing the pressure of high-pressure gas to a state where it is not high-pressure gas for a specific purpose other than disposal, and using the resulting gas that is not high-pressure gas.

High-pressure gas equipment in the Act includes cylinders unless otherwise specified.

Gas Name (Cylinder Color) and Properties

Gas Name Cylinder Color Properties and Safety Information
Oxygen Black Oxygen is not flammable. However, it strongly supports combustion and may cause materials to ignite or burn violently in oxygen-enriched atmospheres.When using oxygen, there is a risk of ignition if the cylinder or equipment (valves, regulators, etc.) is covered with oil, grease, or other combustible materials.
Acetylene Brown Extremely unstable gas which may explode if ignited, heated or struck. Contains impurities, has an odor, and can be toxic if inhaled.
Propane
Butane
Propylene		 Gray All are components of LP gas. Originally colorless and odorless, but an unpleasant odor is intentionally added, except for those labeled "industrial odorless" on cylinders. Heavier than air and tends to stay lower. If you breathe a lot, there is a risk of suffocation and mild anesthesia. For safe use of gas, please use the safety reference materials issued by ZenYoRen.