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Changing a Cylinder

If a pressure system (such as a compressed gas cylinder) fails, it is likely to result in an uncontrolled release of energy causing serious injury to personnel and damage to property.

The overall intention of the Pressure Systems Safety Regulations, which came into force on 21 February 2000, is to prevent the risk of injuries from such a failure.


A simple guide to changing a cylinder

It is important both you and your staff can change cylinders safely, efficiently and competently.

This guide to changing gas cylinders will help you fully meet your requirements.

The basics

Anyone who changes a gas cylinder must:

  • be fully trained for their own protection and to comply with the Manual Handling Regulations 1992
  • use appropriate protective clothing such as gloves, safety glasses and protective footwear
  • appreciate and understand the safety precautions required in handling cylinders

For more information, please see 'Manual Handling Regulations'.

Changing a Suregas (carbon dioxide) cylinder

  • Turn and close off the valve on top of the empty cylinder
  • using the correct spanner, undo the nut on the cylinder to disconnect the high
    pressure hose or primary reducing valve, and allow residual gas to escape
    from the hose.
  • place the reducing valve within safe reach (do not drop the spanner or leave
    it hanging)
  • release the bracket or chain securing the cylinder
  • put on protective gloves and carefully move the empty cylinder to the
    storage area (do not replace plastic plugs on the outlet of empty BOC
    cylinders
  • secure the empty cylinder upright, or lie flat and chock it to prevent rolling
  • remove the plastic plug or tape from the new full cylinder outlet and discard it
  • 'snift' the replacement cylinder by quickly opening and closing the valve on
    the top to clear any dust or moisture from the outlet (always point the outlet
    away from your body and wear safety glasses when snifting)
  • connect the high pressure hose or the primary reducing valve, and check that
    the sealing washer is fitted correctly
  • tighten the nut firmly with the spanner
  • turn on the valve on top of the cylinder
  • check for leaks using a solution of soapy water or a commercial equivalent.

Changing a Suremix (mixed gas) cylinder

  • Turn and close off the valve on top of the empty cylinder and also close the
    isolating valve (hand tighten only)
  • open the bleed valve to relieve the pipe of any gas pressure
  • using the correct spanner, undo the nut on the cylinder to disconnect the high
    pressure hose or primary reducing valve and allow residual gas to escape
  • place the reducing valve within safe reach (do not drop the spanner or leave
    it hanging)
  • release the bracket or chain securing the cylinder
  • put on protective gloves and carefully move the empty cylinder to the
    storage area (do not replace plastic plugs on the outlet of empty BOC
    cylinders
  • secure the empty cylinder upright, or lie flat and chock it to prevent rolling
  • remove the plastic plug or tape from the new full empty cylinder outlet and
    discard it
  • 'snift' the replacement cylinder by quickly opening and closing the valve on
    the top to clear any dust or moisture from the outlet (always point the outlet
    away from your body and wear safety glasses when snifting)
  • refit the high pressure hose or primary reducing valve, making sure the
    rubber 'O' ring is not damaged and is fitted correctly
  • tighten the nut firmly by hand (do not overtighten)
  • check that the bleed valve is shut
  • turn on the valve on top of the cylinder
  • check for leaks using a solution of soapy water or a commercial equivalent.
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