Product Overview

Summary: This Compressed Gas Safety Safe Operating Procedure provides a clear, step-by-step framework for the safe storage, handling and use of compressed gas cylinders in Australian workplaces. It helps businesses control high‑risk hazards such as explosion, asphyxiation and cylinder ejection, while supporting compliance with WHS legislation and relevant Australian Standards.

Compressed gases are widely used across laboratories, workshops, manufacturing plants, healthcare facilities and construction sites, but they present significant risks if not managed under a robust safety procedure. Cylinders can become deadly projectiles if damaged or knocked over, leaks can create explosive or oxygen-deficient atmospheres, and incorrect regulators or connections can lead to catastrophic failures. This Compressed Gas Safety SOP provides a structured, practical approach tailored to Australian workplaces, detailing how to select, transport, secure, connect, operate and store compressed gas cylinders safely.

The procedure supports PCBUs, managers and supervisors to demonstrate due diligence under WHS law by defining clear responsibilities, mandatory pre-use checks, isolation and leak-testing requirements, and emergency response steps for gas leaks, fires and exposure incidents. It also standardises training and expectations for workers, ensuring consistent control measures such as correct PPE, segregation of incompatible gases, safe use of trolleys and cylinder restraints, and regular inspection routines. By implementing this SOP, businesses can significantly reduce the likelihood of serious incidents, protect workers and contractors, and provide evidence of a systematic approach to managing compressed gas risks during audits, regulator visits and client prequalification processes.

Key Benefits

• Reduce the risk of explosions, fires and uncontrolled gas releases through clearly defined storage, handling and operating controls.
• Ensure compliance with Australian WHS legislation and relevant standards for compressed gas systems and cylinder management.
• Standardise worker training and expectations across sites, improving consistency and reducing unsafe shortcuts.
• Minimise equipment damage, gas wastage and downtime by embedding pre-use inspections and leak-testing into daily practice.
• Improve incident readiness with clear, role-specific emergency procedures for gas leaks, exposure, fire and cylinder impact events.

Who is this for?

• WHS Managers
• Laboratory Managers
• Maintenance Supervisors
• Workshop Supervisors
• Engineering Managers
• Production Managers
• Gas Fitters and Technicians
• Laboratory Technicians
• Facility Managers
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Explosion and fire from flammable or oxidising gases
• Cylinder ejection and impact injuries due to valve or regulator failure
• Asphyxiation from inert gas leaks displacing oxygen
• Chemical exposure from toxic or corrosive gases
• Burns and cold injuries from rapidly expanding gases and cryogenic effects at valves
• Manual handling injuries from moving and positioning heavy cylinders
• Property damage from unsecured or incorrectly stored cylinders
• Cross-connection of incompatible gases or incorrect regulators

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Compressed Gases
• 3.0 Roles and Responsibilities (PCBU, Managers, Supervisors, Workers, Contractors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Compressed Gases
• 6.0 Required Training, Competency and Authorisation
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Cylinder Storage Requirements (Segregation, Ventilation, Signage, Restraints)
• 9.0 Receiving, Inspection and Labelling of Cylinders
• 10.0 Manual Handling and Transport of Cylinders (Trolleys, Vehicles, Lifting)
• 11.0 Safe Use of Compressed Gases (Connection, Regulators, Hoses and Fittings)
• 12.0 Pre-use Checks, Leak Testing and Isolation Procedures
• 13.0 Specific Controls for Flammable, Oxidising, Toxic and Inert Gases
• 14.0 Ventilation and Control of Hazardous Atmospheres
• 15.0 Housekeeping, Security and Out-of-Service Management
• 16.0 Emergency Procedures for Gas Leaks, Fires and Exposure Incidents
• 17.0 Incident Reporting, Investigation and Corrective Actions
• 18.0 Inspection, Maintenance and Testing of Cylinders and Equipment
• 19.0 Training, Induction and Refresher Requirements
• 20.0 Recordkeeping and Document Control
• 21.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variations)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variations)
• Safe Work Australia – Model Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Model Code of Practice: Managing the work environment and facilities
• AS 4332: The storage and handling of gases in cylinders
• AS/NZS 1596: The storage and handling of LP Gas (where LPG is used)
• AS/NZS 60079 series: Explosive atmospheres (for hazardous area considerations)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1337.1: Personal eye protection
• AS/NZS ISO 45001: Occupational health and safety management systems