THE GAS CYLINDER RULES, 1981

The provisions of these rules pertain to the filling.

Storage, handling and transportation of gas cylinders
exceeding pressure of 1.5kg/cm2 at 15 degrees
Celsius.
The rules regulate the manufacture of cylinders,
valves and regulators, marking, stamping and color
coding of cylinders, import of gas cylinders, testing of
cylinders and the procedures for appointing competent
person authorized to undertake the testing and
inspection of gas cylinders.
“Chief Controller” means the Chief Controller of
Explosives, Government of India
Gas Cylinder Rules
A flashback arrestor or flash arrestor is a special gas
safety device most commonly used in oxy-fuel
welding and cutting to stop the flame or reverse
flow of gas back up into the equipment or supply
line and it prevents the user and equipment from
damage or explosions.
• “Chief Controller” means the Chief Controller of
Explosives, Government of India;
• “Compressed Natural Gas (CNG)” means mixtures
of hydrocarbon gases and vapours, consisting
mainly of Methane in gaseous form, which has
been compressed for use as automotive fuel;
CNG mother station” means CNG facilities connected with natural gas
pipeline and having a compressor meant primarily to fill mobile
cascades of daughter station;
“CNG daughter station” means CNG facilities not connected to natural
gas pipeline. Such CNG dispensing station receives CNG through mobile
cascade
“CNG online station” means CNG facilities connected with natural gas
pipeline and having a compressor primarily to fill stationary cascades for
dispensing CNG to vehicles;
• Filling ratio” means the ratio of the weight of a
liquefiable gas introduced in the cylinder to the
weight of the water the cylinders will hold at 150C;
• Gas Cylinder” or “Cylinder” means any closed metal
container having a volume exceeding 0.5 lites but
not exceeding 1000 litres intended for the storage
and transport of compressed gas LPG/CNG.
• “hydrostatic test” means the test to which a cylinder
is subjected to a hydrostatic pressure equal to the
test pressure of the cylinder;
• test pressure” means the internal pressure required
for the hydrostatic test or hydrostatic stretch test of
the cylinder
Hydrostatic Testing
• Critical temperature” means the temperature
above which gas cannot be liquefied by the
application of pressure alone;
• permanent gas” means a gas whose critical
temperature is below _100C that is to say a gas
which cannot be liquefied under any pressure at a
temperature above _100C;
• high pressure liquefiable gas” means a liquefiable
gas having a critical temperature between - 100 C
and + 700 C;
• low pressure liquefiable gas” means a liquefiable
gas having critical temperature higher than +70ºC;
“tare weight” in relation to -
• (1) acetylene cylinder means the weight of the cylinder
together with any fittings, permanently attached and
includes the weight of valve any safety device, porous
mass, requisite quantity of solvent for dissolving
acetylene, and the weight of acetylene gas saturating
the solvent at atmospheric pressure and temperature
of 150 C;
• (2) liquefiable gas cylinder means the weight of the
cylinder together with any fittings permanently
attached thereto and includes the weight of valve;
• (3) permanent gas cylinder means the weight of the
cylinder together with any fittings permanently
attached thereto and excludes the weight of valve;
 Acetylene Gas cylinder

“Dissolved acetylene cylinder” means a cylinder

containing a porous mass, a solvent for the storage of
dissolved acetylene and at least sufficient acetylene to
saturate the solvent at atmospheric pressure and at a
temperature of +150 C having a valve and with or
without safety devices, ;

Acetone or any other solvent used shall not be capable

of chemical reaction with the acetylene gas or with the
porous mass or with the metal of the cylinder or valve;
What method is to be used to test for leaks on
cylinder valves, regulators and all connections?
Apply 0.5% Teepol solution in water with a brush or
an approved leak detection spray and look for any
bubbles that may appear  
 Identification colours

• Every person filling any cylinder with any compressed

gas shall, before it is stored or despatched, see that
the cylinder is painted with appropriate identification
colours specified in IS:4379 for industrial cylinders and
IS:3933 for medical cylinders.
• For acetylene
• Hydrogen Liquefied petroleum gas ( LPG )
• Methane
• Carbon monoxide
• Carbon di oxide
• Oxygen
• Chloride
Cylinders containing gases or gas mixtures for which
exclusive identification is not provided , shall be
colour-marked in accordance with Table
 Marking on cylinders

• Every cylinder shall be marked with the following

namely the and rotation number, specification to which
Manufacturer’s, owner’s and inspector’s marking date
the cylinder has been made: date of the last
hydrostatic test or hydrostatic stretch test, working
pressure and test pressure; tare weight, water capacity,
• The name plate shall not be affixed to the cylinder by
soldering if there is a risk of corrosion or
embrittlement.
• In conjunction with the original marking, space shall be
provided for stamping the test date obtained at the
periodic inspection.
• No licence needed for filling and possession in certain
cases:
• (a) possession of any cylinder filled with a compressed gas by
a carrier or other person for the purpose of transport
• (b) possession of cylinders filled with -
– (i) liquified petroleum gas when the total quantity of gas does not
exceed 100 kg at a time;
– (ii) any other flammable but non-toxic gas when the total number
of cylinders containing such gas does not exceed 25 or the total
weight of gas does not exceed 200 kg., whichever is less, at a time;
– (iii) any non-flammable non-toxic gas when the total number of
such cylinders does not exceed 200 at a time;
– (iv) any toxic gas when the total quantity of such cylinders does not
exceed 5 at a time;
– (v) acetylene gas contained in cylinders in dissolved state when the
total quantity of such cylinder does not exceed 50 at a time.
 Storage of cylinders

• Cylinders shall be stored in a cool, dry, well ventilated place under

cover, away from boilers, open flames, steam pipes or any potential
sources of heat and such place of storage shall be easily accessible.
• The storage room or shed shall be of fire resistant construction.
• Thin wall cylinders such as liquefied petroleum gas cylinders and
dissolved gas cylinders shall not be stacked in a horizontal position.
• Cylinders containing flammable gases and toxic gases shall be kept
separated from each other and from cylinders containing other types
of gases by an adequate distance or by a suitable partition wall.
• Cylinders shall not be stored under conditions, which will cause them
to corrode.
• Cylinders shall not be stored along with any combustible material.
• Empty cylinders shall be segregated from the filled ones and care
shall be taken that all the valves are tightly shut.
 Handling and use

• Cylinders shall be adequately supported during handling.

• Conveyors, trolleys of adequate strength shall, as far as possible,
be used when moving the cylinders.
• The cylinders are not be allowed to fall upon one another or
otherwise subjected to any undue shock.
• Sliding, dropping or playing with cylinders is prohibited.
• Liquefied petroleum gas cylinders and cylinders containing
liquefiable gases shall always be kept in an upright position
• Cylinders used in horizontal position shall be so secured that
they cannot roll.
• Open flames, lights, mobile phones, lighting of fires, welding and
smoking shall be prohibited in close proximity to any cylinder
containing flammable gases except those while in use for
welding, cutting or heating.
 Safety relief devices
• Cylinders manufactured in India, if fitted with safety
relief devices in their bodies, shall have such safety
devices manufactured and maintained in accordance
with IS:5903
• Cylinders containing obnoxious or poisonous gases
shall not be provided with any safety device.
“obnoxious or poisonous gases” include Carbon
monoxide, Hydrogen chloride, Fluorine, Cynagen,
Hydrogen fluride, Sulphur dioxide, Chlorine
• For Acetylene cylinder, The safety relief devices fitted,
shall operate at a pressure of 53 kgf/cm2 or at a
temperature of 1000C + 40C/–20C.
 General precautions.

• If a leak in the valve cannot be rectified by tightening

the gland nut, the cylinder shall be removed to an open
space where it is least dangerous to life and property
and the filler shall be informed
• Cylinders together with their valves and other fittings
and the identification colours under these rules shall
always be maintained in good condition.
• No oil or similar lubricant shall be used on any valves or
other fittings of any cylinder.
• No cylinder shall be subjected to any heat treatment or
exposed to a high temperature or to the Sun or stored
with any other flammable or explosive material.
 Purity of gas:

• Before filling any cylinder with gases like carbon

monoxide, coal gas, hydrogen or methane, the
gas shall be free from hydrogen sulphide and
other sulphurous impurities as far as practicable.
The moisture shall be less than 0.02 g/m3 of gas at
normal temperature and pressure
• Cylinder subjected to the action of fire: -
• (1) (a) A cylinder exposed to fire shall not be used unless
it has undergone proper examination and hydrostatic
test or hydrostatic stretch test.
• (b) If deleterious structural changes in the material due
to the action of heat of the fire is apprehended to have
taken place, the cylinder shall have to be subjected to
proper heat treatment, followed by hydrostatic test or
hydrostatic stretch test, as the case may be, before the
cylinder is taken into use.
• (2) Dissolved acetylene cylinders, which have been
damaged by fire shall be condemned and destroyed by
an experienced and competent person
Conversion of cylinders.-
• (1) Gas cylinders designed and approved for filling
with a particular gas shall not be used for filling with
any other gas unless specific approval is obtained
from the Chief Controller except that :-
• (a) inert gases, oxygen and compressed air cylinders
made to the same specification and design may be
converted from one gas to another after fitting with
appropriate valve and painting with appropriate
identification colour without prior permission from
Chief Controller, with approval of the cylinder owner.
• (b) proper records of such conversions shall be
maintained by the gas filler for examination of Chief
Controller or Controller as and when needed.
• Working pressure and filling ratios:—
• (1) The working or internal pressure in any
cylinder charged with a permanent gas shall not
exceed two-third of the test pressure.
• (2) Cylinders charged with liquefiable gases shall
not be filled in excess of the filling ratios specified
in IS:3710 for low pressure liquefiable gases and
IS:8866 for high pressure liquefiable gases