Ergonomic Management of Compressed Gas Cylinders for Unloading Within Refineries

Construction and maintenance within operational refinery units frequently require the use of compressed gas cylinders— primarily oxygen, fuel, and inert gases—for metal cutting and joining. These cylinders, typically weighing over 40 kgs and pressurised over 2000 psi, pose significant safety hazards during manual unloading, especially in the absence of fixed infrastructure. This study focuses on ergonomic and safe unloading practices for gas cylinders at dynamic refinery construction sites. A comparative evaluation of various unloading methods was conducted, including manual dropping, sliding on steel ramps, and the use of mobile ramps with tyre restraint. Impact velocity, cylinder stability, and operational feasibility were analysed across different ramp angle configurations. The findings reveal that a 30° inclined mobile steel ramp equipped with tyre restraints offers optimal safety and control. This solution effectively absorbs impact forces, avoids metal-to-metal contact, and provides mobility suited to decentralised site demands. For permanent setups, fixed concrete ramps with tyre restraints were identified as appropriate. The study underscores the importance of ergonomic design, material selection, and mobility in mitigating risks associated with compressed gas cylinder handling in refineries, aiming to enhance site safety while maintaining operational efficiency.