Regulators are an essential piece of gas control equipment. Fitted to the outlet of the gas cylinder valve or bundle output valve, the pressure regulator reduces the pressure of the gas from the cylinder, to the lower pressure required for the operation of the process equipment.
There are many precautions to take and unsafe practices to avoid for users of gas regulators. Here we list eight of the most common safety issues to be aware of:
1. Fitting the wrong regulator for the gas inside the cylinder
Codes of Practice issued by the British Compressed Gases Association state that a pressure regulator shall (must) not be used with any gas other than that for which it is designed and labelled. Also, once a pressure regulator has been in service with a particular gas it must remain in that gas service for the remainder of its life.
2. Not ensuring that a regulator is suitable for the gas pressure inside the cylinder
Codes of Practice issued by the British Compressed Gases Association state that a pressure regulator must be suitable for the maximum cylinder pressure being used.
3. Using out of date regulators
Many of our clients are not aware that regulators are stamped with a service date. They should be replaced 5 years from the date of manufacture or manufacturer’s recommendations.
4. Using the wrong orientation
Before attaching a pressure regulator to a cylinder, operators must check that the regulator is in a serviceable condition and that it can be fitted in a suitable orientation. Traditionally, gas cylinder valve outlet connections were predominantly bottom entry. However, many valves now use side entry outlet connections. Regulators are designed to fit either a bottom entry or a side entry gas cylinder outlet.
5. Using thread tapes to try to stop gas leaks
All pressurised joints and connections must be leak tested with an approved solution or spray prior to use. If a joint or connection is leaking operators must not use any form of jointing paste or tape between the regulator and cylinder valve or the regulator outlet and the hose or flashback arrestor. Specialist jointing tape may be used by some manufactures of gas equipment. However, jointing tape should not be used by end-users. If your equipment is worn or leaking, replace it.
6. Repairing regulators
Operators must not undertake unauthorised repairs on gas regulators. Damaged, contaminated or life-expired pressure regulators must not be used and must be removed from service.
7. Using contaminated regulators
Whether they are in storage or in use, pressure regulators must be kept free of dust, debris, oil, grease, solvents or any other contaminants. When they’re not in use, protective covers should be placed over the gas ports and they should be stored in clean, dry conditions.
8. Setting incorrect working pressures and/or flow rates
It is essential that the correct pressures and/or flow rates are set on the regulator for the work/task undertaken. Operators must check with the suppliers of the equipment being used to establish what outlet pressure/flow rate needs to be set on the outlet gauge of the regulator.
Gas Regulator Training
If you check the regulators in use within your organisation and you recognise any of these faults, then please contact us to discuss how our training packages can educate your workforce. You can also take a look at our gas safety training workshops, including Connecting Regulators and Cylinder Setup in Laboratory environments and Connecting Regulators for Universities and Colleges.
