7 compressed gas cylinder safety issues a gas generator can solve

Compressed gas cylinders are used in research labs across the globe and they are used in abundance. When installed and handled correctly they can be a safe and reliable solution. When they are poorly treated, however, the lab is open to a number of safety risks.

We’ve examined seven safety issues that come with the presence of compressed gas cylinders in the lab and identified the ways that an on-site gas generator can help you overcome these issues.

1. Cylinders not secured properly

Cylinder risk

A cylinder needs to be supported above its midpoint – 70-80% of the height of the cylinder is usually a good benchmark for this support. The cylinder needs to be supported on something that is fixed such as a wall or a bench; the support should be strong enough to hold the cylinder and it should not be supported to another cylinder.

If you have multiple cylinders secured by a single support point, these can easily injure lab staff when this support is removed.

Generator solution

A gas generator, on the other hand, does not need to be secured. It can be placed next to your instrument or even moved around the lab on the attached wheels if you need to safely move your gas supply. By having an on-demand gas generator in your lab, you are removing the need to switch cylinders which also removes the hazards associated with the job of replacing gas cylinders when the supply runs out.

2. Failing to separate incompatible gas cylinders

Cylinder risk

There are a number of safety codes which state that flammable, toxic and oxidizing cylinders need to be separated by either 25 feet or an appropriate fire wall. The NFPA and the IFC both state the requirements for the separation of incompatible materials, but these concerns are, again, rectified where a gas generator can be used as an alternative source of gas.

Generator solution

By introducing the use of a gas generator to the lab you are removing the need for gas cylinders which, in turn, removes the need for separating the incompatible gas cylinders.

3. Not having a plan in place to deal with leaking gas cylinders 

Cylinder risk

Labs should always have an emergency plan in place if compressed gases are stored or handled. This could be different from lab to lad, depending on the type of gas that is used, but all scenarios should be carefully evaluated and a plan should be in place before a critical incident occurs.

Generator solution

PEAK’s range of on site gas generators come with built in safety features which include internal and external leak detection, auto shutdown features and alarm functionality which kicks in in the event of a gas leak. With these safety factors present in the generators from the point if installation, you already have the peace of mind built into the generator should anything go wrong, removing any uncertainty in the event of a leak.

4. An excess amount of spare cylinders in the lab

Cylinder risk

As with the separation of incompatible gas cylinders, the NFPA and the IFC also limit the maximum allowable quantity of flammable materials allowed in a control area. The table below illustrates the quantity of flammable gas that can be stored in specific areas.

Generator solution

With a gas generator you can be sure that the maximum flow rate of gas that you need for your instruments can be met by the gas generator. By having this guarantee, there will be no need to have excessive spare cylinders in the operating space as these will not need to be switched out or replaced when the volume of gas is too low for your analysis. The gas generator will provide gas on-demand, exactly when you need it.

5. Unsafe hose length used to connect equipment

Cylinder risk

Cylinders will always need some level of flexibility in the piping for re-positioning after changing out the empty cylinders. However, it is much safer to keep this piping as short as possible – no more than 3 feet.

Generator solution

The benefit of having a gas generator is you no longer need to change cylinders because your lab gas is produced on demand.

6. Failing to consider the effects of a leak in small areas

Cylinder risk

While the majority of labs are well ventilated, toxic gas leaks can result in extremely hazardous areas. Flammable and explosive gases can create an atmosphere that is considerably higher than the lower explosive limit and this is why risk assessments should carefully evaluate the effects of leaks and failures in the lab.

Given the shortage of space in many research laboratories, gas cylinders are often placed in areas with little or no ventilation system.

Generator solution

Similar to labs that don’t develop a procedure to handle a leak before it occurs, not considering the effects of a major leak in a smaller area can also benefit from the built-in safety features of a gas generator.

A PEAK gas generator has a maximum flow rate and output pressure which can provide you with peace of mind when it comes to potential leaks. Considering the differences in pressure between pressurized gas cylinders and a gas generator it would take considerably longer for your lab personnel to be affected by the results of a gas leak.

7. Running hazardous gas lines in unventilated parts of the lab

Cylinder risk

Gas lines should never be piped in poorly ventilated locations, whether that is above a suspended ceiling or through an unventilated area. The piping should be run in a ventilated laboratory or outside the building and directly into the instrument.

Generator solution

Many gas generators have a relatively small footprint and, for the most part, can be situated next to or beneath the equipment it is used to supply. By using the generator next to the instrument you are removing the need for unsafe lines from the gas source to your instrument. By removing the unsafe line, you are removing the number of points where a safety risk can occur.

Gas Generator Solution

Gas cylinders are common-place in many labs around the world and, because lab staff are so used to seeing them, the safety risks are sometimes forgotten or not considered at all. There are many ways that gas cylinders can have a negative impact on the safety of lab personnel, but there are definitely alternatives that you can use to avoid these concerns.

By removing cylinders from the lab, you are not only improving the safety of the lab, you are also removing the requirements that come with having cylinders in the lab. Aspects like safety training of new staff and annual refresher for current staff and manual handling training all have an impact on the lab over time and take your personnel away from the job they should be doing. 

Gas generators have a number of built-in safety features, they are portable and allow labs to streamline their practices. With one simple switch, labs can remove a large number of health and safety risks while also making life in the lab easier for everyone.