8 Most Common Safety Issues When Using Gas Regulators

Usage of gas is a common feature for various purposes, in homes and commercial properties, as well as in industrial units. In most cases, natural gas, commonly referred to as “gas,” is supplied directly to the end users through a network of gas pipelines by the gas supply companies. However, another option is also available: bottled gas, also known as cylindered gas, commonly known as “LPG Cylinders.” 

The pressures of gas supplied through natural gas distribution networks may be very high, as high as 10 PSI. The gas pressure in an LPG cylinder is even higher, like 32 PSI, based on factors such as temperature. However, the gas appliances cannot operate with high gas pressure. To make these appliances function properly, the gas pressure needs to be reduced. Here, the "Gas Regulators" come into play. A gas regulator is a device, which controls the gas pressure by bringing it within a safe and usable level. 

The gas regulators come in different makes and types, based on the purpose of use. The gas regulators used with LPG cylinders are of different specifications, as compared to the ones, installed on the natural gas service lines, just before the gas meters, mostly near the main entrance of a property.   

Types of Natural Gas Regulators

The supply network of natural gas consists of different phases. At each stage, the pressure of gas needs to be regulated for consistent and safe supply to the end users, whether a home, a business, or an industry. Let's have a brief look at the distribution system and the gas pressure regulated at each stage: 

• Main Supply Line – This is the first stage of the natural distribution network, which starts from the distribution point and ends at the “Feeder Main.” The gas pressure at this stage is typically set between 150 to 400 PSI. 
• Feeder Main Regulator Station – The Feeder main is actually a gas regulator station. At this point, the gas pressure is considerably reduced through regulators to make it safer for onward transmission. Here the gas pressure is reduced to somewhere around 26 PSI 60 PSI.
• Main Distribution Supply Line – After the regulator station, gas is transmitted to the Min Distribution Supply Line. This supply line runs through the entire service area, where it is ultimately supplied to the end users. Here, the gas pressure might range somewhere between 1 to 25 PSI. 
• Service Supply Line – From the Main Distribution Supply Line, the gas is then transmitted to the Service Line, which runs underground in streets to connect the end users, such as homes and businesses. Here, the gas pressure is reduced to ¼ to 1 PSI based on the consumption level of the end user. Service Line terminates at the gas meter, installed just outside the property by the gas distribution company. 
• Fuel Line – Finally, the gas pipeline enters the home or business and is connected with the appliances, through Fuel Line. It starts from the gas meter and runs through the property to supply gas to different appliances such as cookers, burners, heaters, boilers, and so on. At this stage, the gas is regulated to the safer consumable level, which is often ¼ PSI.

Gas Regulators Used in Natural Gas Pipe Networks 

Typically, a gas pipe network uses 5 different types of Gas Regulators to bring the pressure down to the safest and consumable level, for homes, businesses, and industries. Each gas regulator is installed at a particular point within the gas supply network. These are:

1. Gas Pressure Regulators 
2. Pilot Operated Gas Regulators
3. Service Line Gas Regulators
4. Gas Line Pressure Regulators
5. Gas Appliance Regulators

Types of LPG Regulators 

Contrary to the natural gas supply system, the LPG cylinders typically need a single gas regulator, which is installed at the gas outlet point of the cylinder. However, the specifications and type of this regulator vary with the type, size, and purpose of usage of an LPG cylinder. The type of gas supplied in LPG Cylinders also varies, such as Butane or Propane. So, the type of gas regulator also varies with the type of gas supplied in the Cylinder. 

Here is a brief list of commonly used LPG Cylinder Gas Regulators: 

• Butane Clip-on Gas Regulators
• Propane Clip-on Gas Regulators
• 37 mbar Propane Gas Regulators
• Gas Appliance Regulators
• Camping Gas Regulators
• Low-Pressure Gas Regulators
• Pilot Operated Gas Regulators
• Service Gas Regulators
• Pressure Gas Regulators
• Single Stage Gas Regulators
• Dual Stage Gas Regulators

The purpose of all the gas regulators is to bring down the gas pressure to the safe consumable level, enabling the end users to use it without any risk. However, consumers also need to observe a certain level of awareness and maintenance to ensure safe and risk-free usage of gas. Gas Regulators play a vital role in it. 

8 Most Common Safety Issues When Using Gas Regulators

A Gas Regulator is one of the most important gadgets, which ensures the safe usage of gas, whether supplied directly through a gas supplying company or through gas cylinders. The gas providers are supposed to install the correct type of gas regulators, both for direct supply and supply through cylinders. On the other hand, consumers are required to maintain a certain level of upkeep and maintenance for the safe use of gas. 

The most common safety issues when using Gas Regulators are summarized here:

1. Gas Leaks

One of the most common safety issues associated with gas regulators is gas leaks. There might be different reasons behind gas leaking from the gas regulators, such as wrong or incorrect installation. But the most common reason is the loose connection or wear and tear of the seals. In more serious situations, the culprit might be a damaged diaphragm, as well. In any case, the leaking gas, which is often odorless and colorless, may result in fire or explosion. It may also cause health issues if left unattended. 

You need to keep a close watch on this issue, especially before using the gas appliance. Make sure that the connections are tight enough. Also, check the regulators for any signs of wear and tear. Consider replacing the damaged part or the entire gas regulator, as the case may be.

2. Incorrect Gas Pressure

Sometimes the gas regulator may start malfunctioning, resulting in transmitting the gas, with incorrect pressure. The gas appliances are designed to function at an appropriate gas pressure. In case of excessive gas pressure, the appliances may be damaged. But the most serious outcome might be a gas leak, fire, or explosion if the gas regulator starts transmitting the gas beyond the permissible level.

Make sure that the gas regulator is set at the correct pressure and that the relief valve is functioning as expected. You may also need to replace the regulator if it transmits gas at an incorrect pressure.

3. Freezing of Gas Regulator 

In the event of a rapid and high-flowing gas, the moisture inside the regulator tends to freeze. This may result in blockage of the gas regulator. This situation might end up in an interruption in gas supply, malfunctioning of the gas regulator, or buildup of higher gas pressure. Any of these situations might be dangerous. Hence, always use the appropriate gas regulators for the appliances that are designed for higher gas flow. Similarly, the gas regulators might need insulation in colder environments to prevent freezing.

4.  Appropriate Regulator Selection

Gas regulators are designed for a certain gas pressure range. While the gas providers are supposed to install the correct gas regulator, considering the usage of gas at your property, you may also need to replace it, in case a new gas appliance is installed that may need a different gas pressure. Using an incorrect gas regulator may result in malfunctioning. 

5. Backflow of Gas or Contamination

At times, a reverse flow can occur, which may send contaminants back into the gas regulator and even inside the cylinder. Any such happening may result in chemical reactions and may also damage the regulator and cylinder. An anti-backflow valve can be installed to avoid this situation. 

6. Using Thread Tapes to Fix Gas Leaks

It is highly recommended to check all connections, including the gas regulators for any possible gas leak. This can be done with simple tests such as soapy water tests. But never use thread tapes to fix the gas leak. 

7. Inconsistent Maintenance

A gas regulator needs timely care and maintenance, as it tends to accumulate dirt or corrosion. Similarly, with consistent usage, some of the parts of a gas regulator also tend to wear out. Hence, a regular and periodic inspection and maintenance of the gas regulator is important to avoid any unpleasant situation. 

8. Exposure of Gas Regulators to Extreme Weather Conditions

Extreme weather conditions, such as high or very low temperatures and higher levels of moisture in the environment, may badly damage the gas regulators by way of corrosion or physical damage. The avoid any such happening, always use a gas regulator specifically designed for extreme weather conditions. 

Additional Tips

• Never handle the gas regulators without the PPE (Personal Protective Equipment).
• Try to get at least the basic training on handling, installation, and using the gas regulators.
• Never attempt to repair a damaged regulator on your own. Get it done by a professional gas worker.
• Store gas cylinders and regulators in well-ventilated areas away from heat sources.

Conclusion

Handling the gas regulators is a critical matter when using gas, especially cylindered/bottled gas. Using the correct type of gas regulator is highly important. The main role of a gas regulator is to transmit gas to the appliances with a controlled gas pressure, which can only be achieved by using the appropriate gas regulator. Similarly, some gas appliances are specifically designed to use high flow of gas, for which an appropriate gas regulator needs to be installed. 

For the perfect functioning of the gas regulators, you need to be aware of the common possible issues a gas regulator may come across. While normal and simple issues can be handled and fixed on your own, never try to repair the gas regulator on your own, as it may result in an accident. Always get it repaired by a professional gas engineer, preferably a gas-safe registered engineer.