Fire and explosion hazards from flammable gases
Flammable gases are a common yet hazardous presence in many industrial settings, posing significant risks of fire and explosions
Flammable gas insights:
- The proper storage and handling of flammable gases is essential to minimizing fire and explosion risks in industrial settings.
- Regular maintenance, staff training and adherence to safety regulations are vital components of emergency preparedness to prevent accidents involving flammable gases.
Businesses that use flammable gases in industrial settings need to be aware of fire and explosion hazards to ensure the safety of workers, company property and the surrounding community. Emergency preparedness is crucial, especially when processes rely on flammable gases.
Common sources of flammable gases
Industrial settings may use one or more of the following common sources of flammable gases:
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Acetylene: An explosive gas that is stored in cylinders with stability-maintaining porous materials. Acetylene must be stored upright to avoid risking worker safety, including those working with acetylene torches.
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Ammonia: A toxic and corrosive gas, ammonia finds many uses in industrial environments; including as a refrigerant in food production. Because of its strong scent, workers should notice ammonia leaks fairly rapidly.
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Butane: A colorless gas that smells similar to natural gas, butane is extremely flammable. Companies use butane to make chemicals for solvents. When butane comes into contact with the air, it can become explosive. In the food industry, enterprises rely on butane to produce vegetable oils. A variant, isobutane, is used in refrigeration.
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Hydrogen: Hydrogen is a flammable gas prized for burning cleanly (with byproducts being water and heat). Companies commonly use hydrogen to refine petroleum, create fertilizer and treat metals.
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Natural gas: Mostly composed of methane, natural gas also contains trace amounts of butane, propane and ethane. In its unprocessed state, natural gas/methane is odorless, but for safety in industrial applications, it is scented with ethyl mercaptan, which makes it smell like rotten eggs for easier detection.
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Silane: Businesses use silane gas to manufacture semiconductors. Because it can ignite spontaneously in the air, caution must be used when handling silane.
Figure 1: Advanced Gas Detection Systems Safeguarding Tank Farms and Liquefied Gas Storage: Ensuring Safety and Compliance in High-Risk Environments. Courtesy: Gene May Heating and Cooling
Preventing gas leaks and mitigating risks
The following key safety measures will go a long way in preventing leaks and mitigating any risks in a facility.
Proper storage:
Before storing gases, check their safety data sheets to learn about their potential risks.
Do not accept compressed gas cylinders that lack labels clearly stating their contents and instead, return them with a note about “contents unknown.”
Store flammable gas cylinders securely in well-ventilated areas, using chains or straps to keep them in place in a designated storage area. Do not leave them in public areas where they might be subject to tampering, or in locations where heavy objects could fall on them and damage the cylinders.
Keep oxygen tanks at least 20 feet away from flammable gases to avoid oxidizing them and causing explosions. Never store flammable gas cylinders where they can be exposed to direct sunlight.
Handling procedures:
Verify that the protective cap is secure over the cylinder’s valve before moving it. Never attempt to lift a cylinder by grasping the valve cover. Dropping a cylinder can make it explode.
Use a cylinder basket or cart to transport flammable gas cylinders, instead of sliding, rolling or dragging them.
Regular maintenance:
Schedule regular maintenance and conduct ongoing inspections to check that any equipment using flammable gas is functioning properly and safely. Verify that the cylinders of flammable gas are free of corrosion and that their valve covers are intact.
Gas detection systems:
Don’t rely on your nose alone to discover sources of leaking flammable gas. It’s prudent to install gas detection systems, such as wireless gas monitors that constantly check if flammable gas has leaked inside the industrial facility.
In addition to detectors mounted in place, a team can use handheld flammable gas detectors to check a specific area or piece of equipment.
Figure 2: Spherical tanks provide a safe and efficient solution for storing liquefied gases. Courtesy: Gene May Heating and Cooling
Prepare for the worst:
The safety officer or facilities manager will want to drive home to workers the importance of always being prepared for potential emergencies. This includes establishing regular training in storage, handling, and maintaining systems using flammable gases.
What’s more, each worker should be aware of current safety regulations. If you need assistance, you can hire third-party safety experts to update workers about how to handle flammable gases appropriately.
Emergency preparedness plans
Scheduling regular maintenance for the facilities is crucial for avoiding fire and explosions. It’s also a good idea to reinforce to your employees the importance of following established material handling procedures and industry best practices for storing flammable gases.
Furthermore, installing or upgrading your gas detection systems will give you greater peace of mind, knowing that you’re doing what it takes to make your company a safer environment for workers and visitors.
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