Propane Safety Guide: Essential Best Practices for Businesses

Propane safely powers countless businesses every day, but improper handling can lead to serious accidents. This guide covers essential safety practices that protect your business, employees, and customers from preventable propane hazards. 

Below, we will cover:

• Propane’s dangers and safety risks
• Choosing the right equipment for your business needs
• Common safety mistakes and how to avoid them
• Proper storage requirements and best practices
• Inspection and maintenance guidelines
• Leak detection methods and emergency response
• Emergency planning and supplier selection

Is Propane Dangerous?

Yes, propane is dangerous because it is highly flammable and can cause fires, explosions, and suffocation if mishandled. That said, propane is safe if you follow proper handling procedures.

Specifically, propane becomes dangerous when it reaches concentrations between 2.1% and 9.5% in the air. Below this range, there’s not enough propane to ignite. Above it, there’s not enough oxygen.

The gas is heavier than air, so it settles in low areas like basements, pits, and floor drains. This creates hidden pockets of flammable gas that can ignite unexpectedly.

Health risks are generally low with brief exposure. Propane isn’t toxic like carbon monoxide, but high concentrations can displace oxygen and cause suffocation. You might experience dizziness, headaches, or nausea in poorly ventilated areas.

Propane’s distinct smell comes from an added chemical called mercaptan. Pure propane is odorless, so this additive helps you detect leaks quickly.

What Types of Propane Equipment Do I Need for My Business?

Your propane equipment needs depend on your usage, application type, and the layout of your facility. Most businesses use either large stationary tanks or portable cylinders.

Large propane tanks work best for high-volume applications like heating systems, industrial processes, or busy kitchens. These tanks typically hold 100 to 1,000 gallons and require professional installation and permanent placement.

Portable cylinders are ideal for lower-volume uses, temporary applications, or equipment that moves around your facility. Standard cylinders range from 20 to 100 pounds and can be easily transported and connected.

Most jurisdictions require permits for permanent installations and have specific rules about tank placement and safety equipment. Professional installation is often legally required to ensure proper connections and code compliance.

Having the right tank size helps prevent supply interruptions and keeps you within local storage regulations. Your propane supplier can help determine the right equipment setup based on your usage and local requirements.

What Are the Biggest Propane Safety Mistakes?

The most dangerous mistakes involve overfilling tanks, ignoring relief valve functions, and storing propane in the wrong locations. These errors cause the majority of commercial propane accidents.

Overfilling can cause dangerous pressure buildup. Many suppliers overfill tanks beyond their safe capacity.

Relief valves are sometimes misunderstood or ignored. These valves automatically release pressure to prevent tank explosions, but many people think a venting valve means the tank is broken. If your relief valve activates, move the tank away from people and ignition sources and let it finish venting safely. 

Improper storage is another common mistake, especially by restaurants trying to prevent theft. Businesses hide propane cylinders inside closets, basements, or other enclosed spaces where gas can accumulate. Even small leaks become dangerous in confined areas.

Poor leak detection leads to dangerous gas buildup over time. Make sure you do regular inspections and properly check for leaks.  

Where Should I Store My Propane Tanks and Cylinders?

Propane tanks and cylinders must be stored outdoors in well-ventilated areas, away from buildings and ignition sources. Storing propane inside can create dangerous gas accumulation that leads to fires or explosions.

Use dedicated propane cages placed at proper distances from your building. These cages protect your equipment from tampering while maintaining required ventilation and access for deliveries.

Keep propane away from windows, doors, air intakes, and electrical equipment. Distance requirements vary based on size and local codes, typically ranging from 3-10 feet from building openings and 5-10 feet from ignition sources for smaller cylinders, with larger tanks requiring greater distances.

Ground-level storage works best since propane is heavier than air. Avoid storing tanks in pits, basements, or below-grade areas where gas can collect and concentrate.

Protecting equipment from harsh weather helps extend its life, but be careful not to create enclosed spaces. Use open-sided shelters that allow air circulation while protecting tanks from direct sunlight and precipitation.

Your propane supplier can recommend the best storage setup for your specific location and local code requirements.

How Often Should I Inspect My Propane Equipment?

You should inspect your propane equipment monthly for basic safety checks, but leave complex inspections and maintenance to qualified professionals. Regular visual inspections catch many problems before they become dangerous.

Check for obvious damage like dents, rust, or corrosion on tanks and cylinders. Look for damaged valves, loose connections, or worn hoses that could lead to leaks.

Listen for unusual sounds when equipment is operating. Hissing, whistling, or other odd noises often indicate gas leaks or pressure problems that need immediate attention.

Leave the evaluation of relief valve function to professionals – specialized knowledge is required for proper assessment. 

Many propane suppliers offer detailed inspection and maintenance services, or you can work with licensed maintenance professionals. Professional maintenance includes pressure testing, leak detection with specialized equipment, and replacement of worn components.

Keep simple inspection logs and note any concerns. Tasks like valve adjustments, pressure testing, and internal tank inspections must be done by licensed technicians.

How Do I Know If My Propane Tank Is Leaking?

The most reliable way to detect propane leaks is by smell – propane has a distinctive “rotten egg” odor that’s easy to recognize. Also, you can apply soapy water to connections and look for bubbles that indicate gas is escaping.

When you discover a leak, first determine if it’s coming from the tank itself or if the relief valve is functioning normally. Relief valves sometimes vent gas to prevent dangerous pressure buildup.

If you identify a leaking tank, move it away from people and ignition sources immediately. Let it finish venting safely in an open area while you contact your propane supplier or emergency services.

For detailed detection methods, see our article on how to detect propane leaks.

What Should My Emergency Plan Include for Propane Accidents?

Your emergency plan should cover immediate response procedures, evacuation routes, and emergency contact information for both your propane supplier and local emergency services. Your employees need to know these basics before an emergency happens.

Here are key elements to include in your plan:

• Shutdown procedures and evacuation routes – designate trained employees to turn off gas valves and establish upwind evacuation paths away from storage areas.
• Emergency contacts and training – post supplier emergency lines and fire department numbers throughout your facility while training staff to recognize leaks and respond appropriately.  
• Regular drills and coordination – practice emergency procedures regularly and coordinate with local fire departments so they understand your propane systems.
• Emergency equipment placement – position fire extinguishers and safety equipment away from propane storage areas for safe access.

How Do I Choose the Right Propane Supplier?

Choose a propane supplier that prioritizes safety, provides a reliable supply of propane, and does not overcharge you for cylinders.    

Again, don’t use suppliers who overfill tanks beyond safe capacity limits – overfilling creates dangerous pressure problems.

Go with a supplier that is not only focused on preventing accidents, but is also ready to help you if an accident does occur. 

WestAir is a safety-focused propane supplier that offers standard next-day propane delivery for businesses, and 24/7 emergency service throughout California. And with WestAir, you don’t pay rent on cylinders NOT in your possession.

Contact us if you are looking for a propane supplier for your business. 

Tyler O'Brien

Tyler is a results-driven marketing professional specializing in the industrial gases and equipment industry, bringing his 10 years of technical expertise and digital marketing acumen to the complex industrial gas B2B environment.