Whether you use individual CO2 cylinders or a bulk CO2 tank system, you should be aware of CO2 tank safety. This is because, thousands of liquid carbon dioxide cylinders and tanks are used across the country for soda or beer carbonation, refrigeration, industrial purposes, medical and scientific research, fire suppression systems and even indoor agriculture. All of these vessels are a potential safety hazard if not installed and maintained properly.
An accident can quickly injure or even kill staff or customers.
Why CO2 Tank Safety Matters
CO2 cylinders and bulk tanks store liquid carbon dioxide under high pressure. If a leak occurs, CO2 rapidly expands into a gas, displacing oxygen in the air and creating an invisible hazard.
CO2-related incidents can result in:
- Headaches, dizziness, and fatigue
- Loss of consciousness
- Asphyxiation or fatal exposure in extreme cases
Because carbon dioxide is colorless and odorless, gas detection and CO2 monitoring safety systems are the only reliable way to identify unsafe conditions before symptoms occur.
CO2 Tank Installation and Professional Setup
All bulk CO2 tanks, cylinders, and delivery systems should be installed by trained professionals. In most cases, your CO2 supplier can provide installation services or recommend a qualified technician.
Facilities that use draft beer, soda systems, or industrial CO2 should always:
- Obtain multiple installation quotes
- Verify technician credentials
- Ensure systems meet OSHA and fire code requirements
Proper installation significantly reduces leak risk and improves long-term CO₂ safety.
Safe CO2 Tank Storage Best Practices
To improve carbon dioxide (CO2) tank safety, follow these storage guidelines:
- Secure indoor CO2 cylinders upright with chains or restraints
- Bolt bulk CO2 tanks to the floor to prevent tipping
- Store tanks in areas below 125°F (51.7°C)
Use approved regulators with pressure relief valves>Vent bulk CO2 systems outdoors when requiredInstall CO2 safety alarms and monitoring systems near storage areas
Carbon dioxide monitoring is essential, even when tanks are installed outdoors, because the gas is used inside the facility where people are present.
CO2 Monitoring and System Repairs
Repairs to CO2 delivery systems should only be done by trained personnel. Even the smallest leak in a hose or fitting can have potentially dangerous results. While it may be tempting to wrap a leaking hose with tape as a temporary fix, it may not only be unwise, but could leave management open to a lawsuit or denial of insurance coverage in the case of an accident.
Fortunately, most CO2 delivery services include CO2 system installation, maintenance and 24/7 repair as part of their service package.
If you need recommendations for a gas distributor or service company in your area please contact CO2Meter. We will be delighted to provide a comprehensive list of partners in your area.
CO2 System Accidents and Employee Safety Training
Accidental damage to CO2 delivery systems can and does happen. For example, a worker opening boxes with a utility blade might inadvertently slip and puncture a CO2 line. A cylinder tank cart might fall over while being moved over an uneven floor. It is important that employees who work with or around bulk CO2 tanks are trained to understand the dangers of leaking tanks and understand what to do when a leak happens. Proper training and signage are critical for protecting employees and customers around stored CO2.
The use of bulk storage of carbon dioxide in cylinders or outdoor tanks has grown exponentially over the last several years. Every restaurant, brewery, welding supplier, indoor grower as well as many manufacturers rely on bulk CO2 as part of their business.
Note that installing your CO2 storage vessel outside does not mitigate the potential for a safety hazard. The gas is being used inside and the people are inside creating the hazard. When CO2 storage vessels are installed outside safety monitors should still be installed inside your facility.
Because we offer CO2 storage safety alarms, we get asked questions about CO2 storage tanks and cylinders. Here are some of the most common questions with links to additional resources.
What’s the difference between CO2 at the welding store and CO2 in a restaurant?
Most bulk CO2 isn’t processed from fresh air, but is collected as a byproduct of other industrial processes like ethanol or ammonia production. Once the CO2 is collected it is rated according to its purity. For example the industrial CO2 in a welding shop is rated at 99.5% purse, while beverage grade CO2 used in restaurants must be at least 99.9% pure. Learn more about CO2 purity levels here.
While 0.3% doesn't sound like a big difference it is. The additional impurities in the CO2 will cause off flavors and oxidization making the beer taste "funky".
How big a CO2 tank can I use without a safety alarm?
The National Boiler Inspection Code and the International Fire Code recommend that any business that stores more than 100lbs. of CO2 use a CO2 Storage Safety Alarm. A 100lb. cylinder is 62” tall and 10.5” wide. This size is used in venues who want to reduce the number of tank changes each day. While the old-style cylinders are smaller, if the total combined weight of CO2 is over 100lbs. an alarm must also be used.
How do I know how much CO2 is in my tank?
You have a few options:
1. If your tank has a dual gauge regulator, you can read the amount of pressure on the dial. The pressure will go down as the tank empties. The downside of this method is that once the pressure begins to drop it will run out fairly quickly.
2. For portable CO2 cylinders, the one common way to determine the amount of remaining CO2 is to weigh it. The empty cylinder’s weight should be printed on the side, or you can google it. Subtract the cylinder weight from the actual weight, and you know how many pounds or kilos of CO2 you have remaining.
3. The most accurate way, is using a Pulsa industrial weight sensor that works with all tanks, is reliable, and can last up to 5 years. These sensors measure every 3 minutes and can allow users to see inventory levels in real-time from the Pulsa dashboard to know exactly how much gas is available. Another alternative to this is the Anova Asset Viewer, which gives visibility of all tank assets from your mobile device and is available globally.
How can I prevent CO2 leaks from occurring?
With their sturdy Department of Transportation DOT-3AL rated design, a new CO2 tank or cylinder will not leak for decades. By law, refillable tanks must be retested using a hydrostatic (water pressure) cylinder wall expansion test or ultrasonic wall thickness test and a visual inspection every 5 years before refilling. The date of each test must be stamped on the cylinder.
The possibility of leaks is much more likely via the valves and fittings used to route the CO2 from the tank or cylinder to the place the gas is dispensed. If you’ve ever had a water leak at home, you know that they can be difficult to find and fix. The same goes with CO2 leaks.
While there is no way to prevent all leaks, you can reduce the likelihood by having a CO2 delivery system installed by a qualified technician and inspected regularly. If the CO2 valves and fittings are in an enclosed area in a business, by regulation you should also have a CO2 safety alarm to warn occupants if a leak occurs. Read more about CO2 leak training here.
CO2 Safety Monitoring: Fixed and Portable Gas Detectors
Because CO2 cannot be detected by human senses, CO2 monitoring safety systems are vital for preventing exposure. Without a monitor, individuals may unknowingly enter a space with dangerous gas concentrations.
CO2 monitoring helps:
Protect employees and customersPrevent confined space incidentsMeet OSHA and fire code requirementsReduce liability and downtime
Fixed vs. Portable CO2 Safety Devices
Fixed CO2 safety monitors provide 24/7 area monitoring and can trigger audible/visual alarms or ventilation systems
Portable CO2 safety monitors provide personal protection for mobile workers and confined space entry
Overall, CO2 tank safety is not optional, in fact it is a critical responsibility for any facility using carbon dioxide. While CO2 cylinders and tanks are engineered to be durable, leaks from connected components can occur without warning.
Most facilities benefit in preventing leaks and safeguarding their establishment by using both fixed devices, like the Remote CO2 Storage Safety 3 Alarm or the Portable CO2 Safety Monitor.
For more information regarding gas detection safety solutions or your application - contact us today or request a quote here.
