Compressed gas cylinders and cryogenic materials are part of everyday lab work, but small choices—like grabbing the nearest regulator, using the wrong tool, or moving a cylinder without removing the regulator—can quickly turn into serious hazards. Lab managers need to think about how procurement, equipment selection, engineering controls, handling procedures, monitoring, training, and vendor support all fit together.
EHS and risk professional Jonathan Klane, M.S.Ed., CIH, CSP, CHMM, CIT, says safety starts with the material and its intended use. “It’s the specificity of what the gas is and what you're doing with the gas,” he says.
Start with the gas and application
Regulators, tubing, fittings, sensors, and other components aren’t interchangeable. Labs must confirm compatibility with the gas, delivery pressure, process, and environment. Some gases—such as flammable, toxic, corrosive, or certain oxidizers—may require additional protection, like a gas cabinet.
Klane warns against using equipment simply because it is already available. “Just because you have it doesn’t mean it’s the right one,” he says. “The one you have [may] not [be] designed for that operation. I know you have it. That doesn’t mean that you can use it.”
Monitoring systems also need to match the hazard. For example, oxygen sensors can detect oxygen depletion caused by many inert gases, but carbon dioxide requires a dedicated sensor. These needs should be figured out before bringing a cylinder or cryogen into the lab—not after work has already started.
Control connection and transport risks
Once the right equipment is in place, people need clear guidance on how to connect, check, and move it safely. Klane recommends using a proper leak-detection solution and watching for bubbles that signal a leak. If a leak appears, shut off the supply and investigate rather than tightening the connection.
Cross-threading and overtightening can damage fittings and make them hard to remove later. “If it’s not going on easily, there’s probably a problem,” Klane says. He also cautions against using improvised tools or cheater bars for extra leverage. And while Teflon tape is common in plumbing, it’s not appropriate for compressed-gas connections—it can break off, contaminate systems, or interfere with proper sealing.
Transport brings additional risks. Cylinders should be capped, secured to the appropriate cart, and moved along a clear route. Regulators should also be removed before transport. With cryogens, oxygen displacement becomes a greater concern, particularly in elevators and confined spaces. Klane recommends using freight elevators when possible and having a second person keep others from entering. Signage alone may not be enough to control access.
Build safety into procurement and procedures
Suppliers and vendors can offer helpful technical advice, but lab managers still need to clearly explain how the gas will be used, confirm compatibility, and involve internal safety experts. Klane recommends having direct conversations rather than relying solely on online ordering systems. For higher-risk gases, procurement processes can include checkpoints that trigger a safety review before the material arrives.
As for procedures, SOPs should reflect what actually happens in the lab. Klane points out the difference between “work as performed” and “work as imagined.” Generic procedures copied from elsewhere might check a box without matching real workflows.
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“Say what you do and do what you say,” he advises. The people doing the work should help write the SOP, since they understand the equipment and the day-to-day processes. Lab managers or safety professionals can then review and make sure the right controls are in place.
Train for behavior, not compliance
Online training can cover foundational information, but it does not build the hands-on skills needed to handle cylinders and cryogens safely. “Knowledge doesn’t change behaviors,” Klane says. Personnel need to practice using carts, securing cylinders, installing regulators, checking for leaks, and responding to problems. A trainer should demonstrate each step, have the learner repeat it, and confirm that the learner can complete the task correctly on their own.
Training should also reflect each person’s role. Klane recommends a modular approach in which everyone receives core instruction, followed by additional training tailored to the specific gases and processes they use. Overloading personnel with information that does not apply to their work can make an already complex topic harder to understand and retain.
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Storytelling can help bridge the gap between instruction and behavior. Rather than relying only on general warnings, trainers can use relatable scenarios that show how incidents might unfold and why procedures matter, helping researchers connect the steps they follow to real-world consequences.
Creating an environment where personnel feel comfortable asking questions and speaking up is equally important. Safe handling of compressed gases and cryogens depends not only on equipment and procedures, but also on communication. When procurement teams, vendors, safety professionals, lab managers, and researchers understand their roles and work together, they are better positioned to identify gaps before a routine task contributes to a serious incident. Treating every decision—from ordering a cylinder to training the person who uses it—as part of the same system helps keep safety connected throughout the material’s life cycle.
