Gas regulators are used in welding, torch cutting and laboratory applications. A regulator is attached to a high pressure gas cylinder to step down the psi. This is the safest way to reduce gas pressure. Gas cylinders usually have 2,000 PSI in and you must step them down to 20-100 PSI for use with a cutting torch.

I have been asked many times in the past what the difference is between single and two stage regulators. I have found that most people think a two stage regulator has two gauges but that would be incorrect. Nearly all regulators have 2 gauges. Below are some of the differences between a single and two stage regulators.

Single stage regulators are the more popular and the less expensive of the two. Single stage regulators reduce the cylinder pressure to the outlet pressure in one step. Two stage regulators reduce the cylinder pressure in two steps.

The single stage regulators are used in most general welding and cutting applications. These applications do not require an exact outlet delivery pressure throughout the cycle of the cylinder. As the cylinder decreases in pressure the delivery outlet pressure will increase.

Two stage regulators are used when an outlet delivery pressure needs to be maintained at all times. A few applications would be lab, gas chromatograghy or precision welding. The gas is regulated in two steps for greater accuracy in delivery. The first stage is preset and the second stage is fully adjustable to the regulator delivery range.

Most regulators are supplied with two gauges. The number of gauges does not determine if it is a single or two stage regulator. The gauges are used to determine the outlet delivery pressure and the amount of gas remaining in the cylinder; the high pressure gauge located next to the inlet port is used to determine amount of gas remaining in cylinder. And the low pressure gauge next to the delivery port is the delivery pressure gauge.

Single stage regulators cost approximately $60-$90 while two stage regulators are typically twice as much as a single stage regulator and start at about $140-$300. A two stage regulator may not be needed for most home hobbyist applications. So save your money! Hopefully you now have some information to help you purchase the correct regulator.

Gas Cylinder Safety Tips:

Proper handling of gas cylinders is one aspect that usually gets overlooked in the welding industry. Most welding gases contain a combination of CO2, Argon, and Helium which are non flammable and non explosive but they can still be very harmful. If the cylinder gets knocked over causing the valve to be broken off, the exceedingly elevated pressure exiting from the cylinder can cause major harm to you, those around you, and any objects in the area.

Handling the cylinder properly should always be taken seriously. Accidents can happen in the blink of an eye and can cause permanent damage. The following are simple steps that can be employed when handling a gas cylinder.

Have a constant awareness of your surroundings at all times. If you are, transporting, removing from a machine or the cylinder is being stored, the cylinder ought to be firmly fastened. If appropriate, use a threaded cylinder cap when transferring the cylinder. This guards the valve lest the cylinder tips over or bumps into something.

There are a couple ways cylinders should be transported; the first is by using a cart. The second is by rolling the cylinder in its vertical position. The safest way is with the use of a cart which is intended exclusively for cylinders. Most carts include a chain or other restraint to secure the cylinder in place.

Always secure your cylinder with some sort of safety strap or chain while storing your cylinder weather you are storing it on or near your welder, or in a designated full/empty area. In addition, never use the cylinder as a storage hook for cables, MIG guns, power cords, welding torches. With the possibility of heat and the chance of arcs forming in combination with the cylinder can cause damage to the cylinder and be incredibly unsafe.

Every gas cylinder is intended to be used in a vertical position. Some cylinders hold liquid in addition to gas. Using the cylinder in a horizontal arrangement can permit the liquid within the cylinder to escape or seep out of the cylinder.

The single most important advice in handling a cylinder is use your common sense. It is extremely imperative for you to be certain what you are doing when operating all welding and cutting equipment. If you are unconfident of a process please contact somebody who is knowledgeable. With the internet and all the other resources at your fingertips, the correct information is just seconds away.

Use caution at all times when handling welding gas. Everybody knows accidents can occur, so it is your responsibility to do your best in following any safety procedures. And remember; use common sense to keep you and all those around you safe. If a situation feels Unsafe, more often than not is. Take the time to ask somebody who is knowledgeable for help and keep the situation safe.