How Often Should Gas Regulators Be Replaced?

To effectively use gas regulators, you must have a comprehensive understanding of how they work. This ensures you get the best possible use out of them.

In this article, we’ll break down the importance of maintaining gas regulators, how often they should be tested and replaced, and tips for gas regulator compliance.

What do gas regulators do?

Gas regulators are essential devices that control the pressure and flow of gas from a high-pressure source to a safe and usable level for appliances. They ensure consistent performance, safety, and efficiency in residential, commercial, and industrial gas systems.

By automatically adjusting gas pressure, regulators prevent overpressure issues, reduce gas waste, and maintain stable appliance operation. They are used in applications such as BBQs, gas stoves, LPG cylinders, industrial machinery, and more. They serve as a critical component in gas distribution and usage.

For more information, check out our complete guide to how gas regulators work.

How long do gas regulators last?

Gas regulators generally need to be replaced every 5 years. However, there is no universal expiry date. This is why it is important to follow the manufacturer guidelines that the gas regulator is purchased from where this information is outlined in the product’s specifications or manual.

That said, industry experience and manufacturer guidance often suggest that some level of deterioration in performance may become noticeable after approximately 5 to 10 years of use. Environmental factors such as exposure to weather, contaminants, or fluctuating pressures can also influence a regulator’s longevity.

Even if your regulator appears to be functioning normally, subtle issues such as reduced flow rate or inconsistent pressure can develop over time and can affect the efficiency or safety of the gas regulator and system.

Given that performance can decline without visible signs of damage, routine testing plays a critical role in ensuring the ongoing safety and reliability of your gas installation.

How often should gas regulators be tested?

There is no specific testing time frame that is relevant for all gas regulators. Best practice is to always follow the manufacturer’s guidelines when it comes to testing and replacing a gas regulator, to ensure safety and performance. The guidelines are based on aspects including the regulator’s design, materials used to make the regulator and in what application it is being used in.

By regularly testing a gas regulator you will be able to pick up early indications of wear and tear, pressure drops and flow inconsistencies. It will allow you to find any issues early on before they turn into serious safety hazards.
Testing of a gas regulator is also dependent on where the gas regulator is installed and for what it is being used for. A gas regulator, especially a dual stage regulator, should be pressure tested every time the gas cylinder is changed over. A proactive approach to testing not only reduces safety risks but also helps determine the right time for a gas regulator replacement before serious malfunctions occur.

Non-Corrosive Environments

Regulators in clean, dry indoor areas generally experience less wear and exposure. As such, they are recommended to be inspected and tested at least once or twice a month to ensure they are stable and pressure and leak-free.

Mildly Corrosive Environments

These environments can include areas with occasional moisture, minor chemical exposure, or changing temperatures. It is recommended to test 1–2 times per month but visual inspections should be more thorough, checking for early signs of corrosion or seal breakdown.

Corrosive Environments

Corrosive environments can include areas such as laboratories with reactive gases, high humidity, salt air, or chemical vapours. In these environments, regulators are more prone to wear and failure. In these environments, it is recommended to test a gas regulator before each use to verify pressure stability, durability, and safety.

Why do gas regulators need to be replaced?

Not replacing or properly maintaining a gas regulator can cause a range of problems, from poor performance to serious safety concerns. Over time, the internal parts, like springs and seals, can wear out, leading to gas leaks, inconsistent pressure, or malfunctioning flow.

This can make appliances less efficient, increasing fuel costs and operational expenses. In more extreme cases, a faulty regulator can create fire hazards or even cause explosions, especially in environments with unpredictable gases or flammable materials.

If a damaged or outdated regulator isn’t replaced, it can also lead to equipment breakdowns such as stoves, heaters, or fridges not working properly. This can result in costly repairs or downtime. On top of that, continuing to use a faulty regulator can violate safety regulations and may even void warranties or insurance coverage.

Replacing a gas regulator is crucial because it ensures everything works as it should, reduces the risk of dangerous issues, and keeps you in compliance with safety standards. Regularly replacing and maintaining a gas regulator not only helps avoid costly repairs but also keeps gas systems running efficiently and safely, protecting both people and property.

Signs you need to replace your gas regulator

Even though you are testing and maintaining a gas regulator regularly there may be other visible signs that show you it may need your immediate attention. Aside from usual testing protocols, additional signs to look out for include:

• Yellow or inconsistent flames can mean the regulator isn’t supplying the correct gas pressure. Gas appliances should burn with a steady blue flame.
• A rotten egg smell could indicate a gas leak at the regulator or connections. You should turn off the gas and check it immediately. 
• A hissing sound from the regulator or its hose may signal a gas leak or pressure problem.
• If there’s no gas flowing despite full supply, the regulator might be blocked, damaged, or faulty.
• Ice forming on the regulator, especially on LPG systems, could mean it’s leaking or overworking.
• Excessive condensation or frost can also be a sign of internal failure.
• If the appliances that are being used drop in pressure, the regulator may not be keeping consistent flow.

If any of these issues have been identified it is crucial to prioritise safety first, it is recommended to turn the appliance off and shut off the gas supply to prevent any further issues. A licensed gas technician will need to investigate and resolve the problem.

How to maintain gas regulators

To keep a gas regulator in good condition you need to ensure it is maintained for safe and reliable performance.

Here are some useful steps for maintaining gas regulators: 

• Check for cracks, corrosion, rust, or dents on the regulator body. Look for loose fittings or kinked/damaged hoses. Inspect seals and gaskets which should be soft and crack-free.
• Wipe down the regulator and fittings with a dry cloth which will avoid moisture buildup.
• Use a soapy water solution or LA-CO Visu-glow Fluorescent Leak Detector on joints, valves, and regulator body to check for leaks. 
• For outdoor setups, use a regulator cover or install it in a sheltered area. Prolonged exposure to UV, rain, or salt air accelerates wear.
• If your appliances show signs of fluctuating flame size or low pressure, the regulator’s output should be checked. Pressure imbalances can cause inefficient combustion or safety issues.
• Follow the manufacturer’s recommended replacement cycle, typically every 5–10 years. 
• Never swap out the existing gas appliances with higher-capacity appliances, as the regulator is specifically sized and rated for what it is currently serving.

More tips for gas regulator compliance

Here are some extra tips and recommendations when it comes to compliance with best practices when it comes to gas regulators. By sticking to these, you’ll keep your gas systems safe and running smoothly while ensuring they stay reliable and meet all the necessary standards. 

• Match the regulator type to the gas type (LPG or Natural Gas), pressure rating, and appliance demand. Using the wrong type is a compliance and safety issue.
• Always install and maintain regulators according to manufacturer specifications and comply with local standards such as AS/NZS 5601 and AS/NZS 1596 (Australia/New Zealand Gas Installations). 
• Only use certified regulators with appropriate markings (e.g., AGA, UL144 or CE approval). If a regulator doesn’t have these markings, they may not meet compliance requirements. 
• Keep documentation of all installations, testing, and servicing for compliance tracking.
• Every time you install or swap out a regulator, perform a leak test using LA-CO Visu-glow Fluorescent Leak Detector on connections. If you see bubbles foaming, there is a gas leak.
• Keep records of inspection & maintenance and ensure that people who will be using appliances with a gas regulator are aware of how to deal with emergencies if any arise.

Explore Bromic Plumbing & Gas regulators

Gas regulators play a vital role in a wide array of commercial, residential and industrial settings. To ensure safety it is important to follow the manufacturer guidelines outlined in the product’s specifications or manual when it comes to maintaining and replacing a gas regulator.

Choosing the right gas regulator is essential for ensuring safety, performance, and compliance in any gas system. Explore our range of Bromic gas regulators and ensure your gas system operates safely and efficiently for your next project.