Oxygen leaks are one of those problems that can sneak up on you, and they're more common than you may think. A small leak might not seem like a big deal at first, but over time, it can lead to wasted products, higher costs, and, most importantly, serious safety risks.

Whether you're filling cylinders, running a home healthcare operation, or maintaining equipment in the field, knowing how to spot and prevent leaks is key to keeping your facility safe and efficient.

What Causes an Oxygen Leak?

Leaks can happen at just about any connection point in an oxygen system. Some of the most common culprits include:

• Loose fittings or over-tightened connections
• Damaged or worn-out gaskets and O-rings
• Valve threads that aren't sealing properly
• Cracked tubing or small pinholes in lines
• Contaminants left behind during cleaning

Even the tiniest issue, like a missed gasket crack or debris in valve, can create a slow leak. And in a high-pressure oxygen system, a slow leak is still a big deal.

Spotting the Signs

Not all leaks are loud and obvious, which is why regular checks are so important. Keep an eye (and ear) out for:

• Hissing sounds neae valves or regulators
• Frost or condensation around fittings (a sign of escaping compressed gas)
• Unexplained pressure drops in a cylinder
• Unusual oders (oxygen is odorless, but leaks can carry impurities that have a smell)

If anything feels off, whether it's a sound, smell, or pressure issue, it's worth investigating right away.

How to Test for Leaks

Let's clear up one of the biggest myths first: soap and water are NOT safe ways to check for leaks in oxygen systems.

Why? Most soaps contain animal fats or petroleum-based ingredients. These can leave behind flammable residues on valves and fittings, and when they mix with oxygen, it can lead to combustion or even explosion.

Use the right tool for the job:

• Oxygen-safe leak detection fluid: OxyFill Leak Detection Solution is specifically designed for opxygen systems. It's non-flammable, water-soluble, and produces visible bubbles at the site of a leak.
• Pressure decay test: Monitor the system over time to detect abnormal drops in pressure. It's a simple but effective way to catch slow leaks.

Note: Always apply leak detection solution externally, never to internal components or valve openings.

Safety Notes on OxyFill Leak Detection Solution

• OxyFill is non-hazardous by OSHA standards, but it can cause serious eye damage or skin irritation with prolonged exposure.
• Always wear protective gloves and goggles and use in a well-ventilated area.
• In case of a spill, absorb inert material like sand and avoid contact.
• Clean all fittings thoroughly after testing and dry completely before putting the equipment back into service.

The Role of Cleaning in Leak Prevention

Cleaning may not seem directly related to leaks, but it plays a bigger role than you might think. Improper cleaning, especially in areas that contact oxygen, can leave behind residues that damage seals, degrade threads, or interact with high-pressure oxygen, increasing the risk of leaks or even fires.

Here are a quick few reminders:

• Use only oxygen-compatible cleaners on cylinder exteriors and regulators (our CGA-approved cleaner, #, is a great option)
• Never apply cleaners to valve openings, this area must remain residue-free
• Inspect for contamination using a black light before use or filling (try our # for inspection)

Make Leak Prevention Part of Your Routine

Preventing leaks isn't just about luck, it's about consistency. Work these best practices into your daily workflow: