Work Area

Area Should be Clear and Free of
Combustibles




Area Should Be Well Ventilated
Fire Extinguishers Should Be Available
Area Should Be Free of Open Arcs or Flames
Fireproof Blankets and/or Screens Are
Suggested
Personnel Protection
 Wear Approved Eye Protection
 Wear Flame Resistant Clothing
 Wear Long Sleeves, Pocket Flaps and No
Cuffs
 Wear Approved Foot Gear
 Wear Approved Hand Protection
2
Proper Eye Protection
LENS SHADES SELECTION
FOR OXYGEN FUEL GAS
APPLICATIONS
Operation
Material Size
(inches)
Minimum
Protective
Shade number
Recommended
Shade Number*
Oxygen Fuel Gas
Welding
< 1/8”
1/8” to ½”
> ½”
4
5
6
4-5
5-6
6-8
Oxygen Fuel Gas
Brazing
3
3-5
Air Fuel Gas
Soldering
2
2-4
3
4
5
3-4
4-5
5-6
Oxygen Fuel Gas
Cutting
<1
1” to 6”
6
*As a rule of thumb, start with a shade that is too dark to see the weld or cutting
zone.
Then go to a lighter shade, which gives sufficient view of the weld or cutting zone
without going below the minimum.
2A
Proper Attire
Industrial Quality
Face Shield
Gauntlet Leather
Welding Gloves
Hightop
Leather Boots
(Steel Toes
Recommended)
2B
Hard Hat with
Visor Turned to the
Back
Long Sleeve Shirt
Pants without Cuffs
Oxygen Gas



Considered by Many as The Most Dangerous Gas
Know the Difference Between Oxygen and “Air”
Does Not Burn Itself, But Causes Other Materials
To Burn More Vigorously



3
Heat of Recompression – Open Valve Slowly
Keep Away From Combustibles – Especially Oil
Do Not Saturate Clothing, etc.
Combustion Theory
EQUILIBRIUM
EQUILIBRIUM
3A
9A
Courtesy of CGA
Oxygen Cylinder
Valve
Cap

Contents
Vigorously
Supports
Combustion
High Pressure
Hazard

High Pressure Cylinder –
2200 PSIG or
Higher
Hollow, Seamless Steel
Construction

Do Not Abuse Cylinder

Never Use For Other
Than Intended Use

Report Any Damage to
Supplier
Oxygen Cylinder
4
Oxygen Cylinder Valve



Compressed Gas Association
(CGA) 540
Stuck Valve – Valve Wrench
Only/Call Supplier
CGA 540
High Pressure Safety
Lower Valve
Seat
- Do Not Hang Objects On Cylinder
- Never Tamper With Valve
Construction
- Heat Source Can “Blow” Safety


5
To Oxygen
Regulator
Only Fully Open or Fully Closed
Report Any Leaking or Damaged
Valve to Supplier
Upper Valve
Seat
Burst
Disc
From Oxygen
Safety
Cylinder
Moving Oxygen
or Other High Pressure Cylinders

Moving Cylinders Not In
use:
– Must Have Caps On
– Do Not Lift – Roll on Bottom
Edge
– Use An Approved Carrier

Moving Cylinders That Are In
Use (Regulators Attached)
– Must Be In An Approved
Carrier!
6
Using Oxygen
And Other High Pressure Cylinder Gases
7

Secure Cylinder In A Cart Or to Strong Permanent
Structure

Do Not Use Near Flame, Flammables, Open Arc, Etc.

Use Only In An Upright Position

Use Only In A Well Ventilated Area

Always Inspect Cylinders For Damage

Valve Fully Opened or Closed
Acetylene Gas
8

Calcium Carbide and Water

Unstable and Highly Flammable

Shock Sensitive

Lighter Than Air

Not to be used above 15 PSIG
Acetylene Cylinder
Is Unique

Not Hollow –Acetone in Porous
Monolithic Filler Material

Should Only Be Used And Stored Upright

Has Fast Acting ValveOpen ½ - 1 Full
Turn

9
Has “Fusible Plugs” (212o F)
Acetylene Cylinder

Low Pressure – 250 PSIG @ 70o F

Thin Walls, Welded And Easily Damaged

Do Not Abuse – Can Explode If Abused

Do Not Use For Other Than The Intended Use

Never Use A Damaged Cylinder
–
–
–
10
Report Damages To Supplier
Do Not Attempt To Repair Leaks
Move Leaking cylinders Outside If Permitted
Using Acetylene

Flammable – Keep Cylinders Away From Sources of Ignition
or Heat
11

Shock Sensitive – May Decompose Violently

Limited Withdrawal Rate – “1/7th Rule”

Asphyxiation

15 PSIG Maximum Use Pressure

Do Not Use Copper Piping
Acetylene Fires
12

Most Fires Start In Valve Area – Check for Leaks

Fusible Metal Plugs Melt At 212o F

Flames – 5’ x 3’

Very Difficult To Extinguish

Evacuate Area

Call Fire Department
Alternate Fuels

Propane, Propylene, Etc.

Liquid Under Pressure

Heavier Than Air

Not Shock Sensitive

Can Be Used Up To Full Cylinder Pressure

Limited Withdrawal Rate –
Full and Ambient Temperature
8A
Dependent Upon Cylinder Size, %
Liquid Petroleum Gas (LPG)
Cylinder


Hollow, Welded, Thin Wall Cylinder
Vapor Space Above Liquid
–
Use Only While Standing Up

Low Pressure Less Than 500 PSIG

Has Fast Acting Valve
–


CGA 510 Valve
Handwheel
Handwheel
Packing Nut
Open ½ to 1 Full Turn
Valve Safety Relieves and Resets
To To
LPG
LPG
Never Use A Damaged Cylinder
Regulator
Regulator
Valve Seat
Valve Sea
Valve Safety
Valve Safety
9A
From LPG
Cylinder
Oxy/Fuel Equipment
Equipment Set Up


Secure Cylinders Before Removing Caps
“Crack” Oxygen Valve and Wipe Fuel Gas Valve With a
Clean Cloth

Attach Regulators With Smooth Jawed Wrench

Back Out Adjusting Screws

Torch Valves Must Be Closed

Tighten Wrench Connections According To Manufacturers
Instructions

13
Inspect and Test Equipment
NEVER REMOVE THE VALVE
PROTECTION CAP UNTIL CYLINDER
IS SECURED PROPERLY
6A
Secured Cylinders
13A
Tighten all connections
with smooth jaw wrench
13B
Equipment Inspection
14

Look For Any Physical Damage

Look For Other Signs of Abuse or Improper Use

Look For Contamination – Oil, Dirt, etc.

Clean, Replace Or Repair Before Use
Equipment Testing

Properly Tighten All Connections and Check To
See If All Valves Are Closed

Stand To The side And Open Valves Slowly

Check For Leaks
–

15
Use Approved Bubble Solution or Pressure Test
Fix Any And All Leaks Before Proceeding
Before Lighting Oxy/Fuel
Gas Torches




Make Sure All Valves Are Closed And Regulator
Adjusting Screws Are Backed Out
Set Gas Pressures According to the Manufacturers Tip Charts
Open Then Close Each Gas Valve Independently To “Bleed”
The System

16
Set Pressures “At Flow”
Lighting An Oxy/Acetylene Torch

Slightly Open Acetylene Valve And Light With An Approved
Device

Root Flame and Clear Smoke

Open Oxygen Valve And Set Flame To “Neutral”
–

17
Sharp, Defined Inner Cone
Never Light Torch With Both Oxygen And Acetylene Flowing
Welding Flame Types
Carburizing Flame
Neutral Flame
Oxidizing Flame
17A
Lighting Equal Pressure Torches
Using Alternate Fuel Gases



Open Torch Valves 1/8 to ¼ Turn
Ignite Fuel Gas With Approved Igniter and Adjust Flame
Introduce Oxygen And Adjust To The Desired Flame
–
–

It is Permissible To Light The Flame With Both Gases Flowing
–

Sometimes it is Necessary
Adjusting For Large or Heating Tips:
–
17B
“Star Pattern” or Sound
Tip Edge Touching Plate
Increase Fuel Then Oxygen In Successive Steps
Lighting Low Pressure
Injector Torches
17C


It is Permissible To Light Torch With Both Gases Flowing




Open Fuel Gas Valve ½ to ¾ Turn

Adjusting For Large or Heating Tips:
– Increase Fuel Then Oxygen In Successive Steps
Use Special Purge Sequence To Clear The System of Mixed
Gases
Open Oxygen Valve Slightly 1/8 to ¼ Turn
Ignite Flame With An Approved Igniter
Adjust To Desired Flame
– Tip Edge Touching Plate
– “Star Pattern” or Sound
Turning Off An
Oxy/Acetylene Torch
18

Proper Sequence Checks Integrity of Torch Valves

Close Oxygen Valve First

Close Acetylene Valve Second

If Acetylene Valve is Leaking a Small Flame Will Continue
Burning

If Oxygen Valve is Leaking, Torch Will “Pop” as Acetylene
Valve Is Closed

If Either Valve Is Leaking, Repair Before Further Use
Turning Off Alternate Fuel
Torches
18A

Close Fuel Gas Valve First

Close Oxygen Valve Second

This Sequence Can Prevent The Operator From Being Burned

If Fuel Pressure is Great Enough - Check Valves At Initial Light
Up By Turning Oxygen Off First
Shutting Down An
Oxy/Fuel Torch
19

Overnight Or For An Extended Period of Time

Turn Off Torch

Close Cylinder Valves

Open Then Close Each Torch Valve Independently To
Bleed Pressure

Back Regulator Adjusting Screw Out Until Loose

Store Hose and Equipment In a Clean Area Away From
Potential Damage
Check Valves and
Flashback Arrestors
CHECK VALVES
 Are a one way valve that stops the reverse flow of gases
FLASHBACK ARRESTORS
 Have a special element, sintered metal filter, that can

20
quench a flame
Generally also include a check valve
Check Valves and
Flashback Arrestors
CHECK VALVES

Are the basic safety device

Prevents flash back accidents caused by “reverse flow”
-Flashbacks can cause the most serious injuries

Check valves can fail because of “dirt” or other contamination
-Keep equipment clean
-Check them periodically
21
Checkvalves
HOW THEY WORK…
CORRECT FLOW
21A
REVERSE FLOW
Check Valves and
Flashback Arrestors
FLASHBACK ARRESTORS
22

Flashback arrestors are the ultimate safety device

Usually have a check valve built into it, but, can also stop a
flame
-The check valve can fail because of contamination

The Heat sink element will absorb heat from a fire

The element should also be kept free of contamination and
checked periodically
Torch vs Regulator Flash
Back Arrestors
Where should Check Valves and Flashback Arrestors be Mounted
The Golden Rule:
“Mount them as close to the point of mixing as possible”
Torch Mount
23

Gives the best and most protection

May be inconvenient for the operator

Cannot be used for “high flow” applications

Are subjected to more abuse
Mount at the Torch vs
Regulator
-continued
Regulator Mount

Should use check valves at the torch also

High flow types are physically too large for torch

Take less abuse because they are out of the way
Do Not Use Both
24

Too much restriction

Could cause other safety problems