Presents

Oxy-Acetylene Safety
Awareness
Revised 6/01
Just a note
• This program is
informational only and
does not certify or
qualify any persons in
the use of Oxy-Acetylene
burning or welding.

• For the proper use of

your equipment, please
contact your supplier or
manufacturer
 Something to think on……
Every time you use the
oxy-acetylene equipment ,
if certain safety guidelines
are not followed, it would
be the same as handling
live explosives ready to go
off…….

Now let’s talk about the gases

 What is Oxygen
• Remember, oxygen is not air

• There is approximately 21% oxygen in normal air

• Oxygen is found naturally in the atmosphere

• It is produced industrially by distilling air below it’s freezing point

• Pure oxygen does not burn or explode

• Oxygen is an “accelerant” , it causes every thing it comes in contact with to burn

hotter and faster

• Air has a vapor density of 1.000, Oxygen is heavier than air (1.105) This means if a
oxygen bottle is leaking, the gas will settle in low areas before diffusing back into
the atmosphere.

• 30% oxygen in the atmosphere will cause things to burn or explode 8 times faster
 Never use oxygen……….
• in pneumatic tools- the oil and the gas pressure friction can cause a fire or explosion

• in oil pre-heating burners- these burners are set to burn with 21% oxygen to air ratio

• to start internal combustion engines- gasoline is flammable enough with 21% oxygen
available

• to blow out pipelines- Leftover flammable or combustible vapors may still be present to
cause an explosion

• to dust off clothing or work area- the oxygen will remain present in the cloth fibers
causing them to be more flammable

• to create pressure

• for ventilation

• Remember, oxygen is not air

 How are oxygen bottles constructed

• Usually of steel construction

• 244 cu. ft is standard size (K size)
• 2000 to 2600 psi
• Hollow in construction
• An electric arc can cause an oxygen bottle to explode (the
carbon in the steel will atomize into a fuel)
• The orifice at the top of the bottle is the diameter of the
lead in a pencil ( if the bottle top is damaged, the bottle
can become projectile causing injury or property damage
• Never allow a tank to go empty (this may allow acetylene
to travel into the oxygen lines or bottle
• Keep free from oil and grease
 What is acetylene
• Acetylene is a compound of Hydrogen and Carbon
(C2H2) a member of the hydrocarbon gases
• Explosive range is 3.0 to 93%
• Needs only 10% of oxygen to ignite
• Produced when calcium carbide is mixed with water
• It is an unstable gas, will violently decompose when
in a pure state above 15 psi
• Has a burning temperature of 4,600o F, 5,700o F when
burned with oxygen
• Auto-ignition temperature is 763o - 824o F, this means
if acetylene reaches 30 psi in a free state, it can
explode by itself without a spark or flame being
present
• Remember, acetylene is a very dangerous gas
 Why doesn’t acetylene explode in the bottle

• Acetylene burns in air readily, and is most safely hand-

led/stored in cylinders filled with crushed firebrick wet
with acetone.

• Acetylene happens to dissolve readily into acetone, and

the dissolved gas is no longer in contact with gaseous O2
(which does not tend to dissolve in acetone) and therefore
is not as prone to decomposition by O2.

• The firebrick also helps by minimizing the free volume of

the cylinder, cooling and controlling any thermal
decomposition before it gets out of control (each
decomposition of acetylene gives off heat).

• Acetylene cylinders must, therefore, be refilled only by authorized

gas distributors. Acetylene cylinders must never be transfilled.
 How are acetylene bottles constructed

• Usually are steel construction

• Filled with a porous material to allow the acetone to dissolve the
acetylene, which makes it stable
• Porous filler(8-10%), Acetone(42%)
• Acetylene gas(36%),
• Reserve volume-70o F(10-12%)
• Never allow a tank to go empty
– Oxygen may back pressure into the bottle
• Comes in various sizes
• Must always be stored upright
– This prevents the acetone and acetylene
from separating
• Should not be stored below freezing
– Acetone may come out instead of acetylene
and may clog the regulators
 Care & maintenance of the Gas Regulators
The internal working parts of the regulator are precision units. Only
qualified technicians should clean or repair a regulator

The Low pressure The High pressure gauge

gauge Indicates the pressure
Indicates the from tank
delivery
pressure to
the hoses & The Inlet Connections
torch Oxygen are right hand
thread/Acetylene are left
hand thread
Keep free of oil, grease, &
The Pressure adjusting screw dirt
Turning clockwise allows the gas allows to flow
Turning counterclockwise reduces or stops the gas
flow
Some more info on regulators
Warning -Always keep the regulator free of oil, grease and other
flammable substances

Never use oil or grease on the regulator, cylinder or manifold

connection

DO NOT change the inlet connection on a regulator in an

attempt to use the regulator for a different gas service

Never stand in front or behind a

regulator when opening the cylinder
valve
Backfires and flashbacks

• Backfires occur when the torch flame burns back into the
torch tip and is extinguished with a loud pop.
• They occur either because the torch tip touched the work or
because of insufficient gas pressure.
• They are generally harmless. However, flashbacks are more
serious when the flame front does not extinguish, but burns
back sometimes beyond the mixing chamber, through the
hoses, and even into regulator and supply.
• A common inside diameter of oxy-fuel gas hose is 1/4 inch. If
you calculate the volume of 100 feet of hose with an inside
diameter of 1/4 inch, this means, should oxygen enter the
fuel gas hose or should fuel gas enter the oxygen hose, a
mixed gas explosion with the force potential of 20 sticks of
dynamite could occur.
 Check valves
•The purpose of an internal check valve is to reduce the
possibility of reverse flow gas.
•It is not intended to act as a fire stop!
•Ensure that the internal check valves are working properly
by testing at least every six months, more often if the hoses
are frequently removed from the torch.

Spring activated

Gas flow Once flow

pressure
decreases, valve
will closes
Flow of gas keeps valve open preventing back
flow of gas
 Flashback arrestors
•Flashback arrestors are designed to prevent a
flashback from reaching upstream equipment.

•They offer added safety and often include reverse flow

check valves in a single unit

Torch handle

Flame path is extinguished by meshed

material inside
 The Hoses
• The hoses are usually color coded, but not always
– Oxygen(green)
– Acetylene(red)
– Be careful not to use other hoses, such as air lines, LP gas, etc.
• They are neoprene over braided inner section
– Be careful around sharp objects, they can be cut very easily
• They are constructed of flame retardant materials, but will burn if there is a flashback or exposed to sustained
heat
• Hoses are graded
– Make sure you are using the right hose for the right gas
 More hose stuff
• Keep welding hoses clear of any failing metal, slag or
sparks.
• Never allow hoses to become coated with oil, grease or
dirt. Such coatings could conceal damaged areas.
• Examine the hoses before attaching to welding torch
handle or regulators.
• If cuts, burns, worn areas or damaged fittings are
found, replace the hose.
• Completely replace welding hose if it contains multiple
splices or when cracks or severe wear is noticed.
 Torch handle

Control valve &

body”Y”

Barrel

Torch head
Torch cutting attachment

There must always be two

o-rings on the cone end.
The absence or damage of
either of these o-rings
allows premixing and leaks
of oxygen and fuel gases.
This can lead to flashback
within the torch handle.
What size cutting-tip do I need?
The type of torch you are using and the thickness of material
being cut determine the proper size cutting-tip for use in oxy-
acetylene flame cutting
•Always make sure your equipment is rated for the size tip you
have selected.

•A tip with too much capacity for the equipment can starve or
choke the tip. This causes overheating of the head and a
flashback may result.

•A damaged seating surface on either the tip or the head can

create a dangerous condition, resulting in a fire or flashback.
This may damage the cutting attachment.

•If the seating surface of a tip becomes damaged, DO NOT use

it. Discard the damaged tip.

•If the head requires repair, take the torch to a qualified repair
technician.
What tip sizes do I use for oxy-acetylene welding and what
pressures do I set on my regulators?

Tip sizes and gas regulator settings are dependent on the

thickness of the material to be welded and the type torch being
used
Always refer to the manufacture’s
supplied cutting chart for the
cutting tips you are using.

Remember, if you do not use the

proper oxygen to acetylene ratio,
you may cause an accident, at the
very least you will waste gas,
which costs $$$$.
 Cutting tips
and nozzles

• Never starve or choke a multi-flame heating nozzle.

This causes overheating of the head and a
flashback may result.
• Should a flashback occur (flame disappears and/or
a hissing sound is heard, the flame is burning inside
the nozzle), immediately turn off the oxygen valve
on the torch handle. Then, turn off the fuel valve.
• Allow the nozzle to cool before using.
• If a flashback reoccurs, have the apparatus
checked by a qualified technician before using
again.
 Laws & Regulations
for
Oxy-Acetylene Use

Link to MSHA Regulations

Link to OSHA Requirements

Link to Pennsylvania Stat

e Requirements
 Let’s Finish With Some Final General Safety Tips

• Never allow oxygen to contact oil, grease or other

flammable substances

• Never mix brands

• Purge the lines before and after usage

• Always wear protective clothing

• Use proper eye protection

If flashback occurs, immediately turn off the O2, then the
acetylene, and allow unit to cool

Always work in a well ventilated area

Always light the acetylene first

Oxygen cylinders must be opened the whole way

Use an approved striker, never use matches or cigarette lighter

Use the proper regulator for each specific gas

Only qualified technicians should repair a regulator

Keep regulators free of oil, grease and other flammable

substances
General Safety Tips
Keep regulators free of oil, grease and other flammable
substances

Check valves stop reverse gas flow, they do not act as a fire
stop

Never starve a tip, this can cause a flashback

Always keep cylinders in an upright position

Never stand in front or behind a regulator when opening the

cylinder valve

Do not open acetylene valve more than 1 1/2 turns

Always make sure area is safe and flammable free

 Safety Checklist for Getting Started
What is the necessary safety equipment you need?
•Proper Eye protection

•Appropriate gloves

•Clothing free of grease & oil

•Clean work area

•Proper Task Training

•Fire extinguisher
Thank you and Be
Careful