2. 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

3. 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

4. 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
Oxygen Fuel Gas Cutting
< 1
1” to 6”
3-4
*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

5. (Steel Toes Recommended)
Proper Attire
Industrial Quality Face Shield
Hard Hat with Visor Turned to the Back
Long Sleeve Shirt
Gauntlet Leather Welding Gloves
Pants without Cuffs
Hightop
Leather Boots
(Steel Toes Recommended) 2B

6. 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
Heat of Recompression – Open Valve Slowly
Keep Away From Combustibles – Especially Oil
Do Not Saturate Clothing, etc. 3

7. Combustion Theory
EQUILIBRIUM
EQUILIBRIUM 3A

8. 9A
Courtesy of CGA

9. Oxygen Cylinder High Pressure Cylinder – 2200 PSIG or Higher
Valve
Cap
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
Contents
Vigorously
Supports
Combustion
High Pressure Hazard
Oxygen Cylinder 4

10. Oxygen Cylinder Valve CGA 540 Compressed Gas Association (CGA) 540
Stuck Valve – Valve Wrench Only/Call Supplier
High Pressure Safety
- Do Not Hang Objects On Cylinder
- Never Tamper With Valve Construction
Heat Source Can “Blow” Safety
Only Fully Open or Fully Closed
Report Any Leaking or Damaged Valve to Supplier
Upper Valve
Seat
Lower Valve
Seat
To Oxygen Regulator
Burst Disc
Safety
From Oxygen Cylinder 5

11. 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

12. Using Oxygen And Other High Pressure Cylinder Gases
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 7

13. Acetylene Gas Calcium Carbide and Water Unstable and Highly Flammable
Shock Sensitive
Lighter Than Air
Not to be used above 15 PSIG 8

14. 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
Has “Fusible Plugs” (212o F) 9

15. 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
Report Damages To Supplier
Do Not Attempt To Repair Leaks
Move Leaking cylinders Outside If Permitted 10

16. Using Acetylene
Flammable – Keep Cylinders Away From Sources of Ignition
or Heat
Shock Sensitive – May Decompose Violently
Limited Withdrawal Rate – “1/7th Rule”
Asphyxiation
15 PSIG Maximum Use Pressure
Do Not Use Copper Piping 11

17. Acetylene Fires 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 12

18. 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 – Dependent Upon Cylinder Size, %
Full and Ambient Temperature 8A

19. 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
Open ½ to 1 Full Turn
Valve Safety Relieves and Resets
Never Use A Damaged Cylinder
CGA 510 Valve
Handwheel
Handwheel
Packing Nut
Packing Nut
To LPG
Regulator
To LPG
Regulator
Valve Seat
Valve Seat
Valve Safety
From LPG
Cylinder
From LPG
Cylinder
Valve Safety 9A

20. 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
Inspect and Test Equipment 13

21. NEVER REMOVE THE VALVE PROTECTION CAP UNTIL CYLINDER IS SECURED PROPERLY

22. Secured Cylinders
13A

23. Tighten all connections with smooth jaw wrench
13B

24. Equipment Inspection 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 14

25. 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
Use Approved Bubble Solution or Pressure Test
Fix Any And All Leaks Before Proceeding 15

26. 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
Set Pressures “At Flow” 16

27. 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”
Sharp, Defined Inner Cone
Never Light Torch With Both Oxygen And Acetylene Flowing 17

28. Welding Flame Types Carburizing Flame Neutral Flame Oxidizing Flame

29. 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
“Star Pattern” or Sound
Tip Edge Touching Plate
It is Permissible To Light The Flame With Both Gases Flowing
Sometimes it is Necessary
Adjusting For Large or Heating Tips:
Increase Fuel Then Oxygen In Successive Steps
17B

30. Lighting Low Pressure Injector Torches
It is Permissible To Light Torch With Both Gases Flowing
Use Special Purge Sequence To Clear The System of Mixed Gases
Open Fuel Gas Valve ½ to ¾ Turn
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
Adjusting For Large or Heating Tips:
Increase Fuel Then Oxygen In Successive Steps
17C

31. Turning Off An Oxy/Acetylene Torch
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 18

32. Turning Off Alternate Fuel Torches
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
18A

33. Shutting Down An Oxy/Fuel Torch
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 19

34. Check Valves and Flashback Arrestors
Are a one way valve that stops the reverse flow of gases
FLASHBACK ARRESTORS
Have a special element, sintered metal filter, that can quench a flame
Generally also include a check valve 20

35. Check Valves and Flashback Arrestors
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

36. Checkvalves
HOW THEY WORK…
REVERSE FLOW
CORRECT FLOW
21A

37. Check Valves and Flashback Arrestors
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 22

38. 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
Gives the best and most protection
May be inconvenient for the operator
Cannot be used for “high flow” applications
Are subjected to more abuse 23

39. 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
Too much restriction
Could cause other safety problems 24