GAS WELDING

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

1
 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

Material Size Minimum Protective Recommended Shade
Operation
(inches) Shade number Number*

< 1/8” 4 4-5

Oxygen Fuel Gas Welding 1/8” to ½” 5 5-6
> ½” 6 6-8

Oxygen Fuel Gas Brazing 3 3-5

Air Fuel Gas Soldering 2 2-4

<1 3 3-4
Oxygen Fuel Gas Cutting 1” to 6” 4 4-5
6 5 5-6
*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 for OFW and
OFC
Industrial Quality Cap with Visor
Safety Glasses Turned to the Back

Gauntlet Leather Long Sleeve Shirt

Welding Gloves

Hightop Leather Boots Pants without Cuffs

(Steel Toes Recommended)

2B
 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
 Combustion Theory

EQUILIBRIUM

3A
 Oxygen Cylinder
Valve Cap

 High Pressure Cylinder – 2200 PSIG or

Higher

High Pressure Hollow, Seamless Steel Construction

Hazard
Contents  Do Not Abuse Cylinder
Vigourously
Supports
Combustion
 Never Use For Other Than Intended Use
 Report Any Damage to Supplier

Oxygen Cylinder
4
4A
 Oxygen Cylinder Valve
 Compressed Gas Association (CGA)
540 Upper Valve
Seat
 Stuck Valve – Valve Wrench Only/Call
Supplier
Lower Valve
 High Pressure Safety Seat
- Do Not Hang Objects On Cylinder
To Oxygen
- Never Tamper With Valve Construction Regulator
- Heat Source Can “Blow” Safety

 Only Fully Open or Fully Closed

 Report Any Leaking or Damaged
Burst Disc
Valve to Supplier Safety

From Oxygen Cylinder

5
 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
NEVER REMOVE THE
VALVE PROTECTION
CAP UNTIL
CYLINDER IS
SECURED PROPERLY

6A
 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
 Acetylene Gas

 Calcium Carbide and Water

 Unstable and Highly Flammable
 Shock Sensitive
 Lighter Than Air
 Not to be used above 15 PSIG

8
 Liquid
Petroleum Gases (LPG)
 Propane, Propylene Mapp®, Etc.
 Liquid Under Pressure
 Heavier Than Air
 Not Shock Sensitive
 Can Be Used Up To Full Cylinder Pressure
 Limited Withdrawal Rate – Cylinder Size, % Full, ,and Ambient
Temperature

8A
 Acetylene Cylinder Is Unique
Fusible
Plug

 Not Hollow – Monolithic Filler and Acetone

Monolithic
 Should Only Be Used And Stored Upright
Porous Filler
Material  Has Fast Acting Valve
Open ½ - 1 Full Turn

Fusible  Has “Fusible Plugs” (212o F)

Plug

Acetylene Cylinder
9
 Liquid Petroleum Gas (LPG)
Cylinder
CGA #510 Valve

 Hollow Welded Thin Wall Cylinder Handwheel

 Vapor Space Above Liquid Packing Nut

– Use Only While Standing Up

 Low Pressure Less Than 500 PSIG To LPG

Regulator
 Has Fast Acting Valve
– Open ½ to 1 Full Turn Valve Seat

 Valve Safety Relieves and Resets

 Never Use A Damaged Cylinder Valve Safety
From LPG
Cylinder
9A
 Acetylene Cylinder
Fusible
Plug

 Low Pressure – 250 PSIG @ 70o F

Monolithic
 Thin Walls, Welded And Easily Damaged
Porous Filler
Material  Do Not Abuse – Can Explode Because of Abuse
 Do Not Use For Other Than The Intended Use
Fusible
Plug
 Never Use A Damaged Cylinder
– Report Damages To Supplier
– Do Not Attempt To Repair Leaks
– Move Leakers Outside If Permitted

Acetylene Cylinder
10
 Using Acetylene

 Flammable – Keep 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
 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
 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
 Secured Cylinders

13A
 Tighten all connections with
smooth jaw wrench

13B
 Equipment Inspection

 Look For Any Physical Damage

 Look For Signs of Abuse or Improper Use
 Look For Contamination – Oil, Dirt, etc.
 Clean, Replace Or Repair Before Use

14
 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
 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
 OFW Welding Tip
Information
THICKNESS OF METAL TIP DIA. OF OXYGEN ACETYLENE
(Inches) SIZE WELDING ROD PSIG P.S.I.G.
1/64 0 -- 1 1

1/32 1 -- 1 1

3/64 2 1/16 2 2

1/16 3 1/16 3 3

3/32 4 3/32 4 4

1/8 5 3/32 5 5

3/16 6 1/8 6 6

¼ 7 1/8 7 7

5/16 8 5/32 8 8

3/8 9 5/32 9 9

1/2 10 3/16 10 10

¾ 13 3/16 13 13

1 15 ¼ 15 15

16A
 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
 Welding Flame Types
Carburizing Flame

Neutral Flame

Oxidizing Flame

17A
 Lighting Equal Pressure
Torches Using Alternate
 Open Torch Valves 1/8 to ¼ Turn
Fuel Gases
 Ignite Fuel Gas With Approved Igniter and Adjust Flame
 Introduce Oxygen And Adjust To The Desired Flame
– Tip Edge Touching Plate
– “Star Pattern” or Sound

 It is Permissible To Light The Flame With Both Gases Flowing

– Sometimes Necessary

 Adjusting For Large or Heating Tips:

– Increase Fuel Then Oxygen In Successive Steps

17B
 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
 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
 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
 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
 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 that can quench a flame
 Usually also include a check valve

20
 Check Valves and
Flashback Arrestors

20A
 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 accidents
 Check valves can fail because of “dirt” or other
contamination
-Keep equipment clean

-Check them periodically

21
 Checkvalves
HOW THEY WORK…

CORRECT FLOW REVERSE FLOW

21A
 Check Valves and
Flashback Arrestors
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