An oxy-fuel cutting torch is one of the most useful, but dangerous tools. It provides welders with a convenient and clean way to efficiently cut metal. However, when using a cutting torch, you are literally playing with fire, which means safety is extremely important.
When used correctly, an oxy-fuel torch is safe and offers unmatched efficiency. Read on for the basics of using an oxy-fuel torch, installing and shutting down processes and a checklist for safer usage.
Why an Oxy-Fuel Cutting Torch Can Be Dangerous
It’s important to understand the triangle of combustion to comprehend the danger of oxy-fuel cutting. Combustion requires fuel, oxygen and a source of ignition, which are all elements that need to be controlled. Oxy-fuel processes produce sparks and flames, so having a clean, well-ventilated workspace is essential to safe operation. This process also produces small amounts of infrared rays, so be sure to wear the appropriate personal protective equipment as outlined in ANSI Z87.1.
The primary fuel choice for oxy-fuel gas-cutting processes is acetylene. This gas has an exceptionally high flame temperature, reaching highs of 3600 degrees Celsius, which makes it the fastest gas-cutting option. While the intense heat helps it cut through metal quickly and effectively, it also makes it one of the riskiest welding equipment options, when used improperly.
Contact a Meritus Gas team expert for the latest and safest oxy-fuel cutting torch equipment!
How to Safely Handle an Oxy-Fuel Cutting Torch
Safe handling ultimately comes down to how you handle fuel cylinders, the pressure coming out of the cylinders and the regulators. Here are some safety guidelines and video demonstrations from Harris Products Group on the handling and storage of gas cylinders:
Transport cylinders with caps installed.
Securely chain cylinders to a cart or structure.
Remove the cylinder caps and store in a safe place.
Debris is the enemy of a regulator, so make sure the valves are free of debris. Aim the oxygen cylinder valve outlet away from you, people and flammable surfaces and open the oxygen cylinder valve momentarily to blow out any trapped debris. DO NOT crack the fuel gas valve. Instead, clean it out with a wet cloth.
Visually inspect the oxygen and fuel gas regulator for damaged surfaces. Do not use the regulator if there are any damaged components.
Inspect the inlet and outlet ports to ensure they are clean and free of oil or debris
Assemble regulators onto the cylinder valves and tighten with a wrench.
Turn the regulator adjusting knob or screw counter-clockwise until it moves freely with no tension.
S-L-O-W-L-Y open the oxygen cylinder valve first and then the fuel gas cylinder valve.
Check both the oxygen and fuel gas regulators for leaks with a solution of warm soapy water or a pressure test. If using warm soapy water, apply the solution to the inlet connection and observe for leaks indicated by the formation of bubbles. If bubbles form, re-tighten the cylinder connection with a wrench and repeat the test. If bubbles continue to form, DO NOT USE and contact your gas supplier. For the pressure test, turn off the cylinder valve and wait 2-3 minutes. If the pressure on the gauge drops, then there is a leak. Re-tighten the connection and repeat the pressure test. If the pressure continues to drop, DO NOT USE and contact your gas supplier.
Now, you’re ready to install the hoses and cutting torch.
How to Install a Cutting Torch
Following the proper setup procedures ensures the torch is functioning properly and maximizes safety. Here’s how to properly install a cutting torch:
Inspect both hoses for cracks.
Attach the hoses and tighten the connections with a wrench.
Inspect the torch for damage and close the valves. Do not use the torch if there are damaged components.
Ensure hoses are straight and not kinked.
Check the entire system for leaks: Turn the oxygen regulator adjusting screw clockwise to get 10 psi on the gauge. Once we have 10 psi, perform a pressure test by closing the oxygen cylinder valve and observing both gauges for 2-3 minutes to ensure the pressure does not drop. Release the excess pressure by opening the oxygen torch valve.
Conduct the same pressure test with the fuel gas.
Open the oxygen and fuel gas cylinder valves again. Set the proper pressures based on manufacturer’s recommendations. Pressures should be set to “at flow.”
Always purge the system before lighting any torch! Always use torches that have check valves. Flashback arrestors can be used where appropriate. Contact the gas equipment manufacturer for guidelines on when and how to use flashback arrestors.
Now, let’s look at how to light the torch and adjust the flame.
How to Light, Adjust and Shut Down an Oxy-Fuel Torch
Knowing how to properly adjust and shut down an oxy-fuel torch is essential to prevent leaks, fires and burns. It also helps prevent over-pressurizing and wasting fuel. Here are the top tips to properly light, adjust and shut down an oxy-fuel torch:
Light only the fuel gas. You should never light both gases at the same time!
Determine if you have too much fuel gas, too little fuel gas or the right amount. You are looking for a properly adjusted or “neutral flame,” which is a sharply defined inner cone with no outer feather
If you have too little fuel gas, you will have a smoky flame. Clear the smoke by opening up the fuel valve more and introduce the oxygen to adjust to a “neutral flame.”
If you have too much fuel gas, close the fuel gas needle valve, clear the smoke and introduce the oxygen.
Always shut off the oxygen first and then the fuel gas to extinguish the oxy-fuel torch.
For more detailed safety information, please refer to Harris Products Oxy-Fuel Safety Guidelines. This blog is intended to offer useful reminders and guidelines — not to serve as a substitute for full hands-on operator safety training.
Checklist for Handling an Oxy-Fuel Torch
Even workers who are trained and have years of experience can sometimes forget essential safety steps when things get busy. Here’s a checklist to follow to work with an oxy-fuel torch more safely:
Check that cylinders are free from oils and grease, which raise the risk of combustion.
Ensure the cylinders are secured to a cylinder rack or stationary support to prevent them from tipping over.
Look for damage to O-rings, which can affect the fit and cause leaks.
Check the regulator or torch handle for an adequately installed reverse flow check valve to prevent backflow into the regulator, torch or hose.
Ensure the area has sufficient ventilation and wear the required PPE to prevent respiratory problems.
Remove debris from the valve with nitrogen or an oil-free rag.
Tighten the regulators and check that the connection is clean.
Leak test all the connections with an approved leak test solution and tighten the connection or take the equipment in for repairs if it persists.
Contact a Meritus Gas team expert for the best equipment to make the oxy-fuel-cutting process more efficient and safe.
Why Training Is Important for an Oxy-Fuel Torch
Training is crucial for understanding best practices and safety measures in welding and cutting. Workers who are already trained should keep up with the latest safety resources to stay updated on regulations.
Specifically, safety training can help prevent flashbacks that occur when an explosion goes through the hoses, cylinders, hoses and torch. Professional education can explain how flashbacks occur, what to look for to prevent them and how to spot them. It teaches operators to properly install flashback arrestors and follow protocol to adequately and safely cool the cylinders down.
Operator safety training also underlines how to work with acetylene to cut, weld, gouge or braze more efficiently and safely.
Contact Meritus Gas Partners for Gases and Welding Equipment
At Meritus Gas Partners, we’re determined to help businesses find the right equipment and tools for welding to scale their operations. We can help you upgrade your equipment and set up automation solutions to boost safety and efficiency. Find a partner near you for the best welding and gas solutions. Our professional team will help your business get the best prices and products to improve productivity and safety.
With decades in the industry and the best partners in the business, we can offer you everything from troubleshooting equipment to customized gas and automation solutions that guarantee your maximum efficiency. Contact us to request a solution!
