November 2010

Use of Flashback Arrestors

A flashback is an unintentional and uncontrolled event where the burning of gas moves upstream into an oxygenfuel gas supply system, resulting in possible serious injury and damage to equipment. People using portable and mobile oxy/fuel gas systems for welding, heating or cutting metal in industries such as plumbing, engineering, demolition, farming, lift installing, scrap metal, air conditioning and gas fitting are those most at risk of a flashback. All fuel-gas flashback arrestors are labelled for whichever fuel-gas it has been designed and for the service pressure for which it is suitable. All fittings on fuel-gas flashback arrestors are left hand thread.

Why are flashback arrestors essential?

A flashback occurs too quickly for the gas to be manually shut off before damage may occur. A flashback is capable of travelling through a supply system at speeds of up to 13 meters per second. Therefore, it is essential that, as a minimum requirement, all oxygen/fuel gas welding, cutting and heating systems be fitted with flashback arrestors to the torch end. For optimum protection flashback arrestors should be fitted to both the regulator and blowtorch ends. Flashback arrestors must be of the correct type and size as recommended by the manufacturer. If they are not of the correct type and size, there may be insufficient gas flow to safely and efficiently complete the work.

What causes flashback

Flashback begins when the flame moves back from the welding tip and into the blowpipe, usually with a loud bang or a shrill hissing noise. Most flashbacks are caused by faults in gas hose fittings, resulting from wear and tear, dirt, excessive heat, carbonising, damage during transport or storage, or from incorrect operating procedures. Uneven gas pressure in the two supply hoses may cause the blowpipe flame to move into whichever gas hose is under least pressure. The occurrence of a flashback always indicates that something is wrong, either with the equipment or the work procedure. Always ensure the cause of the flashback is discovered before attempting to re-light.

Equipment Damage
Correct use and maintenance of flashback arrestors will minimise the risk of equipment failure because of flashback, however flashback arrestors may be damaged by repeated flashbacks and lose their effectiveness. After any flashback incident, flashback arrestors, gas hoses and fittings should be removed from use, inspected by a competent person and if necessary either discarded or repaired to conform to the manufacturers specifications or the relevant Australian Standards. While the fitting of flashback arrestors is essential, they are not a substitute for safe work procedures, safe transport and storage, regular checks and maintenance, instruction, information, training, supervision for operators or for following the manufacturers safety guidelines.

What is a flashback arrestor?

Flashback arrestors are fitted with a sintered flame trap, which will quench the flame, and a non-return valve, which closes off the gas supply in the event of a pressure wave entering the flashback arrestor. Most flashback arrestors are fitted with a temperature sensitive cut-off valve, which closes if the arrestor becomes overheated. Oxygen flashback arrestors are labelled for oxygen and for the service pressure for which it is suitable. All fittings on oxygen flashback arrestors are right hand thread.

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Maintenance
It is essential that all gas welding, cutting and heating equipment is regularly maintained by a competent person and that sufficient instruction, information, supervision and training is provided to operators in the prevention of flashback. Oxygen and fuel-gas flash back arrestors should be regularly inspected by a competent person to ensure they are undamaged and correctly connected. It should be ensured that the correct flashback arrestor is fitted, clearly labelled for oxygen or the type of fuel-gas in use and with a suitable service pressure marking. For fuel gas or oxygen/fuel-gas systems it is advisable to keep records of all inspections.

Emergency procedures
If flashback occurs and the flame moves into the blowpipe, a shrill hissing sound will be heard. Close the blowpipe oxygen valve immediately then close the fuel gas valve. Note: This is the reverse of the normal shut down procedure.

For further information

For further information refer to Australian Standard AS 4839-2001 -The safe use of portable and mobile oxyfuel gas systems for welding, cutting, heating and allied processes and Australian Standard AS4603-1999 -Flashback arrestors-Safety devices for use with fuel gases and oxygen or compressed air.

Safe start up procedures

Before lighting the blowpipe, each gas hose should be purged separately, and the gas allowed to flow freely until the operator is sure the hose contains no impurities such as water, dirt or blockages. After purging, shut each blowpipe valve. This operation should take place in a well-ventilated area away from any naked flame or ignition source. The purging process should follow each period of nonuse before re-lighting. If there are any signs of leakage, fluctuating gas supply, gas starvation or misshapen flames, the equipment should be shut down and the fault corrected. Failure of hoses and fittings can allow gas to escape and trigger a workplace fire or explosion.

Note: This guidance material has been prepared using the best information

WSACT GN 0022 Further information

November 2010

available to WorkSafe ACT. Any information about legislative obligations or responsibilities included in this material is only applicable to the circumstances described in the material. You should always check the legislation referred to in this material and make your own judgement about what action you may need to take to ensure you have complied with the law. Accordingly, WorkSafe ACT extends no warranties as to the suitability of the information for your specific circumstances. WorkSafe ACT disclaims all responsibility and liability for all expenses, losses, damages and costs you might incur as a result of the information being inaccurate or incomplete.

worksafe.act.gov.au Phone: 02 6207 3000 Email: worksafe@act.gov.au

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