OxyFuel Equipment

Introduction
Oxyfuel welding is a welding process where the
heat for fusion is supplied by an torch using
oxygen and a fuel gas.
Several different fuel gasses can be used:

Fuel Gasses

Propane (LPG)
Natural Gas
Acetylene
MAPP
Hydrogen

Uses

Traditionally oxyfuel equipment was used for:

Brazing
Fusion welding
Flame hardening
Metalizing
Soldering
Stress relieving
Cutting
Bending

New technologies in the GMAW process has almost

eliminated the need for oxyfuel welding.
Primary uses today are heating, brazing and cutting.

OxyFuel Safety

The hazards of oxyfuel welding are primarily compressed gas

cylinders, flammable gases and open flame.
Common concerns are (pg 294)
PPE (shade 4 face shield/goggles, gloves).
Store and handle cylinders correctly.
Keep caps on cylinders whenever regulators are not attached.
Never use oil, grease, or any hydrocarbons on fittings.
Store cylinders in a locked enclosure.

Check system for leaks

Follow correct procedures for turning on and off.
Remove combustible materials from area.
Cutting slag can travel 35 feet on concrete

Insure adequate ventilation

OxyFuel system

Before discussing how the system works, it is important to know

the name of the parts.
A. Oxygen safety disc
B. Oxygen cylinder valve
C. Oxygen cylinder pressure
gauge
D. Oxygen working pressure
gauge
E. Oxygen regulator
F. Oxygen regulator adjusting
screw
G. Acetylene cylinder safety disc
H. Acetylene cylinder valve

I. Acetylene cylinder pressure

gauge
6

OxyFuel System--cont.
J. Acetylene working pressure
gauge
K. Acetylene regulator
L. Acetylene regulator
adjusting screw
M. Acetylene hose
N. Oxygen hose
O. Oxygen torch valve
P. Acetylene torch valve
Q. Torch
R. Welding tip
S. Acetylene cylinder
T. Oxygen cylinder
7

Oxygen Cylinder

One piece, seamless construction.

Each cylinder has unique serial
number and number is recorded in
national registry.
Scheduled inspection required.
2,200+ psi when filled
Safety disc, nut, releases at 3,000 psi.
Must not be dropped.
Should not be used as a roller.
Never use any lubricates on threads or
any part of the cylinder.
Three common sizes are 244, 150 &
80 cubic feet.
The valve should never be left
exposed. It must always have the
regulator attached or the cap on.
8

Oxygen Cylinder Valve

Special double seat

valve.
Must be opened all of
the way when in use.
Right hand threads

Acetylene Cylinder

Special cylinder because

acetylene is unstable above
15 psi.
Acetylene is shock sensitive.

Acetylene cylinders are filled entirely with a

porous materials which must be able to stop
the propagation of an acetylene
decomposition within the cylinder initiated by
a backfire or an external heating of the
acetylene cylinder.

250 psi when filled.

Protected by fuse plugs that melt at 212 oF.

The cylinder should be opened only 1/2 to
3/4 of a turn when in use.
The withdrawal rate in cubic feet per hour
should never exceed 1/7 times the cylinder
capacity.
Common sizes are 300, 120 and 75 cubic
feet.
The cylinders must always be used,
transported and stored upright.

10

Acetylene Valve

Acetylene cylinders
are low pressure
cylinders, therefore the
valve packing can
contain the cylinder
pressure and only a
single seat is used.
Fuel cylinders are left
hand threads.

11

LPG Gas Cylinders

Simpler hollow steel containers.

New regulations require float shut-off.
Because gas is under pressure,
cylinder contains both liquid and
vapor.
Equipped with spring loaded pressure
relief valve.
Newer style fitting being adopted.
Common sizes are 30, 70, and 100
pound.

12

Pressure Regulators

Gas systems must have a

pressure regulator to reduce
the pressure from the high
pressure in the cylinder down
to the working pressure.
Many different designs are
used.
They range from simple fixed
output, commonly used for gas
grills and camping stoves,
to double stage regulators used
for oxyfuel welding.

13

Regulators

Oxyfuel welding and cutting

uses two types
Single stage
Two stage

Correct use
Insure adjusting screw is
back off when shut down.
Check before starting.
Set correct working
pressure.

Two potential problems

Regulator creep
Gauge not returning to zero

14

Regulator Problems
Regulator Creep

Regulator creep is a potentially dangerous condition that

occurs when the regular does not maintain working pressure.
When the system is on, and no gas is flowing, the working
pressure slowly increases.

Potential outcomes:
Rupture of regulator safety relief valve.
Explosion of low pressure gauge.
Rupture of gas hose.

Causes
Foreign material inside the regulator.
Failure to release the regulator adjusting screw before opening
the cylinder.
Normal wear

15

Regulator Problems
Not Returning To Zero

The bourdon tube inside the

regulator can be damaged,
distorted.
When this occurs, the gauge
needle does not return to
zero.
Causes
Opening cylinder with the
regulator adjusting screw
turned in.
Hard impact.

16

Working Pressure

Oxygen and fuel gas working pressure should

be set according to manufactures
recommendations for the job being performed.
Potential problems with excessive pressure.
Harsh flame
Damaged equipment
Increased potential of flashback.

Potential problems of insufficient pressure.

Insufficient heat
Unstable flame
Increased plugging of welding or cutting tip.

17

Size selection chart for Victor welding tips.

Welding Tip Size

Metal
Thickness

Tip
Size

Oxy
Pressure

Acet
Pressure

Acet
cfh

1/6 4"
1/3 2"
3/6 4"
1/1 6"
5/6 4"
3/3 2"
1/8"
3/1 6"
1/4"
3/8"
1/2"
3/4"
1"
1- 1/4"
2"
3"
4"

000
00
00
0
0
1
2
3
4
5
5
6
7
7
8
10
12

5
5
5
5
5
5
5
7
8
9
10
11
12
12
12
20
23

5
5
5
5
5
5
5
7
8
9
10
11
12
12
12
14
15

1
2
2
3
3
5
8
14
21
31
31
41
52
52
65
94
130

Example welding tip selection

and working pressure chart.

18

Backfire & Flashback

Backfire: indicated when the torch goes out with a loud pop.
Caused by hot metal in the tip.
The gasses rapidly combust inside the tip and cause a burst of high
pressure.
When it occurs, stop and inspect the tip and clean if necessary.

Flashback: occurs when the flame burns inside of the torch.

Usually accompanied by a shrill hissing or squealing sound.
May have puffs of black smoke coming out of the tip.
A potentially serious condition. If not stopped the flame
can travel up the hoses and into the regulator.
Primary cause is a blocked tip and unequal working pressures.

The potential harm of both backfires and flashbacks is

controlled through the use of check valves and flashback
arrestors.

19

Oxyfuel Torch

The oxyfuel torch is the handle for holding and controlling the system.
It the controls the flow rate of the gasses and delivers them to the
welding tip, or cutting attachment.

The torch valves should only be hand secured, not tightened.

The valve stem packing should be tightened if gasses leak past or
when the torch valve becomes too easy to turn.
20

Oxyfuel Torches

Safety codes require torches to have check valves and

flashback arresters.
Note: this is a relative new code. Older torches will not have check
valves or flashback arresters

If not included, they should be added in line between the

regulator and the torch.

Flashback arrestor

Check valves

21

Oxyfuel Welding Tips

What is normally called a welding tip is actually a welding tip

and a mixing chamber.
Some manufacturers put the mixing chamber in the torch, Victor
are in the welding tip.

Tips have different sizes of

orifices.
Size usually indicated by
number.
Manufacturers use different
number systems.
When fuel gas other that
acetylene is used a larger
size tip is required.

Tips for heating may have multiple

orifices.
Tips require periodic cleaning.
A dirty tip will have a forked outer
envelope.

Tip orifice should be cleaned with a

tip cleaner.
22

Using Tip Cleaner

Start with the smallest size that

will enter the orifice without
excessive force and work up to
orifice size.
Be careful, a broken tip cleaner
usually means a destroyed tip.
Clean the face of the tip with the
included file.

23

Airacetylene Torch

Burns a mixture of
acetylene or MAPP and
air.
As fuel gas flows through
torch it draws in the
correct amount of air.
Lower temperature than
oxyacetylene.
Primary use is in soldering
and brazing copper piping.

24

Hoses and Connections

Requires special nonporous hoses.

Hoses are color coded.
Green: oxygen
Red or Black: fuel gas

Connections
Oxygen: right hand
Acetylene: left hand

Hoses should be protected from hot

metal and physical damage.

25

PPE

Use protection for:

Eyes
Body

Eyes
Correctly shaded lens--not sun glasses.
Shade 4 or 5

Body
Fire resistant gloves
Long sleeves
Button shirt

26

Setting Up Oxyfuel System

Extinguish all open flames and stop processes that produce

sparks.
Steps (assuming new system)
1. Secure cylinders
2. Remove caps
3. Crack cylinder valves
4. Connect regulators
5. Open cylinder valves
6. Connect hoses to cylinders
7. Connect hoses to torch body
8. Connect welding tip to torch body
9. Set working pressures
10.Check system for leaks.
27

Shutting Down System

Close cylinder valves

Open torch valves
Leave open until regulator gauges read zero.
Some sources recommend doing fuel first and oxygen last.

Close torch valves

Release tension on regulator adjusting screw.
Roll up hoses and place torch in a safe position.

28

Questions?

29