SAFETY INFORMATION

EIGA

Published by the Safety Advisory Group

EUROPEAN INDUSTRIAL GASES ASSOCIATION

av. des Arts 3-5, B-1210 Bruxelles. Tel : 32 2 217.70.98 Fax : 32 2 219.85.14 e-mail : info@eiga.org

Safety Information 05/00/E Revision of Safety Information 05/93/E

FLASHBACK AND FLAME ARRESTORS

Backfire and flashback can happen. In oxy-fuel processes it is important to use safety devices to prevent mishaps in the equipment. This issue of Safety Information deals with the most frequently used safety devices for the prevention of backfire and flashback in oxy-acetylene equipment. Oxygen and acetylene may be hazardous if improperly used or handled. This type of equipment should not be used unless proper safety procedures have been understood and applied. The gas and equipment suppliers should place safety and product information at the disposal of the customer. In a backfire the flame burns back into the torch with a cracking sound. Either the flame is extinguished, or it is reignited at the nozzle opening. In a sustained backfire the flame continued back into the torch, often reaching the mixing point for oxygen and fuel gas. An initial crack is followed by a whistling sound. Regarding the cause, general preventative measures and hazards of both backfire and sustained backfire, the reader should refer to the basic guidelines for welders. This Safety Information will only deal with the specific risk of flashback, and the safety devices that can prevent it. Flashback - definition Here, the flame recedes through the torch back into one of the supply hoses. The hose can explode. In the worst case, the flame can continue into the regulator and into the cylinder. Causes of flashback A gas mixture in one of the hoses in combination with a backfire when igniting a burner can cause a flashback. The gas mixture in the hose results from reverse flow, i.e. when gas at a high pressure flows into a hose with a lower pressure. If there is sufficient gas mixture in the hose the explosion can be so violent that the hose bursts. Preventive measures To prevent reverse flow and the consequent risk of a flashback, check valves must be mounted on the torch. If a flashback were still to occur, it can be prevented from reaching the regulators and cylinders by mounting some form of flashback arrestor on the torch and/or regulators. The different safety appliances are discussed below. They are dealt within different standards 1.

Check valves and flashback arrestors By using available safety devices the risk of flashback can in most cases be avoided. The most common safety devices are check valves and flashback arrestors. In some countries the use of check valve and/or flashback arrestors are mandatory, whereas in other countries there are only recommendations to this effect. Check valves are mounted on torches on both fuel gas and oxygen connections (see Figure 1). In many cases the torch is equipped with a check valve from the beginning. The check valve effectively prevents the reverse flow of gas. As already mentioned, reverse flow is a common cause of flashback. But check valves cannot stop flashbacks once they have occurred. If a check valve is to remain reliable, it is important to make functional test or replace it at regular intervals.

Figure 1: Check valves mounted on torch

A flashback arrestor effectively prevents a flashback from invading the gas supply system or cylinder, thus causing a serious accident. Flashback arrestors can either be torchmounted or regulator-mounted. Torch-mounted flashback arrestors (Figure 2) have two functions: stopping the flame in a backfire with a flame arrestor, and preventing reverse flow with a built-in check valve. The flame arrestor consists of sintered metal filter. Gas can flow through the filter, but a flame is extinguished. When using torch-mounted flashback arrestors remember that the flame arrestor causes a pressure drop and thus reduces the flow capacity. Check first what flow the application demands.

(1) ISO 5175 - EN 730 : 1995. Equipment used in gas welding, cutting and allied processes. Safety devices for fuel gases and oxygen or compressed air. General specifications, requirements and test.

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Page 2 capacity than a torch-mounted flashback arrestor. The disadvantage of having the arrestor mounted on the regulator is that it cannot prevent a hose explosion, which a torch-mounted one can do. Maximum safety is therefore achieved by having arrestors on both regulator and torch. This is possible unless high flows are needed. For high flow rates one must be content with check valves on the torch and flashback arrestors on the regulators. It is important to apply this protection not only to the fuel gas but also to the oxygen side. A flashback arrestor on the oxygen regulator can for example prevent oxygen from continuing to flow out in case of fire. This is important, as the additional oxygen raises the combustion rate.

Figure 2. Torch-mounted flashback arrestor

Regulator-mounted flashback arrestors are, as the name implies, mounted on the regulator or gas outlet (Figure 3).

1 3 2 4
Figure 3. Regulator-mounted flashback arrestor

Further safety devices Besides preventing reverse flow with the help of check valves, and extinguishing the flame after a backfire with a flame arrestor, a flashback arrestor can have the following functions: Cutting off the gas supply in the event of a backfire. If this function is activated, the operator himself can reset the trigger. Of course, it is important that the cause of the flashback is found first. Preventing gas from blowing out of the cylinder in case of fire. If this function has been activated, the arrestor cannot be reset - it must be replaced. The principles of these functions are illustrated in Fig. 4. Where to place these safety devices The advantage of having a flashback arrestor mounted on the regulator or outlet is that it can have a far greater flow

Figure 4: Flashback arrestor with four different functions

1. 2.

3. 4.

Pressure sensitive cut-off valve shuts off gas supply after a backfire. Flame arrestor extinguishes flame in the event of backfire. Non-return valve prevents reverse flow. Temperature-sensitive cut-off device cuts off heat supply in case of fire.

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