Oxy‐Fuel Safety Training Leader’s Guide

OXY‐FUEL SYSTEM SET‐UP & SHUT‐DOWN PROCEDURE CHECKLIST –

ALTERNATE FUEL GAS

Items needed for demonstrations:

 Fire extinguisher
 PPE (Personal Protective Equipment):
o Lab coats/welding jackets
o Leather gloves
o Proper shade goggles or safety glasses for process being done
o Clear safety glasses
o Proper shade face shield for process being done (with safety glasses worn underneath)
 Oxygen cylinder
 Alternate fuel gas cylinder
 Open ended or crescent wrench

 Oxy‐Fuel Equipment for Heating / Welding / Brazing Torch:

o Oxygen pressure reducing regulator
o Alternate fuel gas pressure reducing regulator
o Grade T twin hose
o Oxy‐Fuel Torch handle with built‐in check valves and flashback arrestors (or add‐on
accessories)
o Heating/welding/brazing nozzle for alternate fuel gas (size to be determined based on gas
being used and cylinder size available)

 Oxy‐Fuel Equipment for Cutting Torch:

o Oxygen pressure reducing regulator
o Alternate fuel gas pressure reducing regulator
o Grade T twin hose
o Oxy‐Fuel Torch handle
o Cutting attachment
o Appropriate cutting tip for alternate fuel gas (i.e. 1‐GPN)
o Striker
Note: This demonstration can also be done with a straight cutting torch.

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 Oxy‐Fuel Safety Training Leader’s Guide

OXY‐FUEL EQUIPMENT SET‐UP: ALTERNATE FUEL

Inspection & Installation of Cylinders, Regulators and Hoses
Check each step once completed: Completed
 Utilize all appropriate PPE throughout the demonstration.
 Inspect all inlet and outlet valves, threads and seats on both the cylinders and the regulators.
o Inspection includes:
 Valves free from oil, grease and dirt
 No dents/dings on cylinders or regulators
 Clear both cylinder valves correctly:
o Stand on the opposite side of the valve
o Crack the valves by opening slightly for about 5 seconds
 Install the regulators correctly:
o Oxygen regulator on oxygen cylinder, alternative regulator on alternative fuel gas cylinder
o Tighten with open ended or adjustable wrench
 Inspect hose fittings for damage and attach correctly:
o Inspection includes:
 Hose fittings free of oil and grease
 No cracks, cuts, burns worn areas in hose
 Green hose attached to oxygen regulator; red hose to alternative fuel gas regulator
 Tighten both with appropriate wrench
 Open gas cylinders utilizing specific techniques per gas:
o Oxygen cylinder:
 Ensure adjusting mechanism on regulator is “backed out”
 Stand opposite of regulator valve
 Open slowly to stabilize
 Continue by opening cylinder valve completely
o Alternate fuel gas cylinder:
 Repeat process
 Leave tool for opening valve in place for quick shut off
 Purge both hoses by opening the regulator valves correctly per gas, one at a time:
o Open first regulator valve and set to 5 PSI
o Allow gas to flow for 5 seconds
o Close first regulator valve before opening other gas valve
Notes:

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 Oxy‐Fuel Safety Training Leader’s Guide

1) HEATING, WELDING, OR BRAZING TORCH SET‐UP FOR ALTERNATE FUEL

Heating/Welding/Brazing Torch Inspection & Assembly
Check each step once completed: Completed
 Inspect the torch handle and heating/welding/brazing nozzle thoroughly:
o Inspection includes: Check for damage on valves, fittings and seating areas; ensure both o‐
rings are intact and in place on cone end of nozzle; ensure torch is free from oil and grease;
make sure nozzle is free from slag or obstructions at flame end
 Assemble the torch correctly:
o Heating/welding/brazing nozzle: Hand‐tightened (no use of wrench) onto handle
 Attach the hoses correctly:
o Green hose to oxygen fitting on handle; red hose to alternate fuel gas fitting on handle
o Tighten both with appropriate wrench
Notes:

Leak Check and Purging of Heating/Welding/Brazing Torch

Check each step once completed: Completed
 Perform the leak check on the torch correctly:
o Ensure adjusting mechanism completely backed out on both regulators
o Starting with oxygen: Open cylinder valve slowly until high pressure gauge reading stabilizes,
then shut off cylinder valve; monitor gauge for any pressure drop; no leak – open oxygen
cylinder valve; adjust oxygen regulator to deliver 20 PSI
o Repeat process with alternate fuel cylinder valve and regulator with PSI EXCEPTION:
 Alternate fuel gas regulator should be set to deliver only 10 PSI
o Close both oxygen and alternate fuel gas cylinder valves
o Turn adjusting mechanism counterclockwise one‐half turn
o Observe gauges on both regulators for a few minutes, if no changes in gauge readings –
system is leak tight
o Open cylinder valves again; any movement of needles on regulator gauges indicates possible
leak: If leak is observed – STOP ‐ DO NOT USE!
 Check all connections; if leak can’t be found, have equipment inspected by a
qualified technician
 Purge the torch correctly:
o Starting with oxygen: Open oxygen valve on torch handle and adjust oxygen regulator to
required delivery range; close oxygen valve on torch handle; this will purge the oxygen hose
o Repeat process for alternate fuel gas side: Open alternate fuel gas valve on torch handle for 3
to 5 seconds, then shut it off
o Check both regulator pressures and reset if necessary
Notes:

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 Oxy‐Fuel Safety Training Leader’s Guide

Lighting the Heating/Welding/Brazing Torch, Adjusting the Flame, Setting a Neutral Flame, and Shutting Down
Check each step once completed: Completed
 Light the heating/welding/brazing torch correctly:
o Hold torch in one hand, spark lighter in the other
o Point torch away from people, equipment and flammable materials
o Open torch fuel valve about 1/8 turn
o Ignite gas with spark lighter
o Continue opening fuel valve until smoke and soot disappeared
 Adjust the flame correctly to get a bright neutral flame:
o Slowly open oxygen valve on torch until neutral flame achieved
 Shut down the torch flame properly:
o Oxygen valve shut off first
o Alternate fuel gas valve shut off last
Notes:

Shut‐Down of Heating/Welding/Brazing Torch System

Check each step once completed: Completed
 Shut down and bleed the pressure from the system correctly:
o Close both cylinder valves on gas supply
o Open fuel gas valve on torch, bleed the pressure, close fuel gas valve
o Same with oxygen valve (open valve on torch, bleed, close valve)
** CAUTION: Never have both valves open at the same time as it could cause a reverse
flow of gases!
o Release tension on adjusting screws
 Turn counterclockwise until they move freely
 Wait a few minutes and check inlet gauges to ensure no pressure remains in system
Notes:

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 Oxy‐Fuel Safety Training Leader’s Guide

CUTTING TORCH SET‐UP FOR ALTERNATIVE FUEL

Cutting Torch Inspection & Assembly
Check each step once completed: Completed
 Inspect the torch handle and cutting attachment thoroughly:
o Inspection includes: Check for damage on valves, fittings and seating areas; ensure both o‐
rings are intact and in place on cone end of cutting attachment; ensure torch is free from oil
and grease; make sure cutting tip is free from slag or obstructions
 Assemble the torch correctly:
o Cutting attachment: hand‐tightened onto handle (no use of wrench)
o Cutting tip: tightened with wrench for proper seating
 Attach the hoses correctly:
o Green hose to oxygen fitting on handle; red hose to alternative fuel gas fitting on handle
o Tighten both with appropriate wrench
Notes:

Leak Check and Purging of Cutting Torch

Check each step once completed: Completed
 Perform the leak check on the torch correctly:
o Ensure adjusting mechanism is completely backed out on both regulators
o Starting with oxygen: Open cylinder valve slowly until high pressure gauge reading stabilizes,
then shut off cylinder valve; monitor gauge for any pressure drop; no leak – open oxygen
cylinder valve fully; adjust oxygen regulator to deliver 20 PSI
o Repeat process with alternative fuel cylinder valve and regulator with PSI EXCEPTION:
 Alternative fuel gas regulator should be set to deliver only 10 PSI
o Close both oxygen and alternative fuel gas cylinder valves
o Turn adjusting mechanism counterclockwise one‐half turn
o Observe gauges on both regulators for few minutes; if no changes in gauge readings – system
is leak tight
o Open cylinder valves again; any movement of needles on regulator gauges indicates possible
leak; if leak is observed – STOP ‐ DO NOT USE!
 Check all connections; if leak can’t be found, have equipment inspected by a
qualified technician
 Purge the torch correctly:
o Starting with oxygen: Open oxygen valve on torch handle and adjust oxygen regulator to
required delivery range; depress cutting lever for 3 to 5 seconds; close oxygen valve on torch
handle; this will purge oxygen hose
o Repeat process for alternative fuel gas side: Open alternative fuel gas valve on torch handle
for 3 to 5 seconds, then shut it off
o Check regulator pressures and reset if necessary
Notes:

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 Oxy‐Fuel Safety Training Leader’s Guide

Lighting the Cutting Torch, Adjusting the Flame, Setting a Neutral Flame, and Shutting Down
Check each step once completed: Completed
 Light the cutting torch correctly:
o Hold torch in one hand, spark lighter in other
o Point torch away from people, equipment and flammable materials
o Open torch fuel valve about 1/8 turn
o Ignite gas with spark lighter
o Continue opening fuel valve until smoke and soot disappeared
 Adjust the flame correctly to get a bright neutral flame:
o Slowly open preheat oxygen valve on torch until neutral flame achieved
o Depress cutting oxygen lever; readjust if necessary
o Neutral flame = inner and outer cones are almost of equal length
 Shut down the torch flame properly:
o Oxygen preheat valve shut off first
o Alternative fuel gas valve shut off last
Notes:

Shut‐Down of Cutting Torch System

Check each step once completed: Completed
 Shut down and bleed the pressure from the system correctly:
o Close both cylinder valves on gas supply
o Open fuel gas valve on torch, bleed the pressure, close fuel gas valve
o Same with oxygen valve (open valve on torch, bleed, close valve)
** CAUTION: Never have both valves open at the same time as it could cause a reverse
flow of gases!
o Release tension on adjusting screws
 Turn counterclockwise until they move freely
 Wait a few minutes and check inlet gauges to ensure no pressure remains in the
system
Notes:

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