Flashback Arrestor Safety Information

Check valves and flashback arrestors

FLASHBACK AND By using available safety devices, the risk of flashback can
in most cases be avoided. The most common safety devices
FLAME ARRESTORS are check valves and flashback arrestors. In some countries
the use of check valve and/or flashback arrestors are
Backfire and flashback can happen. In oxy-fuel
mandatory, whereas in other countries there are only
processes it is important to use safety devices to prevent
recommendations to this effect.
mishaps in the equipment. This issue of “Safety
Information” deals with the most frequently used safety
Check valves are mounted on torches on both fuel gas and
devices for the prevention of backfire and flashback in
oxygen connections (see Figure 1). In many cases the torch
oxy-acetylene equipment. Oxygen and acetylene may be
is equipped with a check valve from the beginning. The
hazardous if improperly used or handled. This type of
check valve effectively prevents the reverse flow of gas. As
equipment should not be used unless proper safety
already mentioned, reverse flow is a common cause of
procedures have been understood and applied. The gas
flashback. But check valves cannot stop flashbacks once
and equipment suppliers should place safety and product
they have occurred. If a check valve is to remain reliable, it
information at the disposal of the customer.
is important to make functional test or replace it at regular
intervals.
In a backfire the flame burns back into the torch with a
cracking sound. Either the flame is extinguished, or it is re-
ignited 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 Figure 1: Check valves mounted on torch
flashback, and the safety devices that can prevent it.
A flashback arrestor effectively prevents a flashback from
Flashback - definition invading the gas supply system or cylinder, thus causing a
Here, the flame recedes through the torch back into one of serious accident. Flashback arrestors can either be torch-
the supply hoses. The hose can explode. In the worst case, mounted or regulator-mounted.
the flame can continue into the regulator and into the
cylinder. Torch-mounted flashback arrestors (Figure 2) have two
functions: stopping the flame in a backfire with a flame
Causes of flashback arrestor, and preventing reverse flow with a built-in check
A gas mixture in one of the hoses in combination with a valve. The flame arrestor consists of sintered metal filter.
backfire when igniting a burner can cause a flashback. The Gas can flow through the filter, but a flame is extinguished.
gas mixture in the hose results from reverse flow, i.e. when
gas at a high pressure flows into a hose with a lower When using torch-mounted flashback arrestors remember
pressure. If there is sufficient gas mixture in the hose the that the flame arrestor causes a pressure drop and thus
explosion can be so violent that the hose bursts. reduces the flow capacity. Check first what flow the
application demands.
Preventive measures
To prevent reverse flow and the consequent risk of a
flashback, check valves must be mounted on the torch. If a (1) ISO 5175 - EN 730: 1995. Equipment used in gas
welding, cutting and allied processes. Safety devices for
flashback were still to occur, it can be prevented from fuel gases and oxygen or compressed air. General
reaching the regulators and cylinders by mounting some specifications, requirements and test.
form of flashback arrestor on the torch and/or regulators.
The different safety appliances are discussed below. They
are dealt with in different standards 1.

Figure 2. Torch-mounted flashback arrestor
Regulator-mounted flashback arrestors are, as the name
implies, mounted on the regulator or gas outlet (Figure 3).
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.
Flashback Arrestor Safety Information
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
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.
2
4
Figure 4: Flashback arrestor with four different functions
1. Pressure sensitive cut-off valve shuts off gas supply after a
backfire.
2. Flame arrestor extinguishes flame in the event of backfire.
3. Non-return valve prevents reverse flow.
4. Temperature-sensitive cut-off device cuts off heat supply in
case of fire.