Flashback

Prepared by the Safety Advisory Group Safety Info 05/08/E
Flashback and flame arrestors
Summary
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-fuel gas equipment. Oxygen and fuel gas 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.
Backfire and flash back

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 continues 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.
In a flash back, 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 flash back

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 (see References)

To prevent reverse flow and flashback, safety devices incorporating check valve and flashback arrestor must be
mounted on the torch and/or regulators.
The different safety devices are discussed below. They are dealt with in different standards 1,2.
Check valves and flash back 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 the use of these are only recommendations.
Check valves 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 tests or replace it at
regular intervals.
Check valves should be fitted on both fuel gas and
oxygen connections. They may be mounted at the
cylinder connection and/or the torch as shown in Figure 1: Check valves mounted on torch
Figure 1:
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Safety Info 05/08/E – Page 2
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 torch-mounted, hose-mounted or regulator-mounted.
Torch-mounted flashback arrestors (Figure 2) Figure 2. Torch-mounted flashback arrestor

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.
Hose-mounted flashback arrestors: functionally similar to torch-mounted ones, but as the name implies, mounted
on the gas hoses as near as possible to the torch.
Regulator-mounted flashback arrestors are, as the Regulator-mounted flashback arrestors incorporating

name implies, mounted on the regulator or gas outlet several functions as illustrated in Figure 4 have been
(Figure 3). available for many years.
Other models can include additional functions.
1 Pressure sensitive cut-off

valve shuts off gas supply
after a backfire.
2 Non-return valve
prevents reverse flow.
3 Flame arrestor
extinguishes flame in the
event of backfire.
4 Temperature-sensitive
cut-off device cuts off gas
supply in case of fire.
Figure 3. Regulator-mounted flashback arrestor and torch mounted

check valves
Figure 4: An example of a Flashback arrestor incorporating four
different functions
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

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Safety Info 05/08/E – Page 3
be reset - it must be replaced.
Where to place these safety devices

The advantage of having a flashback arrestor mounted on the regulator 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.
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.
(1) ISO 5175 Equipment used in gas welding, cutting and allied processes. Safety devices for fuel gases and oxygen or compressed air.
(2) EN 730-1: 2002 Gas welding equipment- Safety devices – Part1: Incorporating a flame (flashback) arrestor.
DISCLAIMER
All technical publications of EIGA or under EIGA’s name, including Codes of practice, Safety procedures and any other technical information contained in
such publications were obtained from sources believed to be reliable and are based on technical information and experience currently available from
members of EIGA and others at the date of their issuance.
While EIGA recommends reference to or use of its publications by its members, such reference to or use of EIGA’s publications by its members or third
parties are purely voluntary and not binding. Therefore, EIGA or its members make no guarantee of the results and assume no liability or responsibility in
connection with the reference to or use of information or suggestions contained in EIGA’s publications.
EIGA has no control whatsoever as regards, performance or non performance, misinterpretation, proper or improper use of any information or
suggestions contained in EIGA’s publications by any person or entity (including EIGA members) and EIGA expressly disclaims any liability in connection
thereto.
EIGA’s publications are subject to periodic review and users are cautioned to obtain the latest edition.

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Prepared by the Safety Advisory Group Safety Info 05/08/E

Flashback and flame arrestors

Backfire and flash back

Causes of flash back

Preventive measures (see References)

Check valves The check valve effectively prevents

1 EUROPEAN INDUSTRIAL GASES ASSOCIATION AISBL

Torch-mounted flashback arrestors (Figure 2) Figure 2. Torch-mounted flashback arrestor

Regulator-mounted flashback arrestors are, as the Regulator-mounted flashback arrestors incorporating

Other models can include additional functions.

1 Pressure sensitive cut-off

Figure 3. Regulator-mounted flashback arrestor and torch mounted

Further safety devices

2 EUROPEAN INDUSTRIAL GASES ASSOCIATION AISBL

be reset - it must be replaced.

Where to place these safety devices

3 EUROPEAN INDUSTRIAL GASES ASSOCIATION AISBL

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