BCGA CP 7 - Rev 8 - For Publication

CODE OF PRACTICE 7
THE SAFE USE OF OXY-FUEL GAS

EQUIPMENT (INDIVIDUAL
PORTABLE OR MOBILE CYLINDER
SUPPLY)
REVISION 8: 2018
CODE OF PRACTICE 7
THE SAFE USE OF OXY-FUEL GAS EQUIPMENT

(INDIVIDUAL PORTABLE OR MOBILE CYLINDER SUPPLY)
REVISION 8: 2018
Copyright © 2018 by British Compressed Gases

Association. First printed 1986. All rights reserved. No
part of this publications may be reproduced without the
express permission of the publisher:
BRITISH COMPRESSED GASES ASSOCIATION

Registered office: 4a Mallard Way, Pride Park, Derby, UK. DE24 8GX
Company Number: 71798, England
Website:
www.bcga.co.uk
ISSN 2398-9440
ii
BCGA CP 7 – Revision 8
PREFACE
The British Compressed Gases Association (BCGA) was established in

l971, formed out of the British Acetylene Association, which existed
since l901. BCGA members include gas producers, suppliers of gas
handling equipment and users operating in the compressed gas field.
The main objectives of the Association are to further technology, to

enhance safe practice, and to prioritise environmental protection in the
supply and use of industrial gases, and we produce a host of
publications to this end. BCGA also provides advice and makes
representations on behalf of its Members to regulatory bodies, including
the UK Government.
Policy is determined by a Council elected from Member Companies,

with detailed technical studies being undertaken by a Technical
Committee and its specialist Sub-Committees appointed for this
purpose.
BCGA makes strenuous efforts to ensure the accuracy and current

relevance of its publications, which are intended for use by technically
competent persons. However this does not remove the need for
technical and managerial judgement in practical situations. Nor do they
confer any immunity or exemption from relevant legal requirements,
including by-laws.
For the assistance of users, references are given, either in the text or
Appendices, to publications such as British, European and International
Standards and Codes of Practice, and current legislation that may be
applicable but no representation or warranty can be given that these
references are complete or current.
BCGA publications are reviewed, and revised if necessary, at five-

yearly intervals, or sooner where the need is recognised. Readers are
advised to check the Association’s website to ensure that the copy in
their possession is the current version.
This document has been prepared by BCGA Technical Sub-

Committee 3. This document replaces BCGA Code of Practice 7,
Revision 7: 2014, incorporating Corrigendum 1. It was approved for
publication at BCGA Technical Committee 159. This document was
first published on 24/10/2018. For comments on this document
contact the Association via the website www.bcga.co.uk.
iii
CONTENTS
Section Page
TERMINOLOGY AND DEFINITIONS 1
1. INTRODUCTION 4
2. SCOPE 5
3. AWARENESS OF THE PROPERTIES OF GASES USED 5
4. LEGISLATION 6
5. EXAMINATION, INSPECTION AND MAINTENANCE 7
6. SIGNIFICANT HAZARDS 10
6.1 Backfire 10
6.2 Sustained backfire 10
6.3 Intermittent backfire 10
6.4 Flashback 10
6.5 Backflow 10
6.6 Decomposition 10
6.7 Ignition within an oxygen system 11
6.8 Oxygen leakage 11
6.9 Fuel gas leakage 11
6.10 Fumes 11
6.11 Noise 12
6.12 Manual handling 12
7. EQUIPMENT 13
7.1 Pressure regulators 14
7.2 Safety devices 15
7.3 Hose and hose assemblies 16
7.4 Blowpipes 18
8. CYLINDER STORAGE AND HANDLING 19

8.1 Cylinder storage 19
8.2 Cylinder handling 20
8.3 Cylinder transportation 21
9. PREPARATION FOR USE 21

9.1 Personal protective equipment 23
9.2 Fire protection 24
9.3 Work in confined spaces 25
9.4 Hot work on containers 26
9.5 Changes to the workplace atmosphere 28
9.6 Choosing a fuel gas 27
9.7 Location of gas cylinders 29
9.8 Gas cylinders 30
9.9 Pressure regulators 30
9.10 Safety devices 31
iv
9.11 Hose assemblies 32
9.12 Blowpipes 33
9.13 Nozzles 33
9.14 Pressurising the system 33
9.15 System purging 34
9.16 Lighting up 34
10. CLOSING DOWN PROCEDURE 34
11. INFORMATION, INSTRUCTION AND TRAINING 35
12. EMERGENCY PROCEDURES 36

12.1 Key actions for dealing with gas cylinders in the event of fire 36
12.2 Sustained backfire 37
12.3 Flashback / self-extinguishing backfire 37
12.4 Fire damaged gas cylinders 38
13. SECURITY 38
14. REFERENCES * 38
Appendices:
Appendix 1 Guidance on inspection and maintenance 44
Appendix 2 Minimum requirement for all hose sizes and lengths 48
For additional safety 49
Appendix 3 Three-seat cutting nozzles - Dimensions 50
* Throughout this publication the numbers in brackets refer to references in Section 14.
Documents referenced are the edition current at the time of publication, unless otherwise
stated.
v
TERMINOLOGY AND DEFINITIONS
Blowpipe A piece of equipment in which separate supplies of oxygen and fuel gas are
mixed in the appropriate proportions to obtain the required flame.
Composite A unit which embodies a flame arrestor and 1 or more of these devices:
safety device  Non-return valve
 Temperature sensitive cut-off valve
 Pressure sensitive cut-off valve
Bundle (of An assembly of cylinders that are fastened together and which are
cylinders) interconnected by a manifold and carried as a unit. The total water capacity
shall not exceed 3000 litres except that bundles intended for the carriage of
toxic gases of Class 2 (groups starting with letter T according to ADR (17)
2.2.2.1.3) shall be limited to 1000 litres water capacity.
Confined Any place, including room, chamber, tank, vat, silo, pit, trench, pipe, sewer,
space flue, well, or other similar space in which, by virtue of its enclosed nature,
there arises a reasonably foreseeable specified risk.
It has two defining features:

(i) It is a place which is substantially, (though not always entirely)
enclosed.
(ii) There will be a reasonably foreseeable risk of serious injury from;
flammable or toxic atmosphere, oxygen deficient or enriched oxygen
atmosphere.
[as defined in the Confined Spaces Regulations (3)]
Cylinder A transportable pressure receptacle of a water capacity not exceeding 150

litres.
NOTE: This includes the gas cylinder, the valve and all accessories
permanently fitted to the gas cylinder.
Flame A device which arrests a flame front (caused by flashback or decomposition)

arrestor and which is suitable for the most severe type of flame which may occur, i.e.
detonation.
Hose The means by which the gases are conveyed from the regulator to the
assemblies blowpipe.
Hot work Includes any process that generates a source of ignition (for example, naked
flames, heat, sparks) arising from working methods such as welding, flame
cutting, grinding and using disc cutters.
May Indicates an option available to the user of this Code of Practice.
1
Mixing That part of the blowpipe to which gases are separately conducted and in
systems which the mixing of gases takes place.
Non-return A self-actuating valve which prevents the passage of gas in the opposite
valve direction to the normal gas flow.
Specifically a non-return valve shall be effective against the return of gas

towards the cylinder.
Nozzle That part of the blowpipe, which provides the final control of velocity and
gas profile as a gas or gases emerge to the atmosphere.
Pressure Within this Code of Practice the ‘bar’ is used as the unit of pressure.
1 bar = 100 kPa = 105 N/m2 = 14.5 lbf/in²
Pressures used are gauge pressures except where otherwise stated.

Pressure A collective term that includes cylinders, tubes, pressure drums, closed
receptacle cryogenic receptacles, metal hydride storage systems, bundles of cylinders
and salvage pressure receptacles.
Pressure Fitted to the outlet of the gas cylinder valve, the pressure regulator reduces
regulator the pressure of the gas from the cylinder pressure to the lower pressure
required for the operation of the process equipment.
Pressure A valve, which automatically vents gas to the atmosphere in order to prevent
relief valve a build-up of pressure in a system when the pressure exceeds a
predetermined value. The pressure relief valve automatically reseats when
the conditions causing the over-pressure are corrected.
Pressure A valve which automatically stops the gas flow in the event of a slow or
sensitive cut- sudden back-pressure from the downstream side of the cut-off valve. The
off device valve remains closed until manually reset.
Safety device A device which, when correctly used and placed, prevents any damage or
injury from misuse or malfunction of the blowpipe or associated equipment.
Shall Indicates a mandatory requirement for compliance with this Code of Practice
and may also indicate a mandatory requirement within UK law.
Should Indicates a preferred requirement but is not mandatory for compliance with
this Code of Practice.
Temperature A device which stops the gas flow when a predetermined temperature is
sensitive cut- reached.
off device
2
Valve with A device intended to be permanently fitted to a gas cylinder connection and
integrated comprising a shut-off valve system and a pressure reduction system.
pressure
regulator
(VIPR)
Working The settled pressure of a compressed gas at a reference temperature of 15 °C

pressure in a full pressure receptacle.
(for a gas
cylinder) NOTE: This is the ADR (17) definition which refers to the fill pressure
inside the cylinder.
3
CODE OF PRACTICE 7
THE SAFE USE OF OXY-FUEL GAS EQUIPMENT
(INDIVIDUAL PORTABLE OR MOBILE CYLINDER SUPPLY)
1. INTRODUCTION
This Code of Practice has been prepared by the British Compressed Gases Association
(BCGA) to provide guidance on the safe use of oxy-fuel gas equipment, each gas being
supplied from a cylinder and individually controlled by a cylinder-mounted pressure
regulator.
Gas cylinders are designed and constructed to safely contain a gas under pressure. Used
with the correct downstream pressure equipment they provide an efficient and effective
means of delivering a gas to the end process.
Oxy-fuel gas equipment has many uses, including welding, cutting, heating, straightening,
and descaling. The equipment is versatile and relatively easy to move and use, however, it
also has its hazards and consequently its use is governed by several Regulations.
Due to the properties of gases, compliance will be required with the Health and Safety at
Work etc. Act (1), which may include:
 The Construction (Design and Management) Regulations (CDM) (14), which

govern the way construction projects of all types and sizes are planned;
 The Provision and Use of Work Equipment Regulations (PUWER) (4) which
governs the safe use of work equipment;
 The Pressure Systems Safety Regulations (PSSR) (6), which covers the safe
design and use of pressure systems and whose aim is to prevent serious injury from
the hazard of stored energy (pressure) as a result of the failure of a pressure system or
one of its component parts;
 The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR)

(9) which are concerned with protection against risks from fire, explosion and similar
events arising from dangerous substances used or present in the workplace;
 The Control of Substances Hazardous to Health Regulations (COSHH) (8)

which governs how to either prevent or reduce workers' exposure to substances that
are hazardous to their health.
The Health and Safety Executive (HSE) provide advice on welding health and safety at:
http://www.hse.gov.uk/welding/index.htm
Premise owners and users of gaseous equipment should ensure their insurer is aware that there
are gases on-site and that they have adequate insurance to cover their activities, that they
4
choose and use appropriate gases, and that they look after their gas cylinders in a safe and
responsible way.
This code of practice is intended for use in conjunction with current guidance and
information produced by the Health and Safety Executive (HSE) and other related bodies
and trade associations.
2. SCOPE
This Code of Practice gives a guide to the minimum safety standards required for the
assembly, examination, inspection, maintenance and use of individual portable or mobile
cylinder oxy-fuel gas equipment, each gas being supplied from a cylinder and individually
controlled by a cylinder-mounted pressure regulator
The UKLPG provide additional information on the safe use of liquefied petroleum gases
(LPG). As an example, refer to UKLPG User Information Sheet 28 (78), Safe use of
propane and butane cylinders & cartridges.
The safety standards laid down are the minimum for safe working practice and the
importance of the skill and competence of operators, supervisors and managerial staff is
stressed.
It does not apply to cutting machine operations and any other form of use of cylinder gas
supply for any other process.
It does not apply to fixed gas distribution systems or other portable or mobile cylinder gas
supply equipment for which you should refer to:
 BCGA CP 4 (52), Industrial gas control and distribution systems (excluding

acetylene).
 BCGA CP 5 (53), The design and construction of manifolds using acetylene gas
from 1.5 bar to 25 bar.
 BCGA CP 6 (54), The safe distribution of acetylene in the pressure range 0 to

1.5 bar.
 BCGA CP 47 (58), The safe use of individual portable or mobile cylinder gas
supply equipment.
3. AWARENESS OF THE PROPERTIES OF GASES USED
Each gas (whether pure or a mixture) has its own distinctive properties.
On a gas cylinder the label identifies the contents and provides basic information on safe use
and the hazard(s) associated with the product.
5
Safety Data Sheets provide detailed information on the properties of a gas as well as advice
on handling and storage. They can be obtained for all gases and are to be available for the
user of the gas. It is a legal requirement that the gas supplier provides a Safety Data Sheet
to the customer whenever a product is supplied for the first time.
All gases have their hazards, and appropriate control measures, identified by risk
assessment, shall be provided to protect all persons who may be affected by an escape, leak
or accumulation of gases into the workplace. Refer to BCGA Guidance Note (GN) 11 (60),
The management of risk when using gases in enclosed workplaces.
If additional information is required contact your gas supplier for advice.
4. LEGISLATION
The Health and Safety at Work etc. Act (1), places duties on organisations and employers to
protect the health and safety of employees and / or members of the public. The duties
include the provision and maintenance of plant and systems of work that are, so far as is
reasonably practicable, safe and without risks to health. This includes the use of pressure
equipment.
There are several Regulations which are relevant to the use of pressure equipment in oxy-
fuel applications.
The Pressure Equipment (Safety) Regulations (15), which implement the European Union
Pressure Equipment Directive (PED) (16), provide a legal structure whereby pressure
equipment can be manufactured and sold throughout Europe and covers the first placement
on the market and putting into service of pressure equipment and assemblies.
The Provision and Use of Work Equipment Regulations (PUWER) (4) which requires that
work equipment should not result in health and safety risks, regardless of its age, condition
or origin. The PUWER (4) requires that the employer selects suitable equipment and carries
out appropriate maintenance, inspection, identifies any specific risks and provides suitable
information, instructions and training.
The HSE provide further guidance on the PUWER (4) within HSE L22 (20), Safe use of
work equipment. Provision and Use of Work Equipment Regulations 1998. Approved Code
of Practice and guidance.
Gas pressure equipment operating above 0.5 bar is regulated by the Pressure Systems Safety
Regulations (PSSR) (6). The PSSR (6) requires such equipment to be examined and
maintained. It should be noted that the overall intention of the PSSR (6) is to prevent
serious injury from the hazard of stored energy, as a result of the failure of a pressure system
or one of its component parts. The primary responsibility for compliance with these
regulations lies with the user of the pressure equipment and it is the users’ responsibility to
enlist any assistance required to comply with the Regulations.
The HSE provide guidance on the PSSR (6) in HSE L122 (23), Safety of pressure systems.
Pressure Systems Safety Regulations 2000. Approved Code of Practice and guidance.
6
The Acetylene Safety (England and Wales and Scotland) Regulations (13) require that all
acetylene mobile systems shall be fitted with a pressure regulator and various safety devices
which are specifically designed and constructed for use with acetylene.
The Construction (Design and Management) Regulations (CDM) (14) may apply in some
circumstances. For further information refer to HSE L153 (25), Managing health and safety
in construction. Construction (Design and Management) Regulations 2015. Guidance on
Regulations.
The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) (9) places
obligations on site operators who use gas cylinders, especially oxidising or flammable gases,
and are concerned with protection against the risks from fire, explosion or substances
corrosive to metals. Gases that are under pressure (for example, gas in a cylinder) may
present a risk of explosion if not correctly handled in the workplace. Substances that can
corrode metals could cause structural damage reducing integrity of structures if not suitably
contained. DSEAR (9) places a formal requirement on employers to assess the risks for
substances if classified for these properties and put in place suitable control and mitigation
measures. BCGA provide a generic risk assessments, refer to BCGA GN 13 (61), DSEAR
Risk Assessment.
For further information refer to HSE L138 (24), Dangerous substances and explosive
atmospheres Dangerous Substances and Explosive Atmospheres Regulations 2002
Approved Code of Practice and guidance.
The Control of Substances Hazardous to Health Regulations (COSHH) (8). Requires

employers to either prevent or reduce workers' exposure to substances that are hazardous to
their health.
For further information refer to HSE L5 (19), Control of substances hazardous to health.
The Control of Substances Hazardous to Health Regulations 2002 (as amended). Approved
Code of Practice and guidance.
The Management of Health and Safety at Work Regulations (5), as well as other legislation,
such as the Confined Spaces Regulations (3), require employers to conduct risk assessments
for their activities.
The Carriage of Dangerous Goods and Use of Transportable Pressure Equipment

Regulations (12), is applicable for individual gas cylinders, including their valves and
permanently fitted accessories. These regulations govern the safe filling, transport and the
inspection and maintenance requirements. The owner of a gas cylinder, who is normally the
gas supplier, is responsible for compliance.
5. EXAMINATION, INSPECTION AND MAINTENANCE
For gas cylinders, the owner, who is normally the gas supplier, has responsibility for
inspection and maintenance. In the case of gas cylinders fitted with a valve with an integral
pressure regulator (VIPR), the responsibility for the serviceability of the VIPR is also with
the owner of the cylinder. If the user has any queries over the inspection, maintenance or
7
serviceability of a gas cylinder or its permanently fitted valve and accessories, then they
should contact the owner of the cylinder for advice.
To ensure all other pressure equipment remains safe and serviceable throughout its
operational life it shall be subject to regular inspection and maintenance. Pressure
equipment shall also be subject to examination where a Written Scheme of Examination is
in place. All examination, inspection and maintenance shall take into account the
manufacturers’ / suppliers’ recommendations. Such a regime shall ensure pressure
equipment complies with the PUWER (4) and PSSR (6) Regulations. For detailed
information refer to BCGA CP 39 (56), In-service requirements of pressure equipment (gas
storage and gas distribution systems).
PUWER (4) requires that work equipment that is in-service is inspected and maintained at
regular intervals to ensure that it is safe for continued use and remains in good repair
regardless of its age, condition or origin.
PSSR (6) requires that the owner of a mobile system (which does not include the gas
cylinders, as these are managed under the Carriage of Dangerous Goods and Use of
Transportable Pressure Equipment Regulations (12)), shall ensure that the system is
properly maintained in good repair, so as to prevent danger. PSSR (6) requires pressure
systems to undergo a thorough examination in accordance with a Written Scheme of
Examination, unless a specific exclusion applies. The need for a Written Scheme of
Examination shall be formally assessed in accordance with the PSSR (6), Regulation 8.
HSE guidance is that owners and users, in consultation with a competent person, have to
decide if a Written Scheme of Examination is required. HSE provide an example of a
portable oxy-fuel gas welding set being unlikely to require a written scheme of examination
[HSE L122 (23), Clause 113]. However, it is emphasised that such equipment will still
require inspection and maintenance to comply with PUWER (4).
Where assessment of the potential risk of using oxy-fuel gas pressure equipment results in a
recognition that injury could result from a failure of the system, then a Written Scheme of
Examination shall be drawn up by a Competent Person, as defined in the PSSR (6). Such a
Scheme could use the information in Appendix 1, provided it included information about the
nature and frequency of the required examination of all protective devices and parts of the
system where a defect would give rise to danger. When a Written Scheme of Examination
is implemented for the equipment, written records shall be maintained by the User covering
the Scheme itself and the records of examinations carried out by the Competent Person
under the Scheme.
It is the duty of the employer to ensure persons undertaking examination, inspection or

maintenance activities are competent to do so. For further guidance refer to BCGA GN 23
(62), Gas safety. Information instruction and training.
Appendix 1 provides guidance on the recommended inspection and maintenance

requirements for typical pressure equipment used in the gas delivery pressure system.
With reference to Appendix 1, the following checks shall be carried out:
 An ‘assembly’ check. To be carried out when assembling the equipment.
8
The equipment is assembled in accordance with the manufacturer’s instructions, and
checked during and after assembly. To include a check that all appropriate equipment
is installed in the correct order, any maintenance activities necessary are completed, a
visual inspection for correct assembly and to determine suitability for service, for
example, compatibility with the gas, pressure rating, direction of flow, damage, oil,
grease or other contamination.
 A ‘before use’ inspection check. To be carried out by the user prior to the use of
the equipment. The purpose being to check the equipment is serviceable and ready to
use.
Typically a visual examination to determine suitability for service, for example, gas,
pressure rating, damage, oil, grease or other contamination, and, where appropriate,
that the relevant equipment is in-date to the manufacturer’s specification.
Any damaged, contaminated or out-of-date equipment shall not be used. This

equipment shall be replaced.
 An ‘after use’ inspection check. To be carried out by the user on completion of

use of the equipment. The purpose being to check that any faults that occur in-service
are rectified or reported / recorded.
Any damaged or contaminated equipment shall be replaced.
 An ‘annual’ inspection with any associated maintenance. To consist of an in-

depth inspection and maintenance check. The purpose being to ensure the equipment
remains serviceable for continued use.
The risk assessment will determine the control measures required for the frequency of
inspection. Inspections should be carried out at least annually or more frequently,
dependant on the findings of the risk assessment, based on service conditions, the
local environment and the conditions of use.
To include checks that individual components remain within their allowed life, all
components operate over their full design range and that they are still fit-for their
intended purpose.
The inspection shall be carried out by a person who has:
(i) sufficient practical experience of oxy-fuel and related gas equipment,
and can demonstrate a theoretical knowledge of:
(ii) the functioning of the equipment, the properties of gases used, the
potential defects and hazards which may occur and their importance to the
integrity and safety of the equipment.
(iii) relevant current legislation, standards and industry documents.
9
This should be acquired through formal training, for further information on the
competency of personnel refer to BCGA GN 23 (62).
Written records of the last inspection carried out shall be retained. These records shall
identify the individual assets which have been inspected. This may include localised
tagging, labelling etc.
 ‘Examination’ where required by, and in accordance with, a Written Scheme of

Examination. To be carried out by a competent person.
BCGA no longer support refurbishment of components, such as regulators or handheld

blowpipes, by the user. It is recommended that the user purchases a new component, or if
refurbishment is necessary, then the component is returned back to the manufacturer for
refurbishment to take place. Refer to BCGA TIS 19 (68), Refurbishment of components
used with compressed gases for welding, cutting and related processes.
6. SIGNIFICANT HAZARDS
The significant hazards when using oxy-fuel gases and equipment are:
6.1 Backfire
The return of the flame into the blowpipe neck or body with a popping sound, the
flame being either extinguished or re-ignited at the nozzle.
6.2 Sustained backfire

The return of the flame into the blowpipe neck or body with continued burning within
the neck or mixer.
NOTE: This manifests itself either as ‘popping’ or ‘squealing’ with a small

pointed flame issuing from the nozzle orifice, or as a rapid series of minor explosions
inside an overheated nozzle.
6.3 Intermittent backfire

A rapid succession of backfires with the flame re-igniting at the nozzle. This may be
accompanied by a noise resembling machine gun fire.
6.4 Flashback
Return of a flame through the blowpipe body into the hoses and the regulators. It may
also reach a gas cylinder causing heating and possible ignition which may lead to a
rupture of the cylinder.
6.5 Backflow
Flowing back of gas at a higher pressure into the hose of a gas at lower pressure (this
can be caused by the nozzle exit becoming blocked or restricted). Backflow produces
the conditions under which a flashback can occur.
6.6 Decomposition
In an acetylene cylinder, the breakdown of acetylene into carbon and hydrogen in the
absence of oxygen giving rise to high temperatures and pressures.
10
NOTE: Decomposition cannot be caused by cold mechanical impact.
Decomposition will only occur when the cylinder has been subject to temperatures
greater than 350 °C.
6.7 Ignition within an oxygen system

Oxygen systems shall always be completely free of oil or grease, and assembled from
components which are known to be oxygen clean.
Contaminants, such as oils and greases, can ignite in the presence of high pressure
oxygen. This may be caused by high internal temperatures or by sudden pressure
increases, for example, by rapidly opening valves.
6.8 Oxygen leakage

Leakage or an excess of unconsumed oxygen from, for example, a cutting processes,
may lead to increased levels of oxygen, especially in a confined space. Oxygen
enrichment will increase the risk and severity of a fire. Refer to Section 9.5.
6.9 Fuel gas leakage

Fuel gases are flammable. Any leakage of a fuel gas will create a combustible
atmosphere which will increase the risk of fire.
Fuel gases contain no oxygen. Leakage or an excess of unconsumed fuel gas may
lead to a decrease in levels of oxygen in the local atmosphere, especially in a confined
space, which can lead to asphyxiation. Refer to Section 9.5.
6.10 Fumes
The fume given off by welding and hot cutting processes is a varying mixture of
airborne gases and very fine particles which, if inhaled, are hazardous, especially in
high concentration. Inhalation can be a cause of cancer, chronic obstructive
pulmonary disease (COPD) and an increased susceptibility to pneumonia. The fume
will displace breathable air, and may contain toxic products, such as carbon monoxide.
There are hazards from specific fumes in some applications, e.g. silver brazing, work
on painted or galvanised metals, etc.
This fume will affect all persons in the local area, not just those directly involved in
the process. Fume can have an immediate, as well as a long term effect on the health
of those affected. Staff at all levels need to be aware of the potential hazards. It will
be necessary to assess the actual risk in order to comply with the Control of
Substances Hazardous to Health Regulations (COSHH) (8). Reference should be
made to HSE Guidance Note EH 40 (18), Workplace exposure limits. Additional
guidance can be found in the HSE Leaflet INDG 136 (29), Working with substances
hazardous to health. A brief guide to COSHH.
The BCGA has engaged with the HSE and others to try to influence attitudes and
behaviours with respect to welding fume, particularly in encouraging the use of
appropriate workplace protection, such as local exhaust ventilation, as well as
Personal Protective Equipment, refer to Section 9.1.
11
The Welding Fume Health Partnership has produced a website www.badairday.info
which explains in detail the safety concerns associated with welding fume and which
encourages appropriate safe behaviour.
BOHS, the Chartered Society for Worker Health Protection, campaigns to prevent
occupational lung disease in the manufacturing sector and provides advice for welders
at: http://www.breathefreely.org.uk/breathefreelymanufacturing.html
For information on local exhaust ventilation refer to HSE HSG 258 (30), Controlling
airborne contaminants at work. A guide to local exhaust ventilation (LEV).
BCGA has published additional advice on welding fumes within BCGA TIS 24 (70),
Welding fumes. Safety alert.
6.11 Noise
In working areas where the noise level is excessive ear protectors may be required.
The Control of Noise at Work Regulations (11) require employers to prevent or reduce
risks to health and safety from exposure to noise at work. Action has to be taken
when noise reaches specific values. These values relate to the levels of exposure to
noise averaged over a working day or week, and the maximum noise (peak sound
pressure) to which personnel are exposed in a working day.
The values are:
 Lower exposure action value:
o Daily or weekly exposure of 80 dB

o Peak sound pressure of 135 dB
 Upper exposure action value:

 Exposure limit values (which cannot be exceeded):

Employers are required to carry out a risk assessment to determine the noise levels.
The risk assessment is to be recorded and, as necessary, an action plan put in place. If
the noise exposure cannot be reduced by other means then appropriate personal
protective equipment is to be provided. Refer to Section 9.1.
6.12 Manual handling

Gases supplied in cylinders can be in compressed, liquefied or dissolved form. The
cylinders vary in weight, size and shape. These physical characteristics present
potential manual handling hazards. Appropriate risk assessment, training and
handling aids are required. Refer to Section 8.2.
12
7. EQUIPMENT
Oxy-fuel gas equipment will generally consist of gas cylinders for oxygen and a fuel gas,
pressure regulators, safety devices, such as non-return valves and flame arrestors, and a
flexible hose assembly which will supply the output of a mixed gas via a blowpipe. Often
this equipment will be mounted on a handling trolley.
Always refer to the manufacturers’ / suppliers’ instructions for the correct and safe use of all
equipment and materials used. Any modifications, changes or repairs to gas equipment
shall be done by a competent person, or authorised third party, and will require the gas
equipment to be retested to ensure integrity and functionality are within manufacturer’s
original specification.
All equipment should conform to appropriate standards.
All equipment which is in contact with a gas shall be compatible with that gas. For
example, refer to:
 BS EN ISO 11114 (49). Transportable gas cylinders. Compatibility of cylinder

& valve materials with gas contents. Part 1, Metallic materials. Part 2, Non-metallic
materials.
Specialist jointing tape may be used by some manufacturers of gas equipment. However,
jointing tape should not be used by end-users. If your equipment is worn or leaking, replace
it. Your equipment provider or gas supplier can provide further advice.
Equipment is generally marked and identified to show the gas service it has been designed for
and the service for which it is intended. However, some gas equipment is manufactured to a
specification which is suitable for multiple gas use and is labelled as such.
Only equipment designed and cleaned for oxygen service shall be used with oxygen to ensure
that safe operating conditions are met. Equipment not marked for oxygen service shall not be
used with oxygen. Oxygen equipment shall only be used in oxygen service.
The Acetylene Safety (England and Wales and Scotland) Regulations (13) require that any
equipment used for acetylene shall be designed and marked for that purpose.
Under no circumstances shall oil and grease be used on components in oxygen, inert or fuel
gas service. When installing or connecting equipment ensure your hands are free from oil
and grease.
Refer to the manufacturer / supplier to determine the life of your equipment. BCGA TIS 18
(67), Date marking of gas accessories. provides information on some of the equipment
marking schemes used by manufacturers.
HSE HSG 139 (26), The safe use of compressed gases in welding, flame cutting and allied
processes, and HSE INDG 297 (31), Safety in gas welding, cutting and similar processes,
provides guidance for the use of compressed gases for welding, flame cutting and related
processes. They promote the safe use of compressed gases and describe the hazards
13
associated with portable oxy-fuel gas equipment and precautions for avoiding injury and
damage to property.
7.1 Pressure regulators

Fitted to the outlet of the gas cylinder valve, or bundle output valve, the pressure
regulator reduces the pressure of the gas from the cylinder pressure to the lower pressure
required.
A pressure regulator shall be chosen for its compatibility with the gas. Regulators are
designed to be used with a specific gas and once in a specific gas service a regulator
shall not be used with any other gas. Oxygen regulators shall only be used in oxygen
service. Acetylene and propane are both widely used as fuel gases. However, these
gases have quite different properties, which are taken into account in the design and
manufacture of the gas regulators. Due to the different properties, each gas requires a
specific design of gas regulator that has been manufactured from materials compatible
with and type-tested for use with that gas.
The use of an incorrect regulator for acetylene can cause an explosion. The Acetylene
Safety Regulations (13) require that the regulator shall be specifically designed and
constructed for use with acetylene. For further information refer to BCGA Safety
Alert 1 (76), The hazards of using incorrect regulators on acetylene gas cylinders.
Each regulator shall be suitable for the maximum cylinder pressure. Regulators are
designed for use within a specific pressure range. Do not attach a regulator to a
cylinder that is at a pressure higher than that for which the regulator is designed and
labelled.
Regulators may be designed to be adjustable in respect of outlet pressure or, for single
purpose applications, may be pre-set. Pressure reduction within the regulator may be
in one or two stages (single or two-stage regulators). Pressure regulators may be
supplied with a pressure gauge or indicator to show the cylinder contents and a
pressure gauge or flow meter to indicate the outlet pressure or flow.
Pressure regulators are to be positioned as close as is reasonably practicable to the

cylinder. Cylinder outlet valves are designed with either a top outlet or a side outlet.
Where a regulator is attached to the cylinder outlet valve only a regulator configured
with a top inlet, or a side inlet, as appropriate, shall be fitted.
Pressure regulators should be treated as precision instruments and should not be jarred
or knocked.
Regulators which are contaminated, life-expired or damaged shall not be used. BCGA
no longer recommend the repair of damaged components, refer to BCGA TIS 19 (68),
Refurbishment of components used with compressed gases for welding, cutting and
related processes.
Outlet pressures should not be set in excess of those needed for the operation in hand.
The regulator pressure-adjusting screw shall be set to the zero pressure position when
the regulator is not in use by turning the control knob fully anti-clockwise.
14
Whether they are in store or in use, pressure regulators shall be kept free of dust,
debris, oil, grease, solvents or any other contaminants.
When not in use, protective covers should be placed over the gas ports. They should
be stored in clean, dry conditions.
All regulators up to 20 bar working pressure shall conform to:
 BS EN ISO 2503 (44), Gas welding equipment. Pressure regulators and

pressure regulators with flow-metering devices for gas cylinders used in
welding, cutting and allied processes up to 300 bar (30 MPa); or
 BS EN ISO 7291 (48), Gas welding equipment. Pressure regulators for

manifold systems used in welding, cutting and allied processes up to 30 MPa
(300 bar).
These standards state that pressure-adjusting screws shall be captive to prevent inter-
changeability between regulators.
In the case of valves with integrated pressure regulators (VIPR) they should conform
to:
 BS EN ISO 22435 (51), Gas cylinders. Cylinder valves with integrated

pressure regulators. Specification and type testing.
The following information should be clearly and permanently marked on the pressure
regulator body or cover:
 Gas service. In many cases the gas service will be identified by the
manufacturer. Where there is an option to use a regulator designed for a range
of gases, the user should label the regulator at first use;
 Maximum inlet pressure;
 Maximum outlet pressure;
 The name or trademark of the manufacturer and / or distributor;
 A date mark showing either the date of manufacture or a date when the
regulator is to be replaced or refurbished.
Regulators for industrial use shall not be CE marked in accordance with the European
Directives.
For preparing a pressure regulator for use refer to Section 9.9.
7.2 Safety devices

The incorporation of safety devices shall in no way be considered to be a substitute for
safe operating procedures.
15
All safety devices shall conform to BS EN ISO 5175 (47), Gas welding equipment.
Safety devices, and be suitable for the required conditions of service (type of gas used,
maximum operating pressure and minimum operating flow, etc.).
A flame arrestor is a device which extinguishes a flame front (for example, caused by
a flashback) at the point of installation (often referred to as a flashback arrestor). A
composite safety device may incorporate several individual safety devices such as a
flame arresting element, a non-return valve, a quick acting shut-off device, for
example, a temperature sensitive shut off valve and/or a pressure sensitive shut-off
valve.
Flame arrestors may incorporate resettable or non-resettable features. If the flame

arrestor continually needs resetting, seek advice from the supplier.
 A temperature sensitive cut-off valve will not cut off the gas until heated
to a sufficient level. This may require several flashbacks or internal burning.
After cut off they cannot be reset. After investigation and rectification of cause
of flashback they shall be replaced.
 A pressure sensitive cut-off valve will automatically cut off the gas flow
immediately. After cut off, and following investigation and rectification of the
cause of flashback, they can be reset.
Flame arrestors are marked with the direction of gas flow, a manufacture or an
inspection / replacement date and the manufacturing standard.
A flame arrestor, a non-return valve and a quick acting shut-off device is mandatory
when acetylene is the fuel gas
Additional information is available in EIGA Safety Information 5 (83), Flashback and

flashback arrestors in welding applications.
Non-return valves shall be capable of preventing backflow of gases, both at low and
high reverse pressures. They are marked with the direction of flow.
Non-return valves may be damaged by flashbacks and require frequent testing to

ensure that the gas will not reverse flow. Refer to Section 5 and Appendix 1.
NOTE: Historically, a type of non-return valve known as a ‘hose protector’, which

operated by means of a floating plate or disc, was in common use. These will not
prevent backflow at low pressures and do not conform to BS EN ISO 5175 (47).
For preparing a safety device for use refer to Section 9.10.
7.3 Hose and hose assemblies

The hose provides a flexible connection between the pressure regulator, safety devices
and the process equipment. A hose assembly consists of a hose tail inserted into the
end of a flexible hose and secured by a suitable hose clamp.
16
Hoses shall be of a composition compatible with the gas with which they are to be used.
Hoses shall not be used for gases or at pressures other than those for which they have
been designed.
Hose materials shall conform to BS EN ISO 3821 (45), Gas welding equipment.
Rubber hoses for welding, cutting and allied processes.
Hose connections shall conform to BS EN 560 (41), Gas welding equipment - Hose
connections for equipment for welding, cutting and allied processes.
Hose connections are fitted with left-hand threads for flammable gases and right-hand
threads for oxygen.
Assembled hoses shall be tested to BS EN 1256 (43), Gas welding equipment.

Specification for hose assemblies for equipment for welding, cutting and allied
processes, with hose fittings retained by suitable clips or ferrules. Re-usable worm-
drive clamps shall not be used.
Non return valves shall conform to BS EN ISO 5175-2 (47). Refer to Section 7.2.
NOTE: Non return valves are often referred to as ‘Hose check valves’.
Quick action couplings shall conform to BS EN 561 (42), Gas welding equipment.
Quick-action coupling with shut-off valves for welding, cutting and allied processes.
Hoses for welding equipment have identification marks and are colour coded. In the
case of twin hoses, each of the individual hoses shall be coloured. Refer to Table 1
and BS EN ISO 3821 (45).
Gas Hose colour Thread
Oxygen Blue Right hand

Inert gases (compressed air, nitrogen, argon and
Black Right hand
carbon dioxide)
LPG, methane, natural gas and MPS2 Orange Left hand
Acetylene, hydrogen1 and other flammable gases

Red Left hand
(excludes LPG, methane, natural gas & MPS)
Universal fuel gases (included in this table) Red / orange Left hand
NOTE:
1. The manufacturer shall be consulted on the suitability of the hose for use with
hydrogen.
2. Methylacetylene-propadiene mixtures
Table 1: Hose assemblies – colours and threads.
17
Do not tape hoses together. Tape can cover damage to the hose outer layer. To
reduce trip hazards hoses can be joined together by hose clips (plastic or metal)
specifically designed for that purpose. Conjoined hose can be used provided that the
hose and the assembly conform to the required standards. It is important to remember
that failure in one hose can lead to failure in the other and lead to a potentially more
hazardous situation.
Hose lengths shall be kept to the minimum necessary. Where greater lengths are
needed only occasionally, extension hoses, connected by means of hose couplers
conforming to BS EN 560 (41) can be used. The extension being dismantled when the
need for it has passed.
WARNING: Copper pipe or copper fittings shall not be used to couple hoses
carrying acetylene.
The good condition of the hoses is of vital importance to safety. Hoses shall be
protected from heat, mechanical damage, traffic, sparks, hot splatter, slag and oil or
grease. Always discard hoses when the general condition shows signs of
deterioration.
Localised repairs are not recommended, however where repairs are carried out then it
is essential to use the correct style of hose-splicer and associated fittings. Following a
modification or repair the hose assembly shall be re-tested and certified to BS EN
1256 (43). Leak test with an approved leak test solution
NOTE: For further information on leak detection fluids refer to EIGA 78 (81),
Leak detection fluids cylinder packages.
For preparing a hose assembly for use refer to Section 9.11.
7.4 Blowpipes
Blowpipes shall conform to BS EN ISO 5172 (46), Gas welding equipment.
Blowpipes for gas welding, heating and cutting. Specifications and test.
NOTE: Blowpipes are sometimes referred to as torches, lamps, blowtorches, guns,

shanks, burners, handles, etc.
The blowpipe will receive the individual gases and mix the gases together. Some
blowpipes may, by an interchange of components, be adapted to carry out a wide
range of duties.
A number of gas mixing systems can be employed either in the shank, between the
shank and the blowpipe nozzle or in the nozzle and these may call for different
working procedures.
The mixer may require the provision of gases at approximately equal pressures (an
equal pressure mixer), or may require relatively higher oxygen pressure in relation to
that of the fuel gas (an injector mixer). A mixer may be matched to a range of nozzle
orifice sizes or to only one.
18
Mixers may be detachable units or integral with the blowpipe. They may also derive
from assembly by the operator of matching parts.
The wide range of equipment in use makes it imperative that operators refer to the
supplier’s operating instructions in respect of nozzle selection, pressure settings,
lighting and extinguishing procedures. In the case of combined service blowpipes, the
correct assembly and operation of the blowpipe for its various duties and fuel gases is
an important area to study.
The use of safety devices in a gas supply line may require an increase in supply
pressure to compensate for the pressure losses caused. Since these losses vary
between different makes or types of safety devices and their conditions, it is not
possible for the blowpipe manufacturer to provide specific information. The user
should refer to the supplier of the device or devices for information on pressure loss
and the pressure compensation required.
The maintenance of blowpipes shall be carried out as recommended by the

manufacturer / supplier, and at least in accordance with Appendix 1.
For preparing a blowpipe for use refer to Section 9.12.
8. CYLINDER STORAGE AND HANDLING
Unsafe storage and cylinder mishandling have the potential to cause incidents. BCGA TIS
15 (65), Model risk assessment for the storage and use of oxy-acetylene cylinders, can be
used to assist in developing a site risk assessment.
It is essential that proper information, instruction and training is given to all staff who are
involved in the storage and handling of gas cylinders, refer to Section 12.
There are specific regulations for transporting gas cylinders, refer to Section 8.3.
8.1 Cylinder storage

Gas cylinders and cylinder bundles shall be stored in accordance with BCGA CP 44
(57), The storage of gas cylinders, which defines the principles of safe practice for
storage.
All gas cylinder stores should follow these basic principles:
 the store is in an external location;
 the store is in a secure location and has adequate security;
 the store and the local area has good ventilation;
 cylinders are away from sources of ignition or combustible material

(which is not a necessary part of the store);
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 cylinders are not exposed to excessive heat. Take care to prevent the
heating of cylinders from the process or any other external heat source;
 the storage area has appropriate safety signs and warning notices
displayed;
 cylinders are stored in a vertical position, properly restrained to avoid

them falling over;
 in a store, all cylinders have their valves closed. This includes empty
cylinders as this prevents the ingress of moisture or other contaminants. If
available, fit protective covers.
8.2 Cylinder handling

Gases supplied in cylinders can be in compressed, liquefied or dissolved form. The
cylinders vary in weight, size and shape. These physical characteristics present
potential manual handling hazards. Appropriate risk assessment, training and
handling aids are required.
The Manual Handling Operations Regulations (2) require that before any manual
handling takes place an assessment of manual handling operations is conducted.
Following the assessment, appropriate training should take place. Where the assessment
indicates that the work exceeds guideline limits, wherever practicable the operation
should be mechanised or handling aids provided.
BCGA GN 3 (59) Safe cylinder handling and the application of the manual handling
operations regulations to gas cylinders, defines the principles of safe practice for
handling and moving cylinders and provides a basic understanding of the Manual
Handling Operations Regulations (2) relating to gas cylinders. BCGA TIS 17 (66),
Model risk assessment for manual handling activities in the industrial gas industry,
can be used to assist in developing a site risk assessment.
HSE provide guidance in HSE INDG 390 (35), Choosing a welding set? Make sure
you can handle it.
When handling gas cylinders:
 always wear appropriate personal protective equipment, for example, eye,

hand and foot protection. Safety shoes or boots with metatarsal protection are
strongly recommended. Refer to Section 9.1;
 purpose designed trolleys should be used for moving cylinders wherever

practicable;
 do not lift cylinders by using the valve protection device unless they have
been designed for that purpose. Do not use ropes, chains or slings to suspend
cylinders unless the supplier has installed appropriate lifting attachments such as
lugs. Suitable cradles, platforms or pallets to hold the cylinders may be used for
lifting. Refer to BCGA TIS 38 (73), Moving gas cylinders and bundles within
the workplace;
20
 subject to risk assessment, for moving over even, level floors and only for
short distances, by competent operators, the ‘churning’ method may be
considered;
 cylinders shall not be rolled along the ground since this may damage or
even open the valve and will also damage identifying marks and symbols;
 cylinders shall not be moved with the valve open;
 cylinders shall not be moved with the regulators and hoses attached, unless
secured on a purpose designed trolley or carrier;
 cylinders shall not be used as work-supports or rollers.
8.3 Cylinder transportation

The transportation of any gas cylinder shall comply with the Carriage of Dangerous
Goods and Use of Transportable Pressure Equipment Regulations (12). These
regulations implement the European Agreement Concerning the International
Carriage of Dangerous Goods by Road (ADR) (17), which provides a framework for
dangerous goods to be carried nationally and internationally in road vehicles subject to
compliance with standards for the packaging and labelling of the dangerous goods,
and appropriate construction and operating standards for the vehicles and crew. Gases
are classified as Class 2 dangerous goods.
BCGA provide specific guidance for transporting gas cylinders in BCGA GN 27 (63),
Guidance for the carriage of gas cylinders on vehicles, additional advice is provided
in BCGA Leaflet 1 (74), The carriage of small quantities of gas cylinders on vehicles.
Where gas cylinders are transported in mobile workshops and other specialist vehicles
refer to BCGA CP 31 (55), The safe storage and use of cylinders in mobile workshops
and service vehicles.
9. PREPARATION FOR USE
Before commencing any activity, risk assessments shall be carried out in accordance with
the Management of Health and Safety at Work Regulations (5). All potential hazards shall
be assessed and appropriate control measures put in place. BCGA provide a generic risk
assessment, refer to BCGA TIS 15 (65), Model risk assessment for the storage and use of
oxy-acetylene cylinders.
The Control of Substances Hazardous to Health Regulations (COSHH) (8) requires

employers to either prevent or reduce workers' exposure to substances that are hazardous to
their health. Be aware of the properties of each gas, refer to Section 3. Protection will be
required against welding fume, refer to Section 6.10. Appropriate personal protective
equipment shall be provided and worn, refer to Section 9.1. For further information refer to
HSE L5 (19).
21
If the work area may be classified as a confined space then a specific confined space risk
assessment shall be carried out in accordance with the Confined Spaces Regulations (3).
Additional precautions are necessary, refer to Section 9.3.
As oxidant and flammable gases are on-site and in use, a responsible person shall carry out a
Fire Safety Risk Assessment, the findings from which are to be incorporated into the Site
Fire Safety Management Plan, refer to Section 9.2.
Where there is the potential for a flammable or an explosive atmosphere to occur, a specific
risk assessment shall be carried out in accordance with DSEAR (9). A DSEAR (9) risk
assessment may be required for hot work on containers, refer to Section 9.4.
All persons handling and using gaseous cylinders and pressure equipment shall have
received adequate information, instruction, training and, as appropriate, supervision. The
employer is responsible for ensuring that each individual is competent to carry out each task
safely and correctly. Refer to Section 11.
The supplier or employer of a person who puts into service, modifies or repairs a mobile
system, or components of it, shall provide sufficient information to enable the user of a
pressure system to determine how to operate and maintain it safely.
Such information for equipment for use with individual portable or mobile cylinder supply
may include the following:
 safe operating limits for pressure and temperature;
 operating and maintenance instructions.
The correct location of cylinders, correct assembly of equipment and correct operation will
all contribute to minimising the risk of an incident involving gas cylinders. For information
on:
 choosing a fuel gas, refer to Section 9.6;
 locating cylinders, refer to Section 9.7;
 identifying and preparing a cylinder, refer to Section 9.8;
 assembling a pressure regulator, refer to Section 9.9;
 incorporating safety devices, refer to Section 9.10;
 assembling hose assemblies, refer to Section 9.11;
 assembling blowpipes, refer to Section 9.12;
 choosing a nozzle, refer to Section 9.13;
 pressurising the system, refer to Section 9.14;
22
 purging the system, refer to Section 9.15;
 lighting up, refer to Section 9.16.
Whenever oxy-fuel is in use thorough ventilation of the work area and the controlled use of
the fuel gas and oxygen is essential.
The fuel gas and the oxygen should not be used for any purpose whatsoever other than as a
gas supply to the blowpipes. Oxygen will react violently in the presence of oil and grease
and both gases can increase the risk of a fire.
Equipment cleanliness is essential and, to avoid possible contamination, clothing, tools and
the working area should be kept clean.
Standard operating procedures for the handling and use of gas cylinders and the use of oxy-
fuel equipment shall be prepared and used.
Emergency operating procedures shall be prepared and used, refer to Section 12.
BCGA TIS 29 (71), Oxy-fuel gas equipment. Selection and assembly, highlights the
fundamental health and safety practices for selecting and assembling oxy-fuel equipment.
HSE provide information in HSE INDG 297 (31).
9.1 Personal protective equipment

Personal Protective Equipment (PPE) is to be provided as required by the Personal
Protective Equipment Regulations (7). PPE may only be considered as a control to
achieve an acceptable level of residual risk after other levels of control have been
addressed. A risk assessment will determine the requirement for the use of hazard
controls, including PPE. Where PPE is required a PPE Assessment shall be carried out.
Due regard is to be given to the requirements of the Control of Substances Hazardous
to Health (COSHH) Regulations (8), any relevant equipment publications,
manufacturers information and the product Safety Data Sheet. The PPE shall be
selected for a particular task and location and must be appropriate and chosen to
effectively reduce the overall risk. Thus there are different PPE requirements for
differing products, different tasks and possibly different personnel.
HSE L25 (21), Personal Protective Equipment at Work, provides guidance on the
Personal Protective Equipment Regulations (7). EIGA 136 (82), Selection of personal
protective equipment, provides guidance for selecting and using PPE at work.
Eye protection is essential at all times when using oxy-fuel equipment. Goggles
should comply with BS EN 175 (39), Personal protection. Equipment for eye and face
protection during welding and allied processes, and lenses with BS EN 169 (38),
Personal eye protection. Filters for welding and related techniques. Transmittance
requirements and recommended use. The outer lens should be replaced before any
build-up of welding spatter, dirt or scratches impedes the operator’s vision.
Recommendations on the correct shade of filter lens to use are found in BS EN 169
(38). A backing lens should be used if the filter lens is not robust.
23
Safety glasses should be used when connecting or disconnecting gas cylinders.
Suitable leather gloves or gauntlets should be worn during operations or when

handling metal.
For cylinder handling the use of protective equipment for hands, feet and eyes is
essential. Safety shoes or boots with metatarsal protection are strongly recommended.
In areas where the noise level is excessive ear protection may be required. Refer to
Section 6.11.
In certain locations, or site conditions, other personal protective equipment may be

obligatory, for example, hard hats, fire resistant clothing, breathing apparatus, etc.
9.2 Fire protection

As oxidant and flammable gases increase the fire risk when on-site and/or in use, a
responsible person shall carry out a Fire Safety Risk Assessment, the findings from
which are to be incorporated into the Site Fire Safety Management Plan. Each site
should keep a record of the location of its hazardous store(s), this is to be made
available to the emergency services in the event of an incident. Refer to The
Regulatory Reform (Fire Safety) Order (10).
Where there is the potential for a flammable or an explosive atmosphere to occur, a

specific risk assessment shall be carried out in accordance with the Dangerous
Substances and Explosive Atmospheres Regulations (DSEAR) (9). DSEAR (9) places
a formal requirement on employers to assess the risks for substances if classified for
these properties and put in place suitable control and mitigation measures. BCGA
provide a generic risk assessments, refer to BCGA GN 13 (61).
For further information refer to:
 HSE L138 (24), Dangerous substances and explosive atmospheres

Dangerous Substances and Explosive Atmospheres Regulations 2002. Approved
Code of Practice and guidance.
 HSE INDG 370 (34), Controlling Fire & Explosion risks in the
workplace. A brief guide to DSEAR.
Fire- fighting equipment / facilities as identified in the Site Fire Safety Management
Plan shall be provided. The operator shall ensure that fire extinguishers are readily
available at all times when oxy-fuel gas equipment is in use. A dry powder or CO2
extinguisher is recommended.
Emergency procedures for dealing with a fire in the workplace are to be drawn up and
included in the information, instruction and training provided. Refer to Section 11 and
Section 12.
Since there are obvious fire hazards, the work area and its surroundings should be kept
free of flammable and combustible materials as far as is practicable. The floor should
24
be swept clear of flammable debris and dust. All flammable materials within the
range of possible sparks should be removed.
If it is not possible to maintain a safe distance from flammable materials, suitable fire
resisting screening should be used.
Work should not be carried out on wooden floors or close to wooden joists without
using suitable protection. If possible, wooden floors and walls should be dowsed with
water before work is started. Sparks falling through gaps in floorboards or inadvertent
heating of thermal insulation, i.e. polyurethane foam, are a particular hazard since the
material may start smouldering and may take some time to develop into a fire. It is
therefore essential to carry out subsequent inspection of the area, at frequent intervals,
until satisfied that the risk of fire has passed.
Where the consequences of a fire are severe, for example, work inside ships, you may
need to appoint a fire watch during and after the work finishes. A fire watch should
be maintained for a minimum of 30 minutes after hot work finishes. Where oxy-fuel
gases are used on-board ships additional information is provided in HSE Engineering
Information Sheet 43 (37), Storage and use of oxygen and fuel gases on board ships.
9.3 Work in confined spaces

Working in confined spaces is subject to the Confined Spaces Regulations (3). A
specific confined space risk assessment shall be carried out. For further information
refer to HSE L101 (22), ACOP Safe work in confined spaces, and to HSE INDG 258
(30), Confined spaces. A brief guide to working safely.
When working in a confined space, as part of the specific confined space risk
assessment, determine the requirement for:
 the use of a Permit to Work.
A written Permit to Work for the particular type of work (hot work, entry into a
vessel, etc.) shall be issued by an authorised person to the individual(s) carrying
out the work. HSE HSG 250 (27), Guidance on permit-to-work systems. A
guide for the petroleum, chemical and allied industries, and EIGA 40 (80),
Work permit systems, provide guidance on how to plan and execute potentially
hazardous jobs in a safe manner;
 atmospheric monitoring (refer to Section 9.5) to:
o ensure the atmosphere is of a standard suitable to support life;
o detect leakage of a flammable gas, which can cause asphyxiation

and/or increase the risk from hot work causing a fire;
o detect leakage of oxygen, leading to oxygen enrichment, therefore

increasing the risk from hot work causing a fire.
 constant and thorough ventilation.
25
WARNING: Oxygen shall never be used to freshen the air in a confined
space as this will increase the hazard of oxygen enrichment of the atmosphere;
 the need to take gas cylinders into a confined space. Where this cannot be
avoided then appropriate control measures shall be put in place;
 additional personal protection equipment, refer to Section 9.1;
 a system of communication.
When carrying out work in a confined space an assistant (sentry) should be

stationed outside to monitor and communicate with all personnel inside the
confined space and, as necessary, to take the appropriate emergency actions;
 emergency operating procedures (including emergency rescue).
Work in a confined space will require specific emergency operating procedures

to be prepared, and for all individuals who are involved, such as Supervisors,
Operators and Sentries, to be fully informed and trained on their individual
responsibilities.
Emergency operations may require specialist equipment to be provided.
Equipment shall not be left in a confined space after the actual work has been
completed or at times when work has ceased for more than a few minutes.
Where oxy-fuel gases are used on board ships or other similar large fabrications
additional information is provided in HSE Engineering Information Sheet 43 (37),
Storage and use of oxygen and fuel gases on board ships.
Further information on the hazards associated with changes to the local atmosphere
and the actions required in an emergency are available in BCGA GN 11 (60).
9.4 Hot work on containers

Additional precautions shall be taken when carrying out hot work on, or near, any
plant, vessel, tank or container which has previously held hazardous products, such as,
petrol, oil, spirits, paint or other combustible, flammable, explosive or toxic material.
The introduction of an ignition source may cause a fire, which may lead to an
explosion.
A container may appear empty, however seams, creases and folds in the container may
still harbour sufficient liquid residue to give rise to an explosive vapour and so the risk
of ignition and injury remains. Even where the contents of a container may not have
been classified as flammable under normal conditions, the extreme temperatures
which can be generated during hot work can heat the vessel contents sufficiently to
cause them to ignite. There is also a risk that a container may have held a variety of
hazardous products which may not be indicated on the markings on the container.
26
Where there is the potential for a flammable or an explosive atmosphere to occur, a
specific risk assessment shall be carried out in accordance with DSEAR (9), refer to
Section 9.2.
A written Permit to Work for the particular type of work (hot work, entry into a
vessel, etc.) shall be issued by an authorised person to the individual(s) carrying out
the work. HSE HSG 250 (27) and EIGA 40 (80), provide guidance on how to plan
and execute potentially hazardous jobs in a safe manner.
Before undertaking hot work the hazard should be reduced by using methods such as
gas-freeing, cleaning or inerting. It is essential that expert advice be taken before first
undertaking such work and that the container is certified gas and residue free. Work
shall only commence once tests have shown that the atmosphere is safe for the work to
proceed. For more comprehensive guidance refer to:
 HSE INDG 314 (32), Hot work on small tanks and drums;
 UKLPG CP 17 (77), Purging LPG vessels and systems.
Where entry is required into a container, refer to Section 9.3 for confined spaces, and
Section 9.5 for changes to the internal atmosphere.
All employees engaged in hot work shall have received adequate information,
instruction and training in the risks involved and the precautions required, refer to
Section 11.
The following general headings, whilst not exhaustive, indicate some of the
considerations necessary before starting work on any container which has contained
potentially hazardous substances.
 Remove all hazardous product residuals including any in the seams, etc.
 Ensure that the atmosphere inside the work area is non-flammable and, if
possible, vent to open air.
 If internal work is to be done, ensure thorough ventilation or that the

operator is wearing appropriate PPE (refer to Section 9.1), for example, a
respirator supplied with breathing quality air. Refer to BS EN 529 (40),
Respiratory protective devices. Recommendations for selection, use, care and
maintenance. Guidance document, and BS EN 12021 (50), Respiratory
equipment. Compressed gases for breathing apparatus.
WARNING: Never use oxygen for ventilation or for the supply to the
respirator.
Internal work is likely to meet the conditions for being a confined space, as such
the requirements of the Confined Spaces Regulations (3) shall be followed.
Refer to Section 9.3.
27
 Always have a properly trained assistant to the operator stationed outside,
in readiness for emergency actions.
 Never approach with naked lights until satisfied that thorough cleaning
and ventilation have been completed.
 Post warning notices.
 Do not use the containers, for example, oil drums, as work supports.
9.5 Changes to the workplace atmosphere

The normal oxygen content of the air is approximately 21 %. When using oxy-fuel
equipment, changes to the local atmosphere can occur. Any change to the normal
atmospheric conditions can create a hazardous situation.
When using oxy-fuel equipment the fumes generated may contribute to a change in
the local atmosphere, as well creating fine particles and potentially toxic by-products
which are hazardous to health, refer to Section 6.10.
A leakage of a flammable gas can reduce the local oxygen content, which increases
the risk of asphyxiation and / or will create a combustible atmosphere which will
increase the risk of fire.
A leakage of oxygen can lead to oxygen enrichment, increasing the risk of an ignition
source causing a fire.
An enriched atmosphere can arise from unconsumed cutting oxygen. Even with
correct cutting conditions some unconsumed oxygen from the cutting oxygen stream
is released into the atmosphere. To keep this to a minimum, the use of the correct
nozzle and cutting pressures is important.
Oxygen levels greater than 23.5 % are deemed unsafe in which to work. A fire
resulting from oxygen enrichment will spread rapidly across combustible materials
such as clothing and body hair and is extremely difficult to extinguish.
WARNING: It is never safe to search for gas leaks with a naked flame.
BCGA GN 11 (60) provides detailed guidance, also refer to HSE INDG 459 (36),
Oxygen use in the workplace. Fire and explosion hazards.
9.6 Choosing a fuel gas

There are a range of fuel gases available. Fuel gases are mostly hydrocarbon based and
each will have its own unique properties. Your choice of fuel gas is fundamental to the
quality, safety, efficiency and cost-effectiveness of your fabrication processes.
Sometimes the wrong gas is chosen for use and this can increase the risk of a hazardous
situation. Often this is due to incorrect information (from a lack of knowledge) or
generic policies adopted on a particular site. When choosing a fuel gas the specific
requirements of each task and the location of hot work should always be considered.
28
When choosing a fuel gas the following characteristics of each gas should be taken into
account:
 the properties of the flame required. For example, flame temperature,

chemical composition, heat intensity and heat distribution;
 the number of cylinders required to be on site. Fuel gases consume oxygen

at different rates, and your choice may require you to have a greater number of
cylinders on site. Extra cylinders will increase the fire risk and the manual
handling requirements;
 the density of the gas. A gas that is heavier than air will drop into lower
spaces, whereas a gas that is lighter than air will rise and more readily disperse in
the air;
 the location at which it is being used. When working, for example, in

confined spaces, tunnels or on top of a building, a lighter than air gas that will rise
and readily disperse is a safer option.
Acetylene and propane are the most common fuel gases used. For further information
refer to:
 HSE INDG 327 (33), Working safely with acetylene.
 BCGA Technical Information Sheet (TIS) 32 (72), Acetylene or propane

(for welding, cutting and allied processes).
9.7 Location of gas cylinders

In order to ensure safe operation of the equipment it is essential to locate the cylinders
in a safe place relative to the work about to be carried out. They are to be located in a
position with good ventilation, where they will be protected from sources of ignition,
excessive heat, contamination (especially by oils and greases) and mechanical
damage.
The cylinders should be within view of the operator wherever possible.
Where cylinders are close to the work area these additional safety points should be
taken into consideration:
 cylinders shall not be exposed to heat. Take care to prevent the heating of
cylinders or damage to the cylinders from the process, sparks and slag or any
other external heat source;
 precautions shall be taken to ensure that no electric current, for example,

from arc welding processes, can reach the cylinders. Steel floors, structural
members or metal benches can carry earth return currents.
When not required for use gas cylinders should be kept in a gas cylinder store, refer to
Section 8.1.
29
9.8 Gas cylinders
Ensure you have the correct gas product. Prior to use check and confirm that it is the
gas you require. The primary method for identifying the gas contents of a cylinder is
the label. If the label is defaced or missing the cylinder is not to be used and is to be
returned to the gas supplier. Additional information is available on the Safety Data
Sheet. Refer to Section 3 and, as necessary, seek further advice from your gas
supplier.
As an aid to identification, cylinders may be painted in a specific colour. Within the

UK acetylene cylinders are painted maroon. Typically oxygen cylinders will be
painted with a white shoulder, and hydrogen cylinders will be painted red. For further
information refer to BCGA TIS 6 (64, Gas cylinder identification. Label and colour
code requirements.
The number of cylinders in the work area should be kept to a minimum. If a cylinder
is not required for use then it should be returned to the gas cylinder store.
For information on handling gas cylinders, refer to Section 8.2.
Should there be any visible trace of oil or grease on an oxygen cylinder valve, the
cylinder shall be put aside for return to the owner. Contaminated cylinders shall be
suitably marked to prevent accidental re-issue.
Cylinders are normally designed to be used in the vertical position. Acetylene and
liquefied gases, such as propane, shall always be used in the vertical position.
Cylinders shall be restrained to avoid toppling.
Before connecting a regulator onto the cylinder outlet valves, ensure the cylinder
valve outlet is clean, dry, and free from damage and dirt. Refer to BCGA TIS 22 (69),
BCGA policy on connecting gas cylinders.
9.9 Pressure regulators

For information on pressure regulators refer to Section 7.1.
Before attaching a regulator to a cylinder, check:
(i) That the gas inside the cylinder is correctly identified and that the regulator
is suitable for that specific gas.
(ii) That the cylinder valve outlet thread is mechanically compatible with the
regulator inlet connection and is undamaged, clean and free of contamination.
Refer to BCGA TIS 22 (69).
(iii) That the regulator is suitable for the maximum cylinder pressure (regulator
inlet pressure);
(iv) That the regulator is manufactured to the standards detailed in Section 7.1;
(v) The regulator is within its expiry date. Typically 5 years or to the
manufacturer’s recommendation, refer to Appendix 1.
30
(vi) The regulator has a suitable outlet pressure for the application;
(vii) That the regulator is in a serviceable condition.
(viii) The gauges are not damaged nor show signs of over pressurisation.
(ix) If the Regulator is fitted with an ‘O’ ring seal. Check for damage and
replace if necessary with an ‘O’ ring recommended by the regulator
manufacturer.
(x) That the regulator outlet thread is in good condition.
(xi) Check the cylinder outlet valve and the regulator are closed. The regulator
pressure – adjusting screw is set to zero pressure position by turning the control
knob fully anti-clockwise;
Fit the pressure regulator to the cylinder. Only use the correct sized spanner when
attaching a regulator. Do not use any form of jointing paste or tape between regulator
and cylinder valve. Check that:
(xii) The regulator is fitted in the correct orientation:
 suitable for the cylinder valve outlet, that is top outlet or side outlet;
 the gauges and controls naturally face the front so that they are
visible and accessible to the operator;
If the cylinders are mounted on a trolley, the fuel gas regulator outlet should be
pointing away from the oxygen cylinder so that any rupture of the fuel gas hose will
not cause burning gas to play on to the oxygen cylinder.
9.10 Safety devices

For information on safety devices refer to Section 7.2.
The Acetylene Safety Regulations (13) require that all acetylene mobile systems shall
be fitted with a flame arrestor within one metre of the pressure regulator, and incorporate
a non-return valve and a quick acting shut-off device.
The minimum requirement for all hose sizes and lengths is:
(i) A non-return valve (hose check valve) shall be incorporated into the
assembled hose prior to each blowpipe inlet connection.
(ii) A three function flame arrestor shall be fitted in both the oxygen and fuel
gas lines as close to the regulator as possible.
For additional safety to (i) and (ii), and especially if access to cylinders is difficult or
they are remote from the operator, making them difficult to isolate, the following
safety devices may be added:
31
(iii) A blowpipe mounted flame arrestor with a minimum of a non-return valve
and a flame arresting element.
Or
(iv) A blowpipe mounted flame arrestor with a minimum of a non-return valve

and a flame arresting element and replace the three function flame arrestor with
a four function flame arrestor (which incorporates a pressure sensitive cut-off)
as close to the regulator as possible.
NOTE: The use of additional flame arrestors will provide increased safety.
However in such cases, the flow capacity of the system will be less than the rated flow
of each individual flame arrestor. Therefore, care should be taken to ensure flow
capacity is adequate for the correct and safe use of the equipment in accordance with
the supplier’s operating instructions.
The requirements are summarised in Table 2 and illustrated in Appendix 2.
REQUIREMENTS FIT TO BOTH FIT BETWEEN REGULATOR

BLOWPIPE OUTLET & BLOWPIPE IN
INLETS BOTH GAS LINES
Minimum (i) & (ii) NV (Hose) NV + FA + TV
NV (Hose)
Additional safety (iii) NV + FA + TV
+ NV + FA
NV (Hose)
Additional safety (iv) NV + FA + TV + PV
+ NV + FA
Key:
NV (Hose) Non Return Valve (Hose check valve)
NV Non-Return Valve
FA Flame Arresting Element
PV Pressure Sensitive Cut-Off Valve
TV Temperature Sensitive Cut-off Valve
Table 2: Safety devices – Installation requirements.
9.11 Hose assemblies

For additional information on hose assemblies refer to Section 7.3.
Ensure that all threads and seats are in good condition in accordance with
manufacturers’ / suppliers’ instructions. Take particular care to install the device in
the correct orientation such that the direction of flow is correct.
Before attaching a hose assembly, check:
32
 it is compatible with the gas, the gas pressure, and as appropriate, has the
correct colour code and either a left or right handed thread, refer to Table 1;
 all fittings, threads, connection seatings and clips are serviceable;
 for signs of excessive wear, cuts, abrasion, burns, contamination or

general deterioration.
Replace any hose assemblies that are unserviceable or whose condition is in any way
unsatisfactory.
When the equipment is in use the hose assembly should not be coiled around
cylinders, regulators or the handle of the trolley. In a fire a coiled hose is difficult to
extinguish.
As necessary, protect the hose assemblies from heat, mechanical damage, traffic,
sparks, hot splatter, slag and oil or grease.
9.12 Blowpipes
For information on blowpipes refer to Section 7.4.
Before fitting the blowpipe to the hose assembly, check:
 the blowpipe is suitable for the gas and application;
 all threads and seats are in good condition;
 all valves on the blowpipe are in the closed position.
9.13 Nozzles
Nozzle selection. It is essential to select the correct nozzle. Nozzles are specified to
the type of fuel gas being used and sized to the material and its thickness.
In order to ensure there is a gas tight seal in the blowpipe, always use nozzles which
are compatible with that specific blowpipe, refer to Appendix 3.
NOTES:
1. Identify the manufacturer of the blowpipe. Individual manufacturers use

different seat angles and lengths of fitting between the nozzle and head.
2. Using a manufacturer’s nozzle data chart enables the selection of the

correct nozzle and size for the application and gives the operator the required
pressures and gas consumption data for that process.
9.14 Pressurising the system

Before pressuring the system ensure that all regulator pressure adjustment knobs are
fully unwound and downstream equipment valves are closed.
33
Slowly open each cylinder valve in turn. Where the valve is not fitted with a
handwheel, use only the gas supplier’s recommended cylinder key and ensure that once
the valve is open, the cylinder key is left fitted to the valve. Normally a valve is
sufficiently open after one and a half turns. Never open a valve completely so that the
spindle is tight against the back. Leave at least half a turn to let others know that the
valve is open.
Adjust the pressure regulators to give the required gas pressures.
Check the equipment for leaks using a suitable leak detection fluid. For further
information on leak detection fluids refer to EIGA 78 (81).
Re-adjust pressures with the gas flowing.
9.15 System purging

Before attempting to light the blowpipe, purge each hose separately to establish only
oxygen or fuel gas in the appropriate hose, closing each blowpipe valve after the
relevant hose has been purged.
Purging should be continuous. Typically 3 to 5 seconds for a standard (5 m) hose.

Longer times are required for longer hose lengths.
This operation should take place in a well-ventilated space away from any source of
ignition.
It is essential that the procedure of purging gas systems shall take place following
each period of non-use.
NOTE: The majority of flashback incidents occur due to poor purging practices.
9.16 Lighting up
Always ignite the fuel gas before introducing the oxygen stream. The nozzle should
be pointing upwards for lighter than air gases (for example, acetylene), downwards for
heavier than air gases (for example, propane).
Light the blowpipe and adjust it in accordance with the supplier’s instructions. It is
recommended that a spark lighter or pilot flame is used for this purpose. Should there
be any signs of leakage, fluctuations of gas supply, gas starvation or mis-shaped
flames, the equipment should be shut down until the fault has been corrected.
Care should be taken to prevent a fire caused by an excess quantity of unburned fuel
gas and/or oxygen being discharged to the atmosphere, should the blowpipe fail to
ignite immediately.
10. CLOSING DOWN PROCEDURE
When closing down for short periods such as meal breaks, etc., carry out steps (i) to (v) of
the following list. For longer periods, and particularly if equipment is left unattended, then
carry out the full routine of steps (i) to (viii).
34
(i) Extinguish the blowpipe in accordance with the manufacturer’s operating
instructions.
(ii) Extinguish any pilot lights.
(iii) Close both cylinder valves.
(iv) Open blowpipe to vent hoses separately to a safe area. Check that the pressure
gauges on the regulators return to zero. Re-close blowpipe valves.
(v) Fully unwind the regulator pressure-adjusting knob to zero delivery position (by
turning anti-clockwise).
(vi) Visually check equipment for damage.
(vii) Return equipment and cylinders to a place of safe storage, reporting any damage
at the same time.
(viii) Make a final check to ensure that the cylinder valves are properly closed and
that there is no leakage of gas.
When working in a confined space, only Step (i) shall be carried out before the blowpipe is
removed from the confined space. Steps (ii) to (viii) can only then be carried out.
Blowpipes shall be removed from the confined space when work has ceased for more than a
few minutes.
11. INFORMATION, INSTRUCTION AND TRAINING
All personnel directly involved in the assembly, operation and maintenance of oxy-fuel
pressure equipment shall have the necessary skills and knowledge to carry out their job
safely and shall receive appropriate information, instruction and training, including
induction and continuation / refresher training. Such training shall be both theoretical and
practical. It is the duty of the employer to ensure their persons are adequately trained and to
establish competency. It is recommended that a training programme is carried out under a
formalised system. Records shall be kept of the information, instruction and training
provided and of the competence level achieved. The programme shall make provision for
periodic competence re-assessment.
This will include training on:
 the hazards and properties of oxy-fuel gases. Refer to Section 3;
 the gas cylinders;
 associated equipment and the pressure system(s);
 manual handling of gas cylinders. Refer to Section 8.2;
35
 correct storage of gas cylinders. Refer to Section 8.1;
 ventilation and monitoring systems, including gas detection;
 actions in the event of an emergency. Refer to Section 12.
Recommendations for the training of personnel are detailed in BCGA GN 23 (62). For
additional information refer to EIGA Document 23 (79), Safety training of employees.
12. EMERGENCY PROCEDURES
The user shall have fire-fighting equipment / facilities as identified in the Site Fire Safety
Management Plan provided and a site-specific emergency procedure in place for fire
situations in compliance with The Regulatory Reform (Fire Safety) Order (10). Refer to
Section 9.2.
BCGA Leaflet 6 (75), Cylinders in fires, provides guidance on dealing with gas cylinders
involved in a fire.
Correct location of cylinders, correct assembly of equipment and correct operation will all
contribute to minimising the risk of an incident involving gas cylinders.
If a gas leak occurs and / or ignites (flammable gases) in the presence of an operator, if safe
to do so, isolate by turning off the cylinder valve.
The most common incidents to occur are leakages of fuel gas from hose connections or a
defective hose, which then ignites. If this occurs, if safe to do so, close the cylinder valve
and extinguish the fire. If it is not possible to close the valve first, then extinguish the fire
and then close the valve to avoid re-ignition. If the fire is in the vicinity of the regulator, it
may be possible to close the pressure adjusting screw on the regulator.
If a fire continues carry out the actions in Section 12.1.
12.1 For cylinders involved in fires
 KEEP AWAY, DO NOT approach or attempt to move the cylinder or

operate the valve.
 Raise the alarm.
 Evacuate the immediate area and keep others away.
 Contact the Fire and Rescue Service.
Keep well clear until the Fire and Rescue Service arrive and then follow their
instructions.
36
Inform the Fire and Rescue Service immediately of the location, the quantity and type
of any gas cylinders involved in the fire. Also tell them the location of other gas
cylinders on the premises.
Cylinders which are not directly involved in the fire and which have not become
heated, should be moved as quickly as possible to a safe place, provided that this can
be done without undue risk. Make sure that cylinder valves are closed.
12.2 Sustained backfire

Close both blowpipe valves, oxygen valve first.
(i) Check that regulator pressure settings were correct and that the cylinders
are not empty.
(ii) If necessary, cool the blowpipe by immersion in water and then check that
the nozzle, mixer and blowpipe connections are tight.
(iii) Purge both hoses individually and ensure that correct gas flows have been
re-established.
(iv) Relight the blowpipe with care and make sure that the shape and general
behaviour of the flame is correct.
(v) Should there be a recurrence, then the equipment shall be withdrawn from
service for full examination by a person with appropriate experience and
knowledge.
12.3 Flashback / self-extinguishing backfire
(i) Immediately close both blowpipe valves, oxygen valve first.
(ii) Close both cylinder valves.
(iii) Ascertain the cause of the incident and examine all equipment thoroughly
for damage. In particular, check to see if the pressure or temperature-sensitive
cut-off valve has closed.
When using acetylene, check all equipment for signs of soot, which will indicate
the extent of flashback.
Monitor the acetylene cylinder for any signs of it becoming warm after a
flashback. If a hotspot is detected, or the cylinder begins to vibrate, immediately
evacuate the area and call the Fire and Rescue Service.
(iv) Replace any damaged equipment.
Before attempting any steps towards relighting, ensure that the cut-off valve, if
fitted, is reset or replaced as necessary.
37
(v) Carry out all preparation procedures specified in Section 11 and be
particularly vigilant during the first few minutes after relighting.
12.4 Fire damaged gas cylinders

Following an incident the Fire and Rescue Service will inform you when it is safe to
approach the gas cylinders. Do not use any cylinders which have been involved in a
fire. Some may have obvious damage but others may have had their mechanical
properties affected by heat, unnoticeable to the naked eye. Inform your gas supplier
whenever a cylinder has been involved in a fire or if it is suspected that it has been
affected by excessive heat. Your gas supplier will provide advice on what to do next,
which will vary depending upon the circumstances
Contact numbers for the gas supplier are available on the product Safety Data Sheet.
Refer also to BCGA Leaflet 6 (75).
13. SECURITY
Gas cylinders and the gases they contain are hazardous. When not in use they should be
located in a secure store, refer to Section 7.1.
When in use at the workplace they should be accountable and be subject to routine
management checks.
If gas cylinders are empty, or no longer required, then they should be returned to the gas
supplier at the earliest opportunity.
Additional advice is available from your gas supplier and the BCGA.
14. REFERENCES
Document Number Title

1. The Health and Safety at Work etc. Act 1974.
2. SI 1992: No 2793 Manual Handling Operations Regulations 1992.
3. SI 1997: No 1713 The Confined Spaces Regulations 1997.
4. SI 1998: No. 2306 The Provision and Use of Work Equipment Regulations 1998.
(PUWER).
5. SI 1999: No 3242 The Management of Health and Safety at Work Regulations

1999.
6. SI 2000: No. 128 The Pressure Systems Safety Regulations 2000 (PSSR).
7. SI 2002: No 1144 Personal Protective Equipment Regulations 2002.
38
8. SI 2002: No 2677 Control of Substances Hazardous to Health Regulations 2002
(COSHH).
9. SI 2002: No 2776 The Dangerous Substances and Explosive Atmosphere

Regulations 2002 (DSEAR).
10. SI 2005: No. 1541 The Regulatory Reform (Fire Safety) Order 2005.
11. SI 2005: No. 1643 The Control of Noise at Work Regulations 2005
12. SI 2009 No. 1348 The Carriage of Dangerous Goods and Use of Transportable
Pressure Equipment Regulations 2009 (as amended).
13. SI 2014: No. 1639 The Acetylene Safety (England and Wales and Scotland)
Regulations 2014.
14. SI 2015: No. 51 The Construction (Design and Management) Regulations 2015
(CDM)
15. SI 2016 No. 1105 The Pressure Equipment (Safety) Regulations 2016
16. EU Directive Directive 2014/68/EU of the European Parliament and of the

2014/68/EU Council of 15 May 2014 on the harmonisation of the laws of
the Member States relating to the making available on the
market of pressure equipment. (PED)
17. ECE/TRANS/257 European Agreement concerning the international carriage of

dangerous goods by road (ADR) (as amended)
18. HSE EH 40 Workplace exposure limits.
19. HSE L5 Control of substances hazardous to health. The Control of

Substances Hazardous to Health Regulations 2002 (as amended).
Approved Code of Practice and guidance.
20. HSE L22 Safe use of work equipment. Provision and Use of Work
Equipment Regulations 1998. Approved Code of Practice and
guidance.
21. HSE L25 Personal Protective Equipment at Work.
22. HSE L101 Safe work in confined spaces. Confined Space Regulations
1997. Approved Code of Practice, regulations and guidance.
23. HSE L122 Safety of pressure systems. Pressure Systems Safety

Regulations 2000. Approved Code of Practice.
24. HSE L138 Dangerous substances and explosive atmospheres DSEAR 2002.
Approved Codes of Practice and Guidance.
39
25. HSE L153 Managing health and safety in construction. Construction
(Design and Management) Regulations 2015. Guidance on
Regulations.
26. HSE HSG 139 The safe use of compressed gases in welding, flame cutting and
allied processes.
27. HSE HSG 250 Guidance on permit-to-work systems. A guide for the
petroleum, chemical and allied industries.
28. HSE HSG 258 Controlling airborne contaminants at work. A guide to local
exhaust ventilation (LEV).
29. HSE INDG 136 Working with substances hazardous to health. A brief guide to
COSHH.
30. HSE INDG 258 Confined spaces. A brief guide to working safely.
31. HSE INDG 297 Safety in gas welding, cutting and similar processes.
32. HSE INDG 314 Hot work on small tanks and drums.
33. HSE INDG 327 Working safely with acetylene.
34. HSE INDG 370 Controlling Fire & Explosion risks in the workplace. A brief
guide to DSEAR.
35. HSE INDG 390 Choosing a welding set? Make sure you can handle it.
36. HSE INDG 459 Oxygen use in the workplace. Fire and explosion hazards.
37. HSE EIS 43 Storage and use of oxygen and fuel gases on board ships.
38. BS EN 169 Personal eye protection. Filters for welding and related
techniques. Transmittance requirements and recommended use.
39. BS EN 175 Personal protection. Equipment for eye and face protection
during welding and allied processes.
40. BS EN 529 Respiratory protective devices. Recommendations for selection,

use, care and maintenance. Guidance document.
41. BS EN 560 Gas welding equipment. Hose connections for equipment for
welding, cutting and allied processes.
42. BS EN 561 Gas welding equipment. Quick-action coupling with shut-off

valves for welding, cutting and allied processes.
43. BS EN 1256 Gas welding equipment. Specification for hose assemblies for
equipment for welding, cutting and allied processes.
40
44. BS EN ISO 2503 Gas welding equipment. Pressure regulators and pressure
regulators with flow-metering devices for gas cylinders used in
welding, cutting and allied processes up to 300 bar (30 MPa).
45. BS EN ISO 3821 Gas welding equipment. Rubber hoses for welding, cutting and
allied processes.
46. BS EN ISO 5172 Gas welding equipment. Blowpipes for gas welding, heating and
cutting. Specifications and tests.
47. BS EN ISO 5175 Gas welding equipment. Safety devices.

Part 1: Devices incorporating a flame (flashback) arrestor.
Part 2: Devices not incorporating a flame (flashback) arrestor.
48. BS EN ISO 7291 Gas welding equipment. Pressure regulators for manifold
systems used in welding, cutting and allied processes up to 30
MPa (300 bar).
49. BS EN ISO 11114 Transportable gas cylinders. Compatibility of cylinder & valve
materials with gas contents.
Part 1: Metallic materials.
Part 2: Non-metallic materials.
50. BS EN 12021 Respiratory equipment. Compressed gases for breathing

apparatus.
51. BS EN ISO 22435 Gas cylinders. Cylinder valves with integrated pressure
regulators. Specification and type testing.
52. BCGA Code of Industrial gas cylinder manifolds and distribution pipework
Practice 4 (excluding acetylene).
53. BCGA Code of The design and construction of manifolds using acetylene gas
Practice 5 from 1.5 to 25 bar.
54. BCGA Code of The safe distribution of acetylene in the pressure range 0 to 1.5
Practice 6 bar.
55. BCGA Code of The safe storage and use of cylinders in mobile workshops and
Practice 31 service vehicles.
56. BCGA Code of In-service requirements of pressure equipment (gas storage and
Practice 39 gas distribution systems).
57. BCGA Code of The storage of gas cylinders.

Practice 44
58. BCGA Code of The safe use of individual portable or mobile cylinder gas supply
Practice 47 equipment.
41
59. BCGA Guidance Safe cylinder handling and the application of the manual
Note 3 handling operations regulations to gas cylinders.
60. BCGA Guidance The management of risk when using gases in enclosed
Note 11 workplaces.
61. BCGA Guidance DSEAR Risk Assessment.

Note 13
62. BCGA Guidance Gas safety. Information, instruction and training.

Note 23
63. BCGA Guidance Guidance for the carriage of gas cylinders on vehicles.
Note 27
64. BCGA Technical Gas cylinder identification. Label and colour code
Information Sheet 6 requirements.
65. BCGA Technical Model risk assessment for the storage and use of oxy-acetylene
Information Sheet 15 cylinders.
66. BCGA Technical Model risk assessment for manual handling activities in the
Information Sheet 17 industrial gas industry.
67. BCGA Technical Date marking of gas accessories.

Information Sheet 18
68. BCGA Technical Refurbishment of components used with compressed gases for
Information Sheet 19 welding, cutting and related processes.
69. BCGA Technical BCGA policy on connecting gas cylinders.

70. BCGA Technical Welding fumes. Safety alert.

71. BCGA Technical Oxy-fuel gas equipment. Selection and assembly.

72. BCGA Technical Acetylene or propane (for welding, cutting and allied
Information Sheet 32 processes).
73. BCGA Technical Moving gas cylinders and bundles within the workplace.
74. BCGA Leaflet 1 The carriage of small quantities of gas cylinders on vehicles.
75. BCGA Leaflet 6 Cylinders in fires.
42
76. BCGA Safety Alert The hazards of using incorrect regulators on acetylene gas
1 cylinders.
77. UKLPG Code of Purging LPG vessels and systems.

Practice 17
78. UKLPG User Safe use of propane and butane cylinders & cartridges.
79. EIGA Document 23 Safety training of employees.
80. EIGA Document 40 Work permit systems.
81. EIGA Document 78 Leak detection fluids cylinder packages.
82. EIGA Document Selection of personal protective equipment.

136
83. EIGA Safety Flashback and flashback arrestors in welding applications.
Information 5
Further information can be obtained from:
UK Legislation www.legislation.gov.uk
Health and Safety Executive (HSE) www.hse.gov.uk
British Standards Institute (BSI) www.bsigroup.co.uk
International Organization for Standardization (ISO) www.iso.org
European Industrial Gases Association (EIGA) www.eiga.eu
British Compressed Gases Association (BCGA) www.bcga.co.uk
The UK LPG trade association (UKLPG) www.uklpg.org
The Chartered Society for Worker Health Protection www.bohs.org

(BOHS)
43
APPENDIX 1
Sheet 1 of 4
GUIDANCE ON INSPECTION AND MAINTENANCE
INTERVALS
EQUIPMENT AT ASSEMBLEY BEFORE USE AFTER USE ANNUAL REPLACEMENT /
REFURBISHMENT
INTERVALS
Check compatible with the Check body for any signs Check for any damage, Full visual inspection. 5 years from date of
gas. of soot, oil, grease or contamination, defects or manufacture or
other contamination. faults. Check life dates. manufacturer’s
Ensure within life for use. recommendations.
Check compatible with Check that gauges return Functional tests to ensure
the gas. Replace with a new, or
Check the regulator inlet to zero during the venting correct operation.
refurbished unit
pressure is compatible with process. Typically this will
the maximum cylinder Ensure the Pressure include a creep test to
Adjustment control is NOTE 1.
pressure. ensure regulator integrity.
firmly fixed to the body NOTE 2.
Ensure the Pressure and operate freely.
REGULATORS Adjustment control is
and their integral firmly fixed to the body and Ensure the regulator
protective devices operates freely. gauges start at zero prior
to use.
Sections 7.1, 9.9 Check the inlet and outlet
Ensure the pressure rises
connections sit square to
on the high pressure
the regulator’s body.
gauge when opening the
cylinder outlet valve.
Check condition of threads
and sealing surfaces. Check the low pressure
Ensure no signs of PTFE gauge rises smoothly
tape. when setting the gas
pressure.
Check both gauges on
regulator naturally face the Leak test all joints at
front and are undamaged. working pressure.
44
APPENDIX 1
Sheet 2 of 4
Ensure both gauge needles

reset to zero.
No oil, grease or other

contamination.
Leak test all joints at

working pressure.
Check correct type fitted. Ensure flame arrestors are Check for any damage, Check unit for leaks, flow 5 years from date of
fitted. contamination, defects or restrictions and reverse manufacture or
Check manufacturing faults. flow to ensure correct manufacturer’s
standard. Leak test all joints at operation of non-return recommendations.
working pressure. valves.
Replace with a new, or
Ensure within life for use.
refurbished unit.
Where pressure sensitive
Check condition of threads cut off valves are fitted,
FLAME NOTE 1.
and sealing surfaces. they shall operate at a
NOTE 2.
ARRESTORS pressure of no greater
and their integral Check the direction of flow than 1.2 bar.
cut off valves. is correct.
If of a pressure sensitive
No oil, grease or other type, check shut-off in
Sections 7.2, 9.10 contamination. the tripped condition in
the direction of flow.
Leak test all joints at
working pressure. Check life dates.
Check the pressure

sensitive cut-off valve
button is not restricted /
damaged / tied down.
45
APPENDIX 1
Sheet 3 of 4
Check the manufacturing Ensure all the gas hose is Check for any damage, Reverse hose to ensure Determined by local
standard. unwound from gas contamination, defects or the correct operation of operating conditions.
cylinder trolley prior to faults. non-return valve where
Replace as required.
Check suitability of hose use. fitted. Bend hose in a
colour, internal bore size tight radius to ensure
NOTE 2
and length Check hoses condition for reinforcement is not
HOSE damage (e.g. kinking visible and there is no
ASSEMBLIES Check threads and sealing twisting or cracking). sign of collapse or
surfaces. distortion.
Sections 7.3, 9.11 Leak test of all joints at
Check hoses condition for working pressure.
(including damage (e.g. kinking
NON-RETURN twisting or cracking).
VALVES)
Ensure HCV and Nut &
Sections 7.2, 9.10. Tails are fitted using correct
ferrules and are located in
the correct place.
Leak test of all joints at

working pressure.
Check compatible with the Ensure the blowpipe Check for any damage, Test valve functions. Determined by local
gas. nozzle is correct for the contamination, defects or operating conditions.
type of gas being used. faults. Blank exits and leak test
Replace with a new, or
Check the condition of the for internal malfunction.
refurbished unit
body, head and pipes. Check the condition of
BLOWPIPES the body, head and pipes.
NOTE 2
Sections 7.4, 9.12 Check blowpipe nut is
undamaged and is not oval. Ensure the blowpipe taps
are undamaged and
Ensure the blowpipe taps operate freely.
are undamaged and operate
freely.
46
APPENDIX 1
Sheet 4 of 4
Check nozzle and inlet Check nozzle and inlet

seatings for damage. seatings for damage.
Leak test all joints at Leak test all joints at

working pressure. working pressure.
NOTE 1: Components such as elastomers, seals and diaphragms, will wear and deteriorate from their date of manufacture whether in gas service
or not. Items stored out of gas service for one year or over should receive checks in accordance with the annual requirements.
NOTE 2: Some equipment is marked to either identify the date it was manufactured or the date when it needs replacement or refurbishment.
Refer to BCGA TIS 18 (67), Date marking of gas accessories.
47
APPENDIX 2
Sheet 1 of 2
MINIMUM REQUIREMENT FOR ALL HOSE SIZES AND LENGTHS
Refer to Section 9.10 and Table 2.
NV (Hose)
NV + FA + TV
FUEL GASES
ACETYLENE
& OTHER
BLOWPIPE
NV (Hose)
NV + FA + TV
OXYGEN
KEY:
NV (Hose) Non-return valve (Hose check valve)
NV Non-return valve
FA Flame arresting element
TV Temperature sensitive cut-off valve
48
APPENDIX 2
Sheet 2 of 2
FOR ADDITIONAL SAFETY
A.
NV (Hose) + NV + FA
NV + FA + TV
FUEL GASES
ACETYLENE
& OTHER
BLOWPIPE NV (Hose) + NV + FA
NV + FA + TV
OXYGEN
or
B.
NV (Hose) + NV + FA NV + FA + TV + PV
FUEL GASES
ACETYLENE
& OTHER
BLOWPIPE NV + FA + TV +PV
NV (Hose) + NV FA
KEY:
NV (Hose)
Non-return Valve
(Hose check valve)
OXYGEN
NV Non-return valve
FA Flame arresting element
TV Temperature sensitive
cut-off valve
PV Pressure sensitive
cut-off valve
49
APPENDIX 3
Sheet 1 of 1
THREE-SEAT CUTTING NOZZLES - DIMENSIONS
This Appendix specifies the cone angle for three-seat cutting nozzles required for
compatibility with the main UK brands of oxy-fuel gas cutting blowpipes. Refer to Section
9.13.
This angle, although standardised by the main UK brands, is not standardised throughout the
world or within Europe, and is not detailed in BS EN ISO 5172 (46). Users are warned that
problems with head seat leaks can result from using non-compatible equipment.
Figure A3-1 shows the cone angle to be used for three-seat cutting nozzles. Dimensions not
given are left to the manufacturer’s discretion.
Figure A3-1: Cone angle for three-seat cutting nozzles.
50
British Compressed Gases Association
www.bcga.co.uk

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CODE OF PRACTICE 7

THE SAFE USE OF OXY-FUEL GAS

THE SAFE USE OF OXY-FUEL GAS EQUIPMENT

Copyright © 2018 by British Compressed Gases

BRITISH COMPRESSED GASES ASSOCIATION

The British Compressed Gases Association (BCGA) was established in

The main objectives of the Association are to further technology, to

Policy is determined by a Council elected from Member Companies,

BCGA makes strenuous efforts to ensure the accuracy and current

BCGA publications are reviewed, and revised if necessary, at five-

This document has been prepared by BCGA Technical Sub-

3. AWARENESS OF THE PROPERTIES OF GASES USED 5

5. EXAMINATION, INSPECTION AND MAINTENANCE 7

8. CYLINDER STORAGE AND HANDLING 19

9. PREPARATION FOR USE 21

10. CLOSING DOWN PROCEDURE 34

11. INFORMATION, INSTRUCTION AND TRAINING 35

12. EMERGENCY PROCEDURES 36

Appendix 1 Guidance on inspection and maintenance 44

Appendix 2 Minimum requirement for all hose sizes and lengths 48

For additional safety 49

Appendix 3 Three-seat cutting nozzles - Dimensions 50

It has two defining features:

[as defined in the Confined Spaces Regulations (3)]

Cylinder A transportable pressure receptacle of a water capacity not exceeding 150

Flame A device which arrests a flame front (caused by flashback or decomposition)

May Indicates an option available to the user of this Code of Practice.

Specifically a non-return valve shall be effective against the return of gas

1 bar = 100 kPa = 105 N/m2 = 14.5 lbf/in²

Pressures used are gauge pressures except where otherwise stated.

Working The settled pressure of a compressed gas at a reference temperature of 15 °C

 The Construction (Design and Management) Regulations (CDM) (14), which

 The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR)

 The Control of Substances Hazardous to Health Regulations (COSHH) (8)

 BCGA CP 4 (52), Industrial gas control and distribution systems (excluding

 BCGA CP 6 (54), The safe distribution of acetylene in the pressure range 0 to

3. AWARENESS OF THE PROPERTIES OF GASES USED

If additional information is required contact your gas supplier for advice.

The Control of Substances Hazardous to Health Regulations (COSHH) (8). Requires

The Carriage of Dangerous Goods and Use of Transportable Pressure Equipment

5. EXAMINATION, INSPECTION AND MAINTENANCE

It is the duty of the employer to ensure persons undertaking examination, inspection or

Appendix 1 provides guidance on the recommended inspection and maintenance

With reference to Appendix 1, the following checks shall be carried out:

 An ‘assembly’ check. To be carried out when assembling the equipment.

Any damaged, contaminated or out-of-date equipment shall not be used. This

 An ‘after use’ inspection check. To be carried out by the user on completion of

Any damaged or contaminated equipment shall be replaced.

 An ‘annual’ inspection with any associated maintenance. To consist of an in-

The inspection shall be carried out by a person who has:

(i) sufficient practical experience of oxy-fuel and related gas equipment,

and can demonstrate a theoretical knowledge of:

(iii) relevant current legislation, standards and industry documents.

 ‘Examination’ where required by, and in accordance with, a Written Scheme of

BCGA no longer support refurbishment of components, such as regulators or handheld

6.2 Sustained backfire

NOTE: This manifests itself either as ‘popping’ or ‘squealing’ with a small

6.3 Intermittent backfire

6.7 Ignition within an oxygen system

6.8 Oxygen leakage