Oxy-Fuel Torch Lighting and Extinguishing Safety
The Problem
Oxy-fuel torches are powerful tools for cutting and heating metal—but if not handled properly, they carry serious risks. Lighting and extinguishing the torch are the most hazardous stages. Mistakes during these steps can lead to fires, explosions, or serious injuries. Today, we’ll review these risks and how to follow correct safety procedures to keep everyone on site safe.
Identify the Hazards
Safety Practices and Preventative Measures
Initial Preparation
- Turn the regulator screws counter-clockwise to prevent high-pressure gas from flowing suddenly.
- Close the pre-heat oxygen and acetylene valves on the torch before starting.
- Opening the Gas Cylinders
- Stand to the side of the regulators—not in front.
- Slowly open the oxygen cylinder valve fully.
- Open the acetylene valve no more than half a turn to maintain control over gas flow.
Purging the System
- Open and close the oxygen torch valve briefly to purge the hose.
- Repeat with the acetylene valve to clear gas from both lines.
- Setting the Pressures
- Adjust oxygen pressure to a maximum of 40 PSI and acetylene to 3.5 PSI (or per manufacturer’s instructions).
- Once pressures are set, close the valves until lighting.
Lighting the Torch
- Slightly open the acetylene valve on the torch.
- Use a flint striker or approved ignition source—never use a lighter or open flame.
- Adjust the acetylene flame to stabilise it, then slowly open the pre-heat oxygen valve to achieve the correct flame.
Extinguishing the Torch
- Close the oxygen valve first, followed by the acetylene valve.
- Shut off both cylinder valves.
- Purge residual gas from the system: Open the oxygen valve on the torch to bleed pressure, then close it.
- Do the same for the acetylene valve.
Post-Use Safety
- Always close cylinder valves when the torch is not in use or cylinders are being moved.
Real-Life Case or Scenario
Recently, a worker didn’t purge residual gas from the hoses after extinguishing the torch. The next time it was used, the remaining gas ignited, causing a flashback. No one was injured, but the equipment was damaged, and operations were halted for safety inspections. This incident could have been prevented with proper post-use purging.
Employee Responsibilities
- Inspect torch equipment and hoses before each use.
- Follow every step for lighting and extinguishing the torch correctly.
- Use only approved ignition devices.
- Purge the system after every use.
- Report any unsafe equipment or conditions to your supervisor immediately.
Employer Responsibilities
- Provide clear training on torch safety and correct handling procedures.
- Ensure all gas equipment is maintained and regularly inspected.
- Replace damaged gear promptly and enforce correct safety practices on site.
Discussion & Questions
- "What’s the most commonly overlooked step when using an oxy-fuel torch?"
- "Has anyone witnessed an incident involving incorrect torch use? What did we learn from it?"
Encourage open discussion and sharing of safety ideas or concerns.
Commitment/Action Plan
From today onward, let’s all commit to following every safety step when lighting and shutting down oxy-fuel torches. That includes purging, checking equipment, and using proper ignition tools. These details matter—they prevent injuries and keep everyone safe.
Wrap-Up
Oxy-fuel torches are incredibly effective tools, but they must be handled with care. By sticking to these safety procedures—and following the Canadian Centre for Occupational Health and Safety (CCOHS) best practice guidelines—we can eliminate the risks and maintain a safe working environment. Thanks for making safety your priority.
Standards Overview
Under the Canada Labour Code and applicable provincial health and safety regulations, employers must manage risks associated with hazardous equipment like oxy-fuel torches. This includes:
- Providing clear training on gas cutting equipment
- Ensuring workers are competent and confident using torches safely
- Using approved procedures for equipment setup, operation, and shutdown
- Inspecting and maintaining cylinders, hoses, regulators, and torches
The Canadian Centre for Occupational Health and Safety (CCOHS) supports this through guidance on safe gas welding and cutting practices.
Disclaimer
“The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.
It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.
Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.
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