Oxygen regulator fires fortunately do not occur frequently in the welding industry, but when they happen, the damage to property and personnel can be devastating. Regulator burnout can happen to the most experienced welder if proper safety practices are not followed. An operator in a hurry, a safety step overlooked, can lead to an accident. Because the causes of regulator burnout are not always clear, it may be impossible to completely eliminate this safety hazard, but fortunately, the damage and potential injury can be contained, thanks to a patented regulator design available only from ESAB Welding and Cutting Products.

Regulator fires happen when high pressure oxygen passing through the intake valve comes in contact with contaminants on the valve. The high pressure passage of the oxygen through the narrow valve creates heat. Any flammable material on the valve, including dirt, oil, grease or other hydrocarbons, can ignite under this heat. The resulting fire often triggers an explosion, turning parts of the regulator into high-temperature projectiles.

To avoid this problem, the following welding safety procedures should always be followed:

1. Crack the oxygen cylinder valve before you attach the regulator. To do this, stand to one side or to the rear of the cylinder outlet. Open the cylinder valve slight for an instant and then close it. This should clean accumulated dust and dirt from the valve.

2. Use only oxygen regulators to control oxygen supply. Switching regulators from non-oxygen use to oxygen use can introduce contaminants into the system. Be sure the valve is clean and free of grease and oil. Never use an oxygen regulator for other gases.

3. Before opening the cylinder valve, be sure the oxygen regulator pressure-adjusting screw is released. To do this, rotate the screw counter clockwise until it turns freely.

4. Stand to one wide whole opening the oxygen cylinder valve. Open the valve as slowly as possible until the high pressure gauge reaches cylinder pressure. Never open the cylinder valve suddenly, as sudden surges of high pressure can cause a blow out.

Further protection is available by using ESAB oxygen regulators. ESAB’s patented design makes our regulators the safest and most accurate regulators on the market today. Here’s why:

ESAB regulator bodies are machined from solid brass bar stock, not made from forgings. The bar stock provides a thick wall that helps contain a burnout and keeps internal body cavities to a minimum. Small cavities limit the amount of gas that can accumulate in the body and contribute to the seriousness of an oxygen fire. This solid design also contributes to the overall durability of the ESAB regulator.

ESAB’s small cavity design features a long, narrow passage that sharply diminishes the intensity of any fire that might enter from the inlet connection, reducing the possibility that the regulator will explode.

Massive baffle plates protect the diaphragm and keep it away from the main gas stream. The neoprene diaphragm is not directly exposed to hot gas or fire that could destroy it. Small bleeder holes in the baffle plate allow the diaphragm to function and respond to demand for greater or lesser amounts of gas supply. This baffle system prevents the fire from reaching the chamber, where the potential for an explosion is the greatest.

Using a relatively small quantity of seat material lowers burnout intensity should one occur. ESAB keeps the amount of synthetic material used it its regulators to a minimum to reduce possible fuel that could contribute to a fire.

ESAB regulators incorporate a fabric-reinforced neoprene diaphragm that combines thinness and high strength. When heavier diaphragms are used, the rubber can shrink in sub-zero temperatures, resulting in leakage between the body and cap. ESAB regulators shrink less, thereby minimizing leaks.

Regulator fires can occur when gauges are accidentally used for the wrong types of gas. Such misuse increases the potential for contamination of the regulator. Use of a contaminated regulator with high-pressure oxygen can result in a regulator burnout. As a further safety feature, all ESAB regulators are color coded and clearly labeled for their correct usage.

In addition to being safer, ESAB regulators are also durable, accurate and save more gas than competitive brands. Better performance. Greater safety. Why take a chance on anything else? Ask your distributor today about the ESAB line of regulators.