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Maintenance and Use of Gas and Oxy Equipment

Date: 06-03-2025
Weldclass Academy

 

This article outlines recommended maintenance procedures and general use instructions for Weldclass gas and oxy-fuel equipment. Although this is written for the listed Weldclass equipment, many of these steps outline general best-practice that is applicable to other brands.

 

Maintenance Schedule For Gas and Oxy-Fuel Equipment

The following maintenance schedule aligns with the requirements of AS 4839-2001 The Safe Use of Portable and Mobile Oxy-fuel Gas Systems for Welding, Cutting, Heating and Allied Processes. 

Equipment

Maintenance
Weekly As nominated Refurbishment
Gas Regulators Visual examination to
determine suitability for
service, checking for:
  • Any signs of damage
  • Condition of threads & sealing surfaces
  • Any evidence of oil or grease contamination
Leak test all joints & connections at
working pressure.		 Six monthly:
Functional tests to ensure correct operation of internal components.		 Manufacturer or supplier
recommendation, but not
exceeding five years.*
Flashback Arrestors Visual examination to
determine suitability for
service (e.g. gas,
pressure rating, damage);
condition of threads and
sealing surfaces; and oil
or grease contamination.
Leak test all joints at
working pressure.		 Yearly as detailed in AS 4603 or following a flashback:
Proper functioning of non-return valves		 Not
exceeding five years
Hose assemblies Visual examination to
determine suitability for
service (e.g. gas,
pressure rating, damage);
condition of cover; and
threads and sealing
surfaces of the end
fittings.
Leak test all joints at
working pressure.		 Six monthly:
Check for absence of
cuts and excessive wear
by bending the hose in a
tight radius, to ensure
reinforcement is not
visible.		 Determined by the hose
assembly condition.
4. Blowpipes, mixers
and attachments		 Visual examination for
damage of the threads
and sealing surfaces of
the hose connections and
the attachment
connections.
Leak test all joints at
working pressure.		 Six monthly:
Test control valve
function. Blank the
attachment connection
and leak test for internal
malfunction.		 Manufacturer or supplier
recommendation, but not
exceeding five years.*

 * Regulator elastomers and seals will wear and deteriorate in service and deteriorate out of service. Items stored for one year or over without use should receive inspection as per the annual maintenance inspection.

   

General Instructions and Guidelines


⚠️ Safety Guidelines

  • Grease, oil, and substances containing carbon (eg sawdust) can cause explosion when in contact with oxygen. Never allow gas equipment to come in contact with grease or oil or substances containing carbon, keep all equipment clean at all times.
  • Wear protective gear and keep hair and loose clothing away from flames.
  • Check for leaks at all joints before each use using leak detection fluid or soapy water — never use fire.
  • Use flashback arrestors at both ends of the hose. If a flashback occurs, shut off valves immediately and inspect for damage.
  • Only trained professionals should repair or modify the equipment.  

Hose Requirements

  • Use certified hoses and flashback arrestors.
  • When assembling hoses:
  • Choose correct type and diameter.
  • Use approved fittings and clamps.
  • Ensure tight, leak-free connections.
  • Avoid twisting or overheating hoses.
  • Replace worn or damaged hoses.
  • Twin hoses should be 5–10mm in diameter.

System Setup

  • Compatible with:
    Oxygen + acetylene cylinders
  • Oxygen + LPG cylinders
  • Confirm all parts are in good condition.
  • Install flashback arrestors at both ends.
  • Tighten all connections.
  • Keep hoses clear of heat and damage.
  • Inspect torch and fittings.

Assembly Steps

  • Connect hoses to torch and regulators.
  • Attach flashback arrestors.
  • Connect regulators to cylinders.
  • Secure hoses to arrestors.
  • Check all fittings.
  • Close torch valves.
  • Open cylinder valves slowly.
  • Set regulator pressure.
  • Test for leaks with fluid or soap.

Leak Testing

  • Close all valves.
  • Open cylinder valves and set pressure.
  • Apply leak detection fluid to joints.
  • Never use flame to test.
  • If leaks found:
  • Shut valves.
  • Release pressure.
  • Tighten joints.
  • Re-test.
  • If leaks persist, stop use and contact supplier.

Ignition Procedure

  • Confirm secure, leak-free setup.
  • Slightly open fuel valve.
  • Ignite with spark lighter — not matches.
  • Slowly open oxygen valve and adjust flame.
  • If flame is unstable, shut down and inspect.
  • Never aim torch at people.

Shutdown Procedure

  • Close fuel valve.
  • Close oxygen valve.
  • Shut cylinder valves.
  • Release pressure via torch valves.
  • Close torch valves.
  • Store equipment safely.

Key Reminders

  • Use correct flashback arrestors.
  • Always test for leaks.
  • Wear safety gear.
  • Keep hoses away from heat.
  • Never use flame for leak testing.
  • Never point torch at people.
  • Don’t use damaged equipment.

 

 

Tags
Gas & Oxy Equipment