FLASHBACK ARRESTER

Goal is “Zero Incidents”

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 FLASH BACK ARRESTERS

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 WHAT IS FLASHBACK ARRESTER ?

Flashback Arrester is a device that is installed on the Gas Welding or Cutting Torch.

It is also known as “ SAFETY SEAL “

It arrests or prevents the PROPAGATION OF THE FLAME UPSTREAM

It’s a sort of modification of Check Valve which prevents the UNINTENTIONAL

BACKFLOW of gases in the pipe

A "Flashback" is the combustion of a flammable mixture within the equipment's used for
handling of flammable gases viz. Pipelines, Gas Regulators, Gas Mixing Devices,
Cylinders, etc.

Backfire / Flashback is defined as a Retrogression of the Flame( either momentary or

sustained), UPSTREAM of the mixer i.e. at the tip of the torch or the hoses back into
the system

A "Flashback" is a root cause of backfire, which normally appears in a mixing device.

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 DETONATION

A Flash propagation through an un burnt gas at a rate that is above the speed of sound
is called Detonation. It has a power to Explode Pipelines, Cylinders, Compressors &
equipment-etc.

It is prevented by maintaining proper distance between an Ignition source and a

Flashback Arrestor, often termed as the “Run-Up”.

At least at two locations, Flashback Arrestors are to be installed, viz. End-of-line & In-
line for a individual gas line to reduce the possibility of Detonation.

The backfire occurs due to excessive heat and the presence of fuel and oxidizer in the
mixing device.

The heat of compression at the point of use is sufficient enough to cause a "Flashback"
inside the mixing device.

The backfire can be considered as a very tiny or a micro version for cause of an
explosion.

In event of a backflow, the residual mixture is consumed by the flame point in such a
rapid speed that it might create a condition of velocity of a shock wave, which is the
probable cause of eruption of a "Flashback".

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 CAUSES OF FLASH BACK

Presence of Insufficient Quantities of Gases in Cylinders (Pressure Imbalance)

Leaks in the Gas Handling Systems.

Failure to purge the Gas Systems.

Improper pressure setting of Gases.

Clogged or Blocked Tip of Welding or Cutting Torch

Mishandling of Gas Systems under use.

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 FLASHBACK ARRESTER VS. NRV

A “Non Return Valve” will stop the gas traveling back to the source, wherein the
valve seat of the “Non Return Valve” is fit enough to seal a pressure differential
and it is sufficient as essential.

However a “Non Return Valve” will not stop a “Flashback” because it does not
contain a very basic element, which holds back the Flashes traveling back to the
Source or Cylinder.
Nature of Potential Hazard

Gas Flow Reversal generally happens when one cylinder gets empty, thus
causing the Pressure Imbalance in the system

This condition results into the extremely dangerous situation when fuel and
oxygen gases get mixed in the hoses

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 NATURE OF POTENTIAL HAZARD

Back fire is identified with “putt “ sound at the tip of the torch and the flame gets
extinguished

This can happen at very High Gas Exit Velocity at the tip of the nozzle

This can also happen when the tip of the torch is too close to the work piece / job which
is at a very high temperature

The flame may get re-ignited automatically or through the ignition agent
Another points responsible to develop Flash Back

Hot refractory

If the refractory lining a burner or furnace is hot enough to bring the hydrocarbon/air
mixture to the auto ignition temperature, rapid combustion will start. Heat transfer from
the hot surface depends on gas velocity and turbulence, explaining why "swirl,” type
burners often seems more stable than more linear types

Flame
Flames from pilot burners are the typical means of initiating combustion of a hydrocarbon
/ air mixture. Nozzle mix burners (where the fuel mixes with the combustion air within the
furnace) have zones that are too lean or too rich for combustion, so the pilot flame must
be positioned to heat a volume of well mixed gas. Large pilot flames can overcome poor
positioning of the pilot tip.

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 ANOTHER POINTS RESPONSIBLE TO DEVELOP FLASH BACK

Sparks
Sparks are used to ignite pilot burners and also main burners in some cases.
Occasionally small sparks (static electricity) are capable of initiating combustion, but the
extra energy in a large spark helps insure light off. Undesired sparks, such as those
resulting from debris moving through steel ducting or fans, can initiate combustion and
require careful design to avoid.

Dust

Dust or very fine debris are generated while welding or cutting and this dust when in
contact with the nozzle causes a blockage resulting a loud sound “putt” and the flame -
due to the pressurization -results in the flame to fold back into the nozzle

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 FUNCTIONING OF FLASHBACK ARRESTER
Flashback arrestor is a simple devise, which quenches the flame using the following
methods

a) By reducing the flame velocity (even lower than the minimum flame velocity of the fuel
gas )

b) Stops the flame propagation into or through a pipe

c) By placing a flame arrestor at the end of the flammable mixture pipe feeding a flare or
burner, flame can be prevented from moving into the pipe regardless of the mixture
velocity.

d) By passing a potentially flammable mixture through a water chamber or some sort of heat
sink. This dissipates the heat and quenches the flashback.

e) By blocking the fuel gas path, with a suitable thermal fuse plug, casing the flashback to
die out.

f) By blocking the flow of fuel gas in the opposite direction by acting like a non return valve.

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 FUNCTIONING OF FLASHBACK ARRESTER

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 FUNCTIONS OF FLASHBACK ARRESTER
Torch mounted Flash back Arresters have TWO FUNCTIONS :

1.Stopping the flame in a backfire with a flame arrester

2. Preventing the Reverse Flow with a built in check valve ( The flame arrester is made of
sintered metal filter. The gas can flow in smoothly but the flame is extinguished )

Cross Sectional View of Check Valve

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 CROSS SECTIONAL VIEW OF FBA

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 FLASH BACK ARRESTER

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 FLASH BACK ARRESTER

It is always advisable to install a flash back arrestor on fuel line as
well as the oxygen line

Why on Oxygen line ?

Flash back arrester on Oxygen Regulator can cut off the supply of Oxygen in
case of flashback

This is important as additional Oxygen can raise the combustion rate

A WORD OF CAUTION !!

It is extremely important to note that when the Flashback Arrester is installed
on the torch or a line, it creates a ‘PRESSURE DROP’ causing the reduction
in FLOW CAPACITY.

Ensure the Flow Demand of the system as per its design and then install
appropriate Flashback Arrester which will meet the required Flow Demand of
the system

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 NECESSITY OF FLASHBACK ARRESTER
The reasons for using a protective device such as a Flash Back Arrestor
on a fuel gas line or even on a cylinder are :

1. Safety of Human Life and Property.

2. Flashback occurs under various conditions.

3. The flashback occurs inside the pipeline or vessels.

4. The flame moves through a vessel or pipe.

5. The flame velocity increases as it moves through these pipe or vessels, and if the pipe

is long enough the velocity can increase to detonation levels, which are supersonic

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 FLASHBACK ARRESTERS CLASSIFICATION
FBAs are classified depending upon the method of INTERRUPTION Broadly there are
two classes of FBA :

Active Methods ( Require maintenance of certain parameters like Liquid. Level

or Gas Velocity )

Passive Type ( Require only routine maintenance as no moving parts or

instruments are involved

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 ACTIVE TYPE FBA’s
1. Venture Type

Venture flashback arrestors simply create a restriction in the hydrocarbon

/air mixture delivery pipe so that the gas velocity is faster than the flame
speed, preventing progression of a flashback upstream

Flashbacks in the direction of flow can still happen.

Even a partly closed valve can create a high velocity for flashback
prevention

Venture shape creates much lower pressure drop.

If gas flow stops, the venture is no longer effective, so methods to measure

flow and add make up gas (nitrogen, for instance) are often included.

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 PASSIVE TYPE FBAs

On line On Flashback Arresters :

1. Most commonly used

2. Mechanical flame arrestors are filled with metal or ceramic, which absorbs heat from
a flashback, quenching it to a temperature below what is needed for ignition. This
stops the flame.

3. With a low enough hydrocarbon/air mixture flow rate, if a flame travels to the face of
the arrestor, it can become stable at that point. Heating of the arrestor body and
internal parts

4. Once the arrestor temperatures increases enough, ignition temperature can be

reached on the upstream side of the arrestor and the flashback can proceed.

( For this reason, a temperature switch is often installed on the flame side of
each arrestor adding an "active" element).

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 FLASHBACK ARRESTERS - CLASSIFICATION
There are TWO main types :

Dry type & Wet type
(Each type has its own advantages & disadvantages. Most oxy fuel flashback arrestors are the dry type)

DRY TYPE FBAs

Dry flashback arrestors typically use a combination of methods to stop flashback

Type that is typically found on most workshops, home or portable oxy-fuel kits

They work just as effectively with any orientation

Need very little maintenance

Often small and light enough to be installed between the torch and hoses.

Flame Trap :

To cool the flame front. They are designed to allow free flow of gas through them but to
take the heat out of the flame front to get it below the ignition temperature of the burning
gas mixture.

It is a device wherein the sealing is done by a sintered metal or any other means other
than employing a liquid to arrest the Flashes

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 FLAME TRAP- DRY TYPE FBAS

The most common types are:

!1) Sintered metal or ceramic. (2) Layers of mesh.(3) Ceramic beads.

Temperature-triggered valves to stop the gas flow completely.

It relies on extracting heat from the flashback to stop it continuing

Most arrestors have a temperature-controlled valve that will cut off the gas flow when the
unit reaches around 90°C, until either

The unit cools (if the unit is automatic) or

The reset button is pressed (if the unit is manual).

A check valve that closes due to the back pressure.

Dry type Flashback Arrestor is a most widely used in major applications at major
installations because of the inherent design advantage.

Leakage problems are minimized due to absence of wet media.

No reaction with source gas.

Easy to install, handle & maintain

Maintenance is virtually nil.

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 WET TYPE FBAs

Liquid seal flame arrestors are liquid barriers following the “principle of a
siphon” where the liquid stops the entering deflagration and / or detonation
and extinguishes the flame.

On smaller units having a pressure release valve to prevent the unit from
bursting under a severe flashback, the fluid level should be monitored to keep
it always above the intake and not so high that the liquid could splash or
overflow into the outlet.

Normally wet flashback arrestors work by bubbling the gas through a non-
flammable and ideally non-gas-absorbing liquid

It is a device wherein the sealing is done by help of wet media, normally

water used as media.

Sometimes a specialized non-flammable oil in industrial uses is employed for

the sealing .

They stop the flame by preventing it from reaching the submerged intake.
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 WET TYPE FBAs

These devices are normally very effective at stopping flashbacks from reaching
the manifolds or regulators or tanks.

They have the disadvantages of only working in one orientation and tend to be
much larger than dry type arrestors.

The liquid level needs to be constantly checked

Above disadvantage makes them suitable mainly for large or fixed
installations.
19th Century Models of Dry and Wet Flashback Arresters

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 FBA AS FURTHER SAFETY DEVICE

Besides preventing Reverse Gas Flow with the help of Check Valve and
Extinguishing the flame after the Back flash with Flashback Arrester, it can
further CUT OFF Gas Supply which can be reset by the operator

It is essential to find out the cause of back fire and set it right before resetting
the Gas Supply

Prevention of Gas Supply from the Cylinder in case of back fire

If this function is activated, then the FBA cannot be Re set but requires
replacement
Functioning of this FBA is as follows in the event of back fire:

Pressure sensitive cut –off valve shuts off the gas supply after the back fire

Flame Arrester extinguishes the flame

NRV restricts the Reverse Flow

Temperature sensing cut off device cuts of the heat supply

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 LOCATION FOR INSTALLING FBA

Selection for location of installation of FBA depends upon advantages &

disadvantages of each spot

Advantage of installing the FBA on Regulator or outlet is the Far Greater

Flow Rate of Gas than the Rate achieved by installing it on the Torch

Disadvantage of Regulator or outlet installed FBA is that it cannot prevent

the HOSE EXPLOSION which can be avoided by Torch mounted FBA

Maximum safety is therefore achieved by installing FBAs both on Torch as well as

Regulator. This is possible unless high flows are needed

Where High Flow Rates are necessary, it is always advisable to install the
Check Valves on the Torch and Flashback Arrester on the Regulators

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 FBA INSTALLATION ON REGULATOR

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 ROUTINE MAINTENANCE

A defective Flashback Arrestor should be immediately removed form

use.

A Flashback Arrestor should be serviced periodically to get a more
trouble-free life of it.

All connections and joints should be checked periodically from time to
time. Leaky connections and joints will lead to malfunctioning of a
Flashback Arrestor.

Gas should flow from the Outlet of a Flashback Arrestor. If the gas flow
path is blocked there will be a drop in delivery pressure.

Defect should be rectified in accordance with the manufacturer’s

suggestions

To obtain a constant and smooth flow of gas, all Filters in a Flashback

Arrestor should be cleaned from time to time.

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 SHUT DOWN PRECAUTIONS
Follow the following procedures during a Shutdown, whether planned or
unplanned.

Close the Gas cylinder valve that supply the gas to the system where a
Flashback Arrestor is installed.

Drain the residual gas in the Flashback Arrestor, any equipment, device,
instrument or fixture connected any where in the line.

Disconnect the Flashback Arrestor.

On intending for the reuse/restart of the application follow the “FLASHBACK
ARRESTOR INSTALLATION” PROCEDURE as advised by the Manufacturer’s Guide.
STANDARDS RELEVANT TO FBAS

IS :11006 -1984 covers information on Flashback Arrestor.

European Standard EN 730.

European Standard DKSG91 / DKST 91.

International Standard ISO 5175.

British Standard BS 6158.

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 SOME OF THE INDIGENOUS MODELS
Model – FBA – NRV : These Flash Back Arrestors come in two basic design
flanged & threaded. The Normal Size’s are:
DN DN DN DN
Thread DN
1 2 2 3
ed 4
5 0 5 2
(R 0
H)
DN DN DN DN
DN
3 4 5 6
8
2 0 0 5
0
Flange
d DN DN DN DN
DN
1 1 1 2
2
0 2 5 0 Maximum
5
0 5 0 0 Working
0 Media
Pressure

Air / Oxygen 40.00 bar

LPG 10.00 bar

Hydrogen 16.00 bar

Natural Gas 10.00 bar

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 SOME OF THE INDIGENOUS MODELS
Model FBA – WT
The water and the disk, works like a flame arrestors, quench the flash back.
Two Non return valves in series- one in the incoming line and the other at the bottom of the FBA cuts
off supply in the event of any flash back in the down stream equipment. Further relief valve provided at
the top releases vapors and hot gases and prevent damage to the equipment.

Working
Size:
pressure:

Maximum
Inlet /
Media Working
Outlet
Pressure

Acetylene 1.5 bar 1/4"

LPG 5 bar 1/2"

Hydrogen 5 bar 3/4"

Natural Gas 5 bar 1"

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 SOME OF THE INDIGENOUS MODELS : MODEL FBA - HP

Hose Size (mm) Thread Size BSP

INLET / OUTLET OUTLET Max.

Media Working
Pressure
5.0 1/4 LH/RH

Air Oxygen 20.00 bar

6.0 1/4 LH/RH

LPG 5.00 bar

8.0 3/8 LH/RH
Acetylene 1.50 bar

9.0 3/8 LH/RH Natural Gas 1.60 bar

10.0 3/8 LH/RH

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 SOME OF THE INDIGENOUS MODELS
Model FBA – PM

The Flash Back arrestors are designed for fitting on the Pipeline / Manifold to prevent flash back and protect your
precocious equipment and lives. The safety elements are (1) Contaminate Filter, (2) Non Return Valve, (3) Flame Block,
(4) Flame Trap, (5) Temperature Activated Flow cut off device.

Working
Pressure: Size:
Maximum
RH -
Media Working
B FOR AIR /
Pressure
S OXYGE
Acetylene 22.0 bar P N
AIR/OXYGEN 40.0 bar
LPG 5.0 bar LH -
B
Hydrogen 5.0 bar FOR FUEL
S
GAS
P
Natural Gas 5.0 bar

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 THANK YOU

HAVE A SAFE WORKING DAY

CBRE OHSE
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