O2 Regulator Failed:

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   I always back my regulators off till loose after use but yesterday one failed on me when adjusting up to cutting pressure. Opened the tank valve normally and when I started increasing the discharge pressure towards 40psi the secondary regulator "pegged" suddenly and exploded the oxygen hose giving me a good, and quite unexpected blast to the ears. That was a "Pro Star" branded regulator purchased just a couple of years ago from the local welding store.

I've had several regulators go bad from usage through the years but never one like this. Usually they start leaking at the housing where you can either hear, smell, or a combination of the two. 

I have a rebuilt set ready to go but don't think I'll even send this one in but rather circular file it. Don't know if chinese produced or not as never looked, but it was purchased when another was off being rebuilt. 

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Codger Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Joined: 23 Dec 2020 Location: Illinois Points: 1784	Post Options Post Reply Quote Codger Report Post Thanks(0) Quote Reply Topic: O2 Regulator Failed: Posted: 19 Mar 2024 at 6:48am
	I always back my regulators off till loose after use but yesterday one failed on me when adjusting up to cutting pressure. Opened the tank valve normally and when I started increasing the discharge pressure towards 40psi the secondary regulator "pegged" suddenly and exploded the oxygen hose giving me a good, and quite unexpected blast to the ears. That was a "Pro Star" branded regulator purchased just a couple of years ago from the local welding store. I've had several regulators go bad from usage through the years but never one like this. Usually they start leaking at the housing where you can either hear, smell, or a combination of the two. I have a rebuilt set ready to go but don't think I'll even send this one in but rather circular file it. Don't know if chinese produced or not as never looked, but it was purchased when another was off being rebuilt.
	A career built on repairing and improving engineering design deficiencies, shortcomings, and failures over 50 years now.

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steve(ill) Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 77715	Post Options Post Reply Quote steve(ill) Report Post Thanks(0) Quote Reply Posted: 19 Mar 2024 at 9:32am
	Have always heard it is a good idea to BACK OFF the regulator... But all we do is SHUT OFF the supply valve and let the regulator SET.. Too much exercise could be a bad thing ??
	Like them all, but love the "B"s.

WF owner Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Joined: 12 May 2013 Location: Bombay NY Points: 4388	Post Options Post Reply Quote WF owner Report Post Thanks(0) Quote Reply Posted: 19 Mar 2024 at 11:25am
	I was always taught to turn acetylene tank on 1/2 turn and oxygen tank fully on. When done, shut tanks off and open torch until gauges bottom out. I only ever turn my regulators when changing settings. My torches and regulators are (old) Craftsmen, about 50 years old.

DMiller Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Access Joined: 14 Sep 2009 Location: Hermann, Mo Points: 29486	Post Options Post Reply Quote DMiller Report Post Thanks(0) Quote Reply Posted: 19 Mar 2024 at 1:30pm
	My old regulators are Union Carbide, likely exceeds 75 years, been rebuilt at least twice. Follow same considerations as you WF, was how was taught.

Clay Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Joined: 11 Sep 2009 Location: Udall, Kansas Points: 8783	Post Options Post Reply Quote Clay Report Post Thanks(0) Quote Reply Posted: 20 Mar 2024 at 12:29am
	Steve and WF are correct. The oxygen tank has a double seal valve. Shut and fully open. Partially open valve can leak. It is best to back the regulator screw off, when finished. NEVER stand directly in front of regulator, when opening the oxygen cylinder. Acetylene working pressure should NEVER be set to greater than 15 PSI. Above 15 PSI, acetylene may become unstable. The acetylene tank valve should be opened 1/4 to 12 turn. This is a safety factor. Should there be a fire or malfunction, a quick turn of the wrist will shut down the danger. NOTE: NEVER use oil or any kind of grease on an oxygen fitting. The pressure in the tank is over 2,000 PSI. The lubricant trapped in the threads can EXPLODE. Although there is no spark, compression can ignite the lubricant. (Same basic principal as a diesel engine ignition.) Before hooking the regulators to the tanks, stand clear of the tank outlet and crack open the tank valve. This will prevent FOD from damaging your regulators. MAKE SURE the tanks are secure and in an upright position. The acetylene tank has porous fill and acetone. This helps provide stability to the acetylene in the tank. If the acetylene tank was flat on its side, set the tank upright and do not open the valve for at least one hour. The acetone needs time to re-absorb into the filler. Always place the safety caps on the tanks before changing tanks, storage or transport. The oxygen regulator and (green) hoses have RIGHT hand threads. The acetylene regulator and (red) hoses have LEFT hand threads. There is also a mark around the nuts of acetylene. Edited by Clay - 20 Mar 2024 at 12:34am

Codger Members Profile Send Private Message Find Members Posts Add to Buddy List Orange Level Joined: 23 Dec 2020 Location: Illinois Points: 1784	Post Options Post Reply Quote Codger Report Post Thanks(0) Quote Reply Posted: 20 Mar 2024 at 2:22am
	I've followed most of those posted "rules" for over 50 years since acquiring my first cutting torch setup in 1973. First regulator I've had blow internally as I increased the pressure like this. I opened the valve on the O2 tank slowly and fully allowing the pressure to gradually rise which is normal for me. I then started to raise the pressure on the secondary gauge and when approaching 40psi this regulator "pegged" and before I could begin to roll it back the O2 hose popped just inside the ferrule crimp at the torch end I was holding. It was almost as loud as a .22 short going off next to you unexpectedly. I have end repair kits but this hose set is probably 15 years old and a short set so will just trash it after cutting the ends off. Always have a spare set available and this was installed along with a newly rebuilt regulator.
	A career built on repairing and improving engineering design deficiencies, shortcomings, and failures over 50 years now.