Flashback Arrestor Testing_ The Overlooked Safety Check Putting Aussie Workshops at Risk

1. Flashback Arrestor Testing & Gas Safety in Aussie Workshops A Real Wake-Up Call: The 2022 Sydney Welding Shop Explosion In October 2022, a small welding shop in Sydney’s western suburbs made national headlines when a mishandled oxy-acetylene kit triggered a flashback explosion. The blast tore through the workshop, injuring two workers and prompting a full evacuation of the surrounding industrial precinct. Investigations later revealed that the flashback arrestors hadn’t been tested in years, and compressed gas cylinders were stored dangerously close to active welding bays. This wasn’t just a workplace accident—it was a preventable disaster and a stark reminder of how critical proper gas storage and flashback arrestor testing really are. Why Compressed Gas Storage Isn’t Just a ‘Set and Forget’ Task Welding operations across Australia rely heavily on compressed gases—oxygen, acetylene, argon, and CO₂—stored in high-pressure cylinders. These cylinders are essential to the trade, but they can become deadly when mishandled. From unstable storage setups to expired flashback arrestors, it’s often the small oversights that lead to catastrophic outcomes.

2. According to Safe Work Australia, improper handling and storage of compressed gas cylinders is a leading cause of fire-related incidents in workshops. What makes this even more alarming is that these risks are largely avoidable—with proper compliance, vigilance, and the right equipment. The Legal Backbone: Welding Code of Practice and WHS Compliance The Welding Processes Code of Practice, approved under section 274 of the Work Health and Safety (WHS) Act, outlines enforceable guidance for employers and workers in welding environments. This isn’t optional reading—it’s a legally backed framework that regulators and courts can reference. Key Legal Obligations: ● WHS Act Section 19 – A PCBU (Person Conducting a Business or Undertaking) must eliminate or minimise risks as far as is reasonably practicable. ● WHS Regulation 49 – Ensures airborne contaminants don’t exceed safe exposure standards. ● WHS Regulation 57 – Requires atmospheric testing in confined spaces. Adhering to these regulations when storing and using compressed gas cylinders isn’t just best practice—it’s mandatory. This includes routine flashback arrestortesting, the use of compliant

3. PPE such as a welding helmet, and cultivating a proactive weld and safety culture at every level of your business. The Code also offers a structured approach to managing risk—identifying hazards, assessing and controlling risks, and reviewing control measures. It defines roles for PCBUs, officers, and workers, making safety a shared responsibility across your operation. Flashback Arrestor Testing: Your Frontline Defence A flashback arrestor is a small component with a big job: to stop flames from travelling back through the gas line, preventing fires, explosions, and fatalities. But it only works if it’s regularly tested and properly maintained. What happens if it isn’t? ● Gas can ignite inside hoses. ● Cylinders can rupture or explode. ● Operators risk serious burns or worse. Recommended Testing Frequency: ● Manufacturers typically advise testing at least once per year. ● In high-use or high-risk environments, testing should occur every six months.

4. This isn’t just a maintenance task—it’s a form of survival insurance. In Australia, every workshop should maintain a documented flashback arrestor testing schedule and inspection log. Not only does this ensure compliance, but it also provides crucial evidence should a safety incident be subject to investigation or legal review. Common Compressed Gas Storage Mistakes (and How to Fix Them) 1. Cylinders unsecured or stored horizontally: Always store upright and secure with chains or approved stands. 2. No flashback arrestors fitted or testing overdue: Test every 6–12 months; replace damaged or expired units immediately. 3. Fuel gas cylinders stored with oxidisers (e.g. oxygen): Use separate, fire-rated storage areas for fuel and oxidisers. 4. Perished or damaged hoses on oxy-acetylene kits: Inspect regularly and replace during scheduled maintenance. 5. Inadequate ventilation in storage rooms: Ensure compliant passive or mechanical ventilation is installed. Taking the time to audit your storage practices isn’t just housekeeping—it’s an essential part of your risk management plan. Oxy-Acetylene Kits: The Silent Risk If Not Maintained The oxy-acetylene kit is a staple in Aussie welding workshops. But when neglected, it becomes a serious hazard: ● Old regulators may stick, causing dangerous pressure surges. ● Frayed hoses can leak and ignite. ● Missing or damaged flashback arrestors leave no protection. Workshops must incorporate these kits into their wider weld and safetyprotocols. Maintenance routines should include:

5. ● Visual hose inspections ● Flashback arrestor expiry checks ● Regulator functionality tests ● Leak detection using soapy water or certified testers Beyond Equipment: Training and Culture Matter The Welding Code of Practice puts a strong emphasis not only on equipment, but on safety culture. A resilient safety culture ensures: ● Workers understand how to handle and store compressed gases correctly. ● PPE such as an approved welding helmet is worn consistently. ● Supervisors regularly conduct hazard inspections. ● Flashback arrestor testing and gas cylinder audits are routine and documented. This isn’t a box-ticking exercise—it’s about protecting lives. Implementing regular toolbox talks, safety drills, and on-the-job mentoring can embed safety into the everyday operations of your workshop. Even the best systems fail when people aren’t trained to use them.

6. Compressed Gas Safety Is a Non-Negotiable Responsibility If you operate or supply to a welding workshop in Australia, you carry more than just a duty of care—you hold a legal and moral obligation to protect your workforce. Errors in compressed gas storage or flashback arrestor testing aren’t minor oversights—they can be fatal. The difference between compliance and catastrophe often comes down to: ● Routine flashback arrestor testing ● Structured maintenance programs ● Staff training and upskilling ● A deeply embedded safety culture ● Commitment to the Code of Practice Compressed gases aren’t inherently dangerous—human error is. Prioritise education, regular inspections, and documented testing. By doing so, Aussie workshops can drastically reduce preventable risks and protect lives, property, and business continuity. FAQs

7. 1. What is the legal requirement for compressed gas storage in Australia? Compressed gas must be stored upright, securely fastened, away from ignition sources, and in ventilated areas—according to WHS legislation and the Welding Code of Practice. 2. How often should flashback arrestors be tested? At least once a year. In high-use or high-risk environments, testing should occur every six months or after any suspected flashback event. 3. Can oxy-acetylene kits be used without flashback arrestors? No. Operating without them is a serious safety violation and can result in explosions or severe flashbacks. 4. Is it enough to provide PPE like a welding helmet? No. PPE is only part of the equation. Safe gas storage, equipment testing, and staff training are equally essential. 5. What should I look for in a compliant oxy/fuel storage area? Fire-rated walls, separate storage for fuels and oxidisers, secure upright cylinders, adequate ventilation, and clearly displayed emergency procedures.