Faulty gas equipment in industrial operations puts the health and safety of workers at high risk while posing threats to the site, such as damage to infrastructure, owing to the drastic nature of gas-related explosions.

However, cutting, welding and grinding solutions provider First Cut – and its subsidiary gas safety expert Gas Safety International (GSI) – have introduced the Safety Advanced Technology (S.A.T.) system, designed to prevent, or substantially reduce, gas leaks in industrial environments, eliminating the use of faulty welding torches and ensuring more economical gas usage.

This innovation is therefore “highly beneficial” for organisations – including mines – as gas brazing, cutting and heating continue to be essential in metal fabrication processes, notwithstanding the growing use of laser welding solutions.

System Components and Benefits

The S.A.T. system – developed in collaboration with Germany-based manufacturer Messer Cutting Systems – is a “complete safety solution” which integrates uniquely designed gas-cutting equipment, regulators, torches and valves to eliminate gas leaks, thereby ensuring operational safety, explains GSI director Peter Rohlssen.

The system comprises three patent-pending components: an advanced process design, a leak-proof valve, and a cutting torch to enhance operational processes.

“Together, these components mitigate risks associated with worker error, ensuring safer operations in hazardous environments,” Rohlssen comments.

First Cut and GSI have also created a comprehensive manual that will guide users on the best practices for the S.A.T. system, which features a logical design and user-friendly interface. This allows for ease of navigation, allowing experienced personnel to quickly grasp its functions, making integration into daily operations seamless. This, in turn, ensures that even in high-pressure environments, workers can confidently operate the system with precision and efficiency.

The S.A.T. system prevents the use of faulty oxyfuel gas equipment. It operates on a venturi action generated by the torch, transferring through the hose to the S.A.T. valve.

The leak-proof valve thereby ensures that fuel gas cannot escape if a connection is not properly secured.

“With the S.A.T. system, operations cannot continue if the equipment is faulty. Unlike conventional set-ups that allow gas flow, even when there is a minor leak, the S.A.T. valve automatically shuts off in case of damage, preventing hard-to-detect leaks, which could otherwise lead to explosions.”

Rohlssen adds that the system can be used by boilermakers, brazing staff and fitters as a turnkey solution to enhance oxyfuel equipment handling, thereby helping to prevent gas leaks and the use of faulty torches.

Gas Safety Training

First Cut and GSI offer four levels of training to help ensure workers’ safety. At level 1, unskilled personnel attend a day of training, while level 2 comprises two-day training for semiskilled workers and is accredited by the Engineering Council of South Africa (ECSA).

Level 3 entails five days of advanced training for skilled personnel, while engineers can receive “high-level” training at level 4. Both levels are ECSA- accredited.

Additionally, the S.A.T. system is accredited by the International Organisation for Standardisation (ISO), and is ISO 2503-, ISO 5172- and ISO 5175-2-certified.

“By offering the S.A.T. system and comprehensive training, First Cut and GSI provide a complete solution that aligns with regulatory requirements, ensuring compliance and worker protection,” says Rohlssen.

He says South Africa should invest in proper gas safety technology and training, and that the S.A.T. system is a “giant leap” towards ensuring worker safety and meeting environmental, social and governance goals.

“The S.A.T. system marks such a significant shift in gas equipment technology, it is difficult to imagine that it can – or will – be surpassed in the near future,” he enthuses.