A thermal lance is a highly effective tool for cutting, melting, and demolition in industrial applications. Powered by high-pressure oxygen and filled with steel rods, it generates intense heat capable of slicing through steel, concrete, and other hard materials. However, one common challenge operators face is the flame going out during use.
Flame interruptions can delay progress, waste oxygen, and demand repeated ignition efforts. To maximize efficiency and safety, it’s essential to understand why this happens and how to prevent it. This comprehensive guide walks you through the most common causes and proven practices to keep your thermal lance burning consistently.
How to Prevent a Thermal Lance from Burning Out During Cutting
Source: Daiwa Lance International
Why Does a Thermal Lance Stop Burning?
Before we look into solutions, it’s important to identify the typical causes behind a thermal lance going out during operation. Addressing these root problems is the first step toward a smooth and uninterrupted cutting process.
1.Inconsistent or Low Oxygen Pressure
Thermal lances rely heavily on a steady flow of high-pressure oxygen to sustain combustion. If the pressure drops below the required level or fluctuates, the flame may become weak or extinguish entirely.
2. Weak Ignition Source
A proper ignition method is essential. If the flame used to ignite the lance isn’t hot or strong enough, the internal steel rods won’t catch fire effectively. This results in slow starts or immediate flame failure.
3. Contamination or Moisture
Residue such as oil, water, or dust on the surface or inside the lance can severely affect combustion. Even a small amount of moisture can make ignition difficult and disrupt the burning process.
4. Environmental Disturbances (Wind or Airflow)
External air currents, especially strong wind during outdoor use, can blow out the flame at the moment of ignition or during operation, particularly in the early stages before full combustion is established.
5. Poor Internal Wire Design
The structure and quality of the steel wires inside the lance matter. If the wires are packed too tightly, oxygen flow becomes restricted. If they are too loose, they may dislodge or interfere with flame stability. Incorrect metal composition can also hinder the burning process.
How to Keep a Thermal Lance Burning Continuously
To ensure your thermal lance performs efficiently throughout the cutting task, follow these five best essential practices:
1.Ensure a Stable Oxygen Supply
Oxygen is the driving force behind the thermal lance’s performance. Ensuring an uninterrupted and clean flow of oxygen is critical.
Set the oxygen pressure in the range of eight to eleven bar, which is approximately 116 to 160 psi, depending on the material being cut.
Routinely inspect all hoses, regulators, and valves to ensure they are free from leaks, blockages, or wear.
Use a high-purity oxygen source to prevent contaminants from entering the system and disrupting combustion.
Avoid sharp bends or kinks in the hose, which could reduce flow and pressure.
2. Use the Correct Ignition Technique
A strong, controlled ignition method sets the foundation for a successful operation.
Use an oxy-acetylene torch or an equivalent high-temperature flame as your ignition tool.
Position the torch at an angle of approximately 120 degrees to the tip of the thermal lance.
Heat the tip until it becomes red-hot, which typically takes ten to fifteen seconds. Once heated sufficiently, release the oxygen flow to allow full ignition.
Avoid overexposure to the flame before ignition, as this can wear down the lance tip unnecessarily.
3. Keep the Lance Dry and Clean
Any form of contamination—especially moisture—can ruin combust0069on efficiency.
Store lances in a dry, well-ventilated environment, away from water, oil, and dust.
Before use, wipe the outer surface of the lance and inspect the ends for any residue or damage.
If the lance has been exposed to moisture, allow it to dry thoroughly before attempting ignition.
Never use a damp or oily lance, as it may cause incomplete ignition or even hazardous flare-ups.
4. Shield Against Wind and Airflow
Even a strong tool like a thermal lance is vulnerable to environmental conditions.
Conduct cutting operations in controlled environments whenever possible. If working outdoors, use wind guards or shields to block gusts of air from disrupting the flame.
Ensure that the lance tip is directed away from any direct airflow, particularly during ignition.
Try to maintain a consistent body position to avoid shifting the lance into unexpected air currents mid-operation.
5. Avoid Abruptly Cutting Off the Oxygen Supply
How you shut down the lance matters as much as how you start it.
Abruptly closing the oxygen valve can leave unburnt material inside the lance, which makes re-ignition difficult and potentially dangerous.
As you finish the cut, gradually reduce the oxygen flow to allow the combustion to die down naturally.
This helps clear out any remaining metal and ensures the lance is ready for future use.
Thermal Lance Structure
Understanding the internal design, wire configuration, and material composition of a thermal lance is key to improving its performance and lifespan. A well-designed lance ensures optimal airflow and ignition, reducing the risk of premature flame-out.
Key Takeaways
To prevent a thermal lance from burning out during operation, always follow these essential guidelines:
- Use a strong and reliable ignition source, preferably an oxy-acetylene torch
- Maintain oxygen pressure within the recommended range of eight to eleven bar
- Keep your equipment dry, clean, and free of contamination
- Work in controlled environments or shield against wind to protect the flame
- Avoid sudden oxygen shutoffs by reducing flow gradually when ending the cut
Conclusion
Operating a thermal lance requires more than just lighting it and cutting through material. It demands precision, awareness, and proper technique. By ensuring a consistent oxygen supply, using effective ignition methods, and protecting your equipment from contaminants and environmental disturbances, you can significantly reduce downtime and enhance performance.
Whether you’re working in demolition, steel cutting, or infrastructure maintenance, these preventive measures will help you get the most out of your thermal lance—safely and efficiently.
For more information, please contact our sales team at sales@daiwaanayasteel.com
Daiwa Anaya Steel Private Limited is a part of Anaya Steel, LLC (US parent company). Our company has over 30 years of involvement in steel products. It mostly deals in:
Daiwa Anaya Steel Private Limited is a part of Anaya Steel, LLC (US parent company). Our company has over 30 years of involvement in steel products. It mostly deals in:
