Download - Gas cutting welding1
![Page 1: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/1.jpg)
Gas Cutting&
Welding
Gas Cutting&
WeldingPPREPARED BY
SOUMEN MAKARRECLAMATION AND DREDGING WORKS
BMCT/JNPT-4
![Page 2: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/2.jpg)
![Page 3: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/3.jpg)
ACETYLENE CYLINDERS
Maroon in colour.
Acetylene gas (C2H2) is dissolved inacetone (liquid) and stored at 250 psi, ina specially designed cylinder.
Acetylene cylinders has a volume of 8.5m3.
Maroon in colour.
Acetylene gas (C2H2) is dissolved inacetone (liquid) and stored at 250 psi, ina specially designed cylinder.
Acetylene cylinders has a volume of 8.5m3.
![Page 4: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/4.jpg)
![Page 5: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/5.jpg)
Valve Protection Cap
Typical Sectional view ofValve Arrangement
Valve protection cap
ValveValve
![Page 6: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/6.jpg)
OXYGEN CYLINDERS Oxygen is a colourless,
tasteless, and odourlessgas and is slightlyheavier than air.
Oxygen cylinder is blackin colour.
Oxygen stored at 2200psi
Oxygen cylinders has avolume of 6.9 m3
Oxygen is a colourless,tasteless, and odourlessgas and is slightlyheavier than air.
Oxygen cylinder is blackin colour.
Oxygen stored at 2200psi
Oxygen cylinders has avolume of 6.9 m3
![Page 7: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/7.jpg)
CYLINDER STORAGE
Well ventilated room No open flame in the store 10 m distance from oxygen and acetylene
cylinders No materials that are prone spontaneous
combustion Should not be stored in direct sunlight.
Well ventilated room No open flame in the store 10 m distance from oxygen and acetylene
cylinders No materials that are prone spontaneous
combustion Should not be stored in direct sunlight.
![Page 8: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/8.jpg)
CYLINDER STORAGE
Inflammable Gas
![Page 9: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/9.jpg)
CYLINDER STORAGEFullEmpty
Min. 10’
Min.10’
Full CylindersEmpty Cylinders Fuel GasOxygen
Cylinders containing oxygen shall be stored separate fromcylinders fuel-gases.
Minimum 10 feet distance shall be maintained between the storageareas.
![Page 10: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/10.jpg)
Accessories
![Page 11: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/11.jpg)
Regulators
![Page 12: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/12.jpg)
UNLOADING FROM TRUCK
Never drop
Use wooden Ramp and coir matters (50cmthick)
Keep the top of the cylinder up
Roll the cylinder keeping it upright
Never drop
Use wooden Ramp and coir matters (50cmthick)
Keep the top of the cylinder up
Roll the cylinder keeping it upright
![Page 13: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/13.jpg)
Lifting cylinders by crane
Use of cradle
4-leg bridle sling
D-shackle and lifting lug
![Page 14: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/14.jpg)
Use of Cylinder trolley
Shifting cylinders at site
Avoid Rolling & Manualcarrying
Use trolley
![Page 15: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/15.jpg)
Keep the cylinder upright and away fromhot jobs.
Fix the DA and oxygen regulator to therespective cylinders after ensuring freefrom dirt or grease.
Connect the cutting hoses to the regulatorsand cutogen with hose clamps.Blue or blackhoses for oxygen and red for DA.
RIGHT OPERATION
Keep the cylinder upright and away fromhot jobs.
Fix the DA and oxygen regulator to therespective cylinders after ensuring freefrom dirt or grease.
Connect the cutting hoses to the regulatorsand cutogen with hose clamps.Blue or blackhoses for oxygen and red for DA.
![Page 16: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/16.jpg)
Open the cylinder and check for leakage bysoap water test at the joints.The same to befollowed for the oxygen cylinder.Close thecylinders .
Purge the oxygen line and then the DA lineone after the other and close the valves.
RIGHT OPERATION
Open the cylinder and check for leakage bysoap water test at the joints.The same to befollowed for the oxygen cylinder.Close thecylinders .
Purge the oxygen line and then the DA lineone after the other and close the valves.
![Page 17: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/17.jpg)
Open the DA regulator,the torch valve andlight the gas. Then open the oxygen valvesto the required pressure.
After cutting start closing from oxygen andthen DA.
RIGHT OPERATION
Open the DA regulator,the torch valve andlight the gas. Then open the oxygen valvesto the required pressure.
After cutting start closing from oxygen andthen DA.
![Page 18: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/18.jpg)
CUTTING NOZZLESMax. Materials
thickness,(MS in mm)
Size ofnozzle
Cutting oxygenpressure in
kg/cm212255075
100150200250300
1/32”3/64”1/16’1/16’1/16”5/64”3/32”7/64”1/8”
1.43.04.04.05.05.57.58.08.0
12255075
100150200250300
1/32”3/64”1/16’1/16’1/16”5/64”3/32”7/64”1/8”
1.43.04.04.05.05.57.58.08.0
![Page 19: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/19.jpg)
HAZARDS
FLASH BACK.
BACK FIRE.
GENERAL FIRE.
EXPLOSION.
FLASH BACK.
BACK FIRE.
GENERAL FIRE.
EXPLOSION.
![Page 20: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/20.jpg)
FLASH BACK RETROGRESSION OF THE FIRE UPTO THE
CYLINDER.
BACK FIREBACK FIRERETROGRESSION OF THE FIRE IN THECUTOGEN.
![Page 21: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/21.jpg)
When the blow pipe becomes hot.Nozzle blocked.Nozzle close to the job.Job close to the ground.Pressure difference between flame pressure
and the hose pressure.
REASONS
When the blow pipe becomes hot.Nozzle blocked.Nozzle close to the job.Job close to the ground.Pressure difference between flame pressure
and the hose pressure.
![Page 22: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/22.jpg)
IF A BACK FIRE OCCURS
The blowpipe valves shall be shut off,oxygen first and then the fuel gas;
Oxygen and fuel gas cylinder valves shall beshut off;
The blowpipe shall be cooled with water, ifnecessary;
The equipment shall be checked for damageor faults, particularly the nozzle.
The blowpipe valves shall be shut off,oxygen first and then the fuel gas;
Oxygen and fuel gas cylinder valves shall beshut off;
The blowpipe shall be cooled with water, ifnecessary;
The equipment shall be checked for damageor faults, particularly the nozzle.
![Page 23: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/23.jpg)
IF A FLASH BACK OCCURS
Cylinder valves of both fuel gas and oxygenshall be closed immediately.
(If it is safe to do so.)
Replace damaged Hoses, Blow pipe, Flashback arrestors & regulators before reuse.
Cylinder valves of both fuel gas and oxygenshall be closed immediately.
(If it is safe to do so.)
Replace damaged Hoses, Blow pipe, Flashback arrestors & regulators before reuse.
![Page 24: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/24.jpg)
FLASH BACK PREVENTION
Purge hose pipes before lighting. Only Spark igniters shall be used to ignite Flashback arresters shall be provided at both
ends of the hoses to prevent backflow of gastowards cylinders.
Correct gas pressure and for the nozzle sizeshall be used.
Purge hose pipes before lighting. Only Spark igniters shall be used to ignite Flashback arresters shall be provided at both
ends of the hoses to prevent backflow of gastowards cylinders.
Correct gas pressure and for the nozzle sizeshall be used.
![Page 25: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/25.jpg)
FIRE ON CYLINDER
Close the valve
Try to extinguish the fire.
Detach the regulator
Immerse the cylinder in water or apply watercopiously at the bottom half of the cylinder.
Open the valve and keep it the cool water till itbecomes empty
Do not stand in the direction of fusible safety valvefixed at the bottom of the cylinder.
Close the valve
Try to extinguish the fire.
Detach the regulator
Immerse the cylinder in water or apply watercopiously at the bottom half of the cylinder.
Open the valve and keep it the cool water till itbecomes empty
Do not stand in the direction of fusible safety valvefixed at the bottom of the cylinder.
![Page 26: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/26.jpg)
EXPLOSION
Reasons:Fire on cylinder (pouring water on hot
cylinder)
Cylinder exposed to external heat
Rough handling
Reasons:Fire on cylinder (pouring water on hot
cylinder)
Cylinder exposed to external heat
Rough handling
![Page 27: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/27.jpg)
Helmets with face shields
Black glass - din value 4 to 5
Leather gloves
Leather apron
Safety shoes
PPE
Helmets with face shields
Black glass - din value 4 to 5
Leather gloves
Leather apron
Safety shoes
![Page 28: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/28.jpg)
SAFETY IN WELDINGSAFETY IN WELDING
![Page 29: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/29.jpg)
BASIC ELEMENTSOF
WELDING
BASIC ELEMENTSOF
WELDING
![Page 30: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/30.jpg)
![Page 31: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/31.jpg)
SAFETY IN WELDING
The body of the welding machine shouldbe earth.
The terminals of the welding cablesshould be provided with lugs and kepttight.
The body of the welding machine shouldbe earth.
The terminals of the welding cablesshould be provided with lugs and kepttight.
![Page 32: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/32.jpg)
SAFETY IN WELDING
The joints in the cables should be madewith terminals, kept tight and wellinsulated with heat resistant tape.
The cable should be free from jointsatleast for a length of three meters fromelectrode holder to avoid shock hazard.
The joints in the cables should be madewith terminals, kept tight and wellinsulated with heat resistant tape.
The cable should be free from jointsatleast for a length of three meters fromelectrode holder to avoid shock hazard.
![Page 33: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/33.jpg)
SAFETY IN WELDING
Other electrical cables should not bekept laid with welding cables, to avoidinsulation damage.
For the return lead only proper cableshould be used. Using rods, angles,channels etc. Should be avoided.
Other electrical cables should not bekept laid with welding cables, to avoidinsulation damage.
For the return lead only proper cableshould be used. Using rods, angles,channels etc. Should be avoided.
![Page 34: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/34.jpg)
SAFETY IN WELDING
Never change electrode with bare handsor wet gloves, when standing on wetfloors.
Never change electrode with bare handsor wet gloves, when standing on wetfloors.
![Page 35: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/35.jpg)
HAZARDS
Fire Shock Health hazards
Fire Shock Health hazards
![Page 36: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/36.jpg)
HEALTH HAZARDS
Exposure to various toxic gases generatedduring welding may produce one or more of thefollowing effects:
Inflammation of the lungs (chemical phenmonitis) Pulmonary edema (swelling and accumulation of
fluids) Chronic bronchitis. Asphyxiation.
Exposure to various toxic gases generatedduring welding may produce one or more of thefollowing effects:
Inflammation of the lungs (chemical phenmonitis) Pulmonary edema (swelling and accumulation of
fluids) Chronic bronchitis. Asphyxiation.
![Page 37: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/37.jpg)
OCCUPATIONAL EXPOSURE STANDARDS
RELATING TO WELDING FUME CONSTITUENTOES
CHEMICALS LONG TERM SHORT TERMAluminum oxide 10 mg/m3Cadmium 0.05 mg/m3 0.05 mg/m3Chromium III 0.5 mg/m3
VI 0.05 mg/m3Copper 0.2 mg/m3Copper 0.2 mg/m3Fluoride 2.5 mg/m3Iron 5 mg/m3Lead 0.15 mg/m3Manganese 5 mg/m3Nickel (insoluble) 0.5 mg/m3
( Soluble) 0.1 mg/m3Ozone 0.1 PPM 0.3 PPMWelding fume 5 mg/m3
![Page 38: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/38.jpg)
FACTORS TO BE CONSIDERED IN
ASSESSMENTS
Welding position
Welding location
Duration of exposure
FACTORS TO BE CONSIDERED IN
ASSESSMENTS
Welding position
Welding location
Duration of exposure
![Page 39: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/39.jpg)
Elimination or substitution
Modification of the process or
engineering
Local exhaust ventilation
General dilution ventilation
Personal protective equipment
Preventive Measures
Elimination or substitution
Modification of the process or
engineering
Local exhaust ventilation
General dilution ventilation
Personal protective equipment
![Page 40: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/40.jpg)
FACE SHIELD WITH ATTACHED HELMET EYE GOGGLES, FACE-SHIELD. DIN VALUE OF BLACK GLASS 12 to 14 .
HAND LEATHER HAND GLOVES (FLAME
RESISTANT) BODY LEATHER APRON & LEG GAURD.
FOOT SAFETY SHOE.
Personal Protective Equipment
FACE SHIELD WITH ATTACHED HELMET EYE GOGGLES, FACE-SHIELD. DIN VALUE OF BLACK GLASS 12 to 14 .
HAND LEATHER HAND GLOVES (FLAME
RESISTANT) BODY LEATHER APRON & LEG GAURD.
FOOT SAFETY SHOE.
![Page 41: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/41.jpg)
HAZARDS AT SITE
Working overhead.
Working in confined spaces.
Welding or cutting tanks or vessels.
Tripping hazards.
Working overhead.
Working in confined spaces.
Welding or cutting tanks or vessels.
Tripping hazards.
![Page 42: Gas cutting welding1](https://reader031.vdocuments.us/reader031/viewer/2022011722/58e622d41a28ab632a8b5f95/html5/thumbnails/42.jpg)
Thank UThank U