Oxyfuel Cutting Module 32104 07 40104 07 National

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Oxyfuel Cutting Module 32104 -07 / 40104 -07 National Center for Construction Education and

Oxyfuel Cutting Module 32104 -07 / 40104 -07 National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 1 Objectives Upon completion of this module, the trainee will be able to

Transparency 1 Objectives Upon completion of this module, the trainee will be able to do the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. Identify and explain the use of oxyfuel cutting equipment. State the safety precautions for using oxyfuel equipment. Set up oxyfuel cutting equipment. Light and adjust an oxyfuel torch. Shut down oxyfuel cutting equipment. Disassemble oxyfuel equipment. Change empty cylinders. Perform oxyfuel cutting: • Straight line and square shapes • Piercing and slot cutting • Bevels • Washing Apply a rosebud flame to remove frozen components (also for preheat and expanding larger fittings). 10. Operate a motorized, portable oxyfuel gas cutting machine. National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 2 National Center for Construction Education and Research Performance Tasks 1. 2. 3.

Transparency 2 National Center for Construction Education and Research Performance Tasks 1. 2. 3. 4. Set up oxyfuel equipment. Light and adjust an oxyfuel torch. Shut down and disassemble oxyfuel cutting equipment. Perform oxyfuel cutting: • Straight line and square shapes • Piercing and slot cutting • Bevels • Washing 5. Operate a track burner. Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Introduction • Also called flame cutting or burning – uses the flame and oxygen

Introduction • Also called flame cutting or burning – uses the flame and oxygen from a cutting torch to cut ferrous metals(metals containing iron) • The flame is from a fuel gas mixed with pure oxygen • The flame heats the metal to the kindling temperature, then a stream of high pressure pure oxygen is directed from the torch at the metals surface – this causes the metal to instantaneously oxidize or burn • Oxides mix with molten iron to produce dross(the material that is expelled from the kerf when cutting using a thermal process) National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Introduction • Oxyfuel cutting is used on ferrous metals because they oxidize rapidly •

Introduction • Oxyfuel cutting is used on ferrous metals because they oxidize rapidly • Oxyfuel cutting can also be used for certain metal alloys, like stainless steel – this requires higher preheat temperatures and more oxygen for cutting National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Safety • Clothing and equipment – always use safety goggles or glasses with a

Safety • Clothing and equipment – always use safety goggles or glasses with a full face shield or helmet – the shield or helmet must have the proper light reducing tint for the type of welding or cutting to be performed • Never look directly or indirectly at an electric arc without using a proper lens • Wear leather or flame retardant clothing • Wear leather welding gloves • Wear 8 -inch or taller safety shoes or boots covered by a pant leg National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Safety • For overhead cutting or welding wear a solid material hat or a

Safety • For overhead cutting or welding wear a solid material hat or a full leather hood with a welding face plate • Use earmuffs to block noise and to prevent burns to the ears – you can use earplugs to filter out the noise as well • The heat and light produced by cutting or welding can damage the skin and eyes(permanent loss of vision) • Oxyfuel cutting and welding can cause mild burns to the skin because of infrared heat • Welding or cutting involving an electric arc can produce UV radiation – can cause severe burns to the eyes and exposed skin and permanent damage to the retina National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Safety • Never directly or indirectly view an electric arc without wearing properly tinted

Safety • Never directly or indirectly view an electric arc without wearing properly tinted lens designed for electric arc use • For oxyfuel cutting or welding wear welding goggles (shades 4 to 6) OVER safety glasses • For electric arc operations a leather hood or welding helmet with a tinted lens (shades 9 to 14) must be worn over safety glasses • Some may require other safety glasses or goggles based on the MSDS National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Ventilation • You must have adequate ventilation to remove fumes produced by welding or

Ventilation • You must have adequate ventilation to remove fumes produced by welding or cutting processes • The gases, dust, and fumes can be hazardous • The welding area must contain at least 10, 000 cubic feet of air for each welded • There must be air circulation • Partitions, structural barriers, or equipment must not block air circulation • Avoid inhaling welding or cutting fumes • The fumes and smoke generally rise straight up National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Respirators • Special metals require the use of respirators to protect from harmful fumes

Respirators • Special metals require the use of respirators to protect from harmful fumes • Three main types of respirators – air-purifying respirators, supplied-air respirators, self-contained breathing apparatus • Make sure they are clean, put together properly, no missing parts National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Air-purifying respirators • Lowest level of protection • Use filters to remove specific gases,

Air-purifying respirators • Lowest level of protection • Use filters to remove specific gases, vapors, and particles from the air • 4 groups – no maintenance, low maintenance, reusable, powered air-purifying respirators(PAPRs) • No and low maintenance – half mask respirators not for constant use – non replaceable filters • Reusable – half or full face – replaceable cartridges • PAPRs – half, full, or hood style – battery operated blowers pull air through the filters National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Supplied-Air Respirators • • • Supply air for extended period of time Typically used

Supplied-Air Respirators • • • Supply air for extended period of time Typically used in toxic atmospheres Some can be used in atmospheres that are IDLH Two types – continuous-flow and pressure demand Continuous flow – air provided at a constant stream – one or two hoses deliver air to the face piece – unless designed to filter the pump must be located where there is breathable air • Pressure demand – supply air when the user inhales National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

SCBA • Highest level of protection • Provide air from 30 to 60 minutes

SCBA • Highest level of protection • Provide air from 30 to 60 minutes from a compressedair cylinder • Select the proper type of respirator for the job, make sure you are properly trained on use of the respirator • Do a positive and negative fit check before use National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 3 National Center for Construction Education and Research Figure 13 – Use the

Transparency 3 National Center for Construction Education and Research Figure 13 – Use the right respirator for the job Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 4 National Center for Construction Education and Research Table 1 – Effects of

Transparency 4 National Center for Construction Education and Research Table 1 – Effects of an increase or decrease in oxygen levels Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Work Areas • You must be aware of your work space – is it

Work Areas • You must be aware of your work space – is it a confined space – does it have the potential to ignite – can you get out if needed • Keep area clean – things you can trip over – things that can catch on fire • If you are finished working use soapstone to write the word HOT on it before you leave • Make sure you have proper ventilation National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

 • You may have to get a hot work permit to perform work

• You may have to get a hot work permit to perform work that may pose a fire hazard • If working in an area that may pose a fire hazard, you need to have a fire watch person • Containers must be steam cleaned, flushed with water, or washed with a detergent until all traces of the material have been removed • After cleaning, fill it with water or an inert gas (argon or CO 2) to prevent ignition National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 5 National Center for Construction Education and Research Figure 16 – Hot work

Transparency 5 National Center for Construction Education and Research Figure 16 – Hot work permit Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Cylinder storage and handling • Oxygen and fuel gas cylinders or other flammable materials

Cylinder storage and handling • Oxygen and fuel gas cylinders or other flammable materials must be stored separately • All cylinders must be stored vertically and have protective caps screwed on firmly • Secure with a chain or other device so it cannot be knocked over accidentally • Store away from halls, stairwells, or exits so they will not block an escape route • Store away from heat, radiators, furnaces, and welding sparks National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

 • Store where they cannot be tampered with • If cylinders are not

• Store where they cannot be tampered with • If cylinders are not in use they must have a valve protection cap to prevent the valve from breaking off • In gaseous form, acetylene is extremely unstable and explodes easily – its pressure must remain below 15 psi • If tipped over, stand the tank upright and wait at least 30 minutes before use • When using, open the cylinders no more than one and a half turns – preferably no more than three-fourths National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Equipment • The equipment used for oxyfuel cutting – oxygen and fuel gas cylinders,

Equipment • The equipment used for oxyfuel cutting – oxygen and fuel gas cylinders, oxygen and fuel gas regulators, hoses, and a cutting torch, and possibly a torch cart • Oxygen – colorless, odorless, tasteless gas that supports combustion – combined with burning material, pure O 2 allows a fire to flare and burn out of control – when mixed with fuel gases O 2 produces high temperature flames required to cut metals • O 2 cylinders come in different sizes – have a bronze control valve with a safety valve in case the pressure gets too high National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

 • Acetylene – a compound of carbon and hydrogen formed when calcium carbide

• Acetylene – a compound of carbon and hydrogen formed when calcium carbide is dissolved in water – strong garlic like odor • In gaseous form it is extremely unstable and explodes easily – it cannot be compressed more than 15 psi • When combined with O 2, it creates a flame that burns hotter than 5, 500 F • Cylinders are specially constructed to hold acetylene – they are filled with a porous material soaked with acetone to absorb the acetylene and help it stay stable National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

 • Acetylene tanks must be stored upright – if turned over wait at

• Acetylene tanks must be stored upright – if turned over wait at least 30 minutes before using • Do not withdraw the gas at a rate higher than 15 psig and at an hourly rate more than one-tenth of the cylinder capacity • They have a safety plug that will melt if the temperature gets too hot (220 F) so the cylinder will not explode National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 6 National Center for Construction Education and Research Figure 21 – High-pressure oxygen

Transparency 6 National Center for Construction Education and Research Figure 21 – High-pressure oxygen cylinder markings and sizes Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 7 National Center for Construction Education and Research Figure 25 – Acetylene cylinder

Transparency 7 National Center for Construction Education and Research Figure 25 – Acetylene cylinder markings and sizes Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 8 National Center for Construction Education and Research Table 2 – Flame temperatures

Transparency 8 National Center for Construction Education and Research Table 2 – Flame temperatures of oxygen with various fuel gases Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 9 National Center for Construction Education and Research Figure 27 – Liquefied fuel

Transparency 9 National Center for Construction Education and Research Figure 27 – Liquefied fuel gas cylinder Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Regulators/hoses • Regulators reduce the cylinder pressures to the required working pressures and maintain

Regulators/hoses • Regulators reduce the cylinder pressures to the required working pressures and maintain a steady flow of gas • Most have two gauges –a high pressure and a low pressure • Oxygen regulators are often green and have right hand threads and fuel gas are painted red and have left hand threads • Oxygen hoses are green or black • Fuel gas hoses are red National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 10 National Center for Construction Education and Research Figure 30 – Heavy-duty three-tube

Transparency 10 National Center for Construction Education and Research Figure 30 – Heavy-duty three-tube one-piece positive-pressure hand cutting torch Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 11 National Center for Construction Education and Research Figure 32 – One- and

Transparency 11 National Center for Construction Education and Research Figure 32 – One- and two-piece cutting tips Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 12 National Center for Construction Education and Research Table 3 – Sample acetylene

Transparency 12 National Center for Construction Education and Research Table 3 – Sample acetylene cutting tip chart Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 13 National Center for Construction Education and Research Figure 33 – Typical acetylene

Transparency 13 National Center for Construction Education and Research Figure 33 – Typical acetylene torch cutting tips Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 14 National Center for Construction Education and Research Figure 34 – Typical cutting

Transparency 14 National Center for Construction Education and Research Figure 34 – Typical cutting tips for liquefied fuel gases Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 15 National Center for Construction Education and Research Figure 35 – Special-purpose torch

Transparency 15 National Center for Construction Education and Research Figure 35 – Special-purpose torch cutting tips Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

 • Always use a friction lighter to light the torch • You can

• Always use a friction lighter to light the torch • You can use soapstone to mark your cuts because it can be seen through the tinted lens National Center for Construction Education and Research Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 16 National Center for Construction Education and Research Figure 66 – Typical empty

Transparency 16 National Center for Construction Education and Research Figure 66 – Typical empty cylinder marking Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 17 National Center for Construction Education and Research Figure 68 – Cutting thin

Transparency 17 National Center for Construction Education and Research Figure 68 – Cutting thin steel Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 18 National Center for Construction Education and Research Figure 69 – Cutting thick

Transparency 18 National Center for Construction Education and Research Figure 69 – Cutting thick steel Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 19 National Center for Construction Education and Research Figure 70 – Steps for

Transparency 19 National Center for Construction Education and Research Figure 70 – Steps for piercing steel Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 20 National Center for Construction Education and Research Figure 71 – Cutting a

Transparency 20 National Center for Construction Education and Research Figure 71 – Cutting a bevel Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 21 National Center for Construction Education and Research Figure 72 - Washing Industrial

Transparency 21 National Center for Construction Education and Research Figure 72 - Washing Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.

Transparency 22 National Center for Construction Education and Research Figure 74 – Victor track

Transparency 22 National Center for Construction Education and Research Figure 74 – Victor track burner controls Industrial Maintenance Mechanic 1 • Module 32104 -07 Industrial Maintenance Electrical and Instrumentation Technician 1 • Module 40104 -07 Copyright © by NCCER, Published by Pearson Education, Inc.