© 2010 Delmar, Cengage Learning 1 © 2011 Delmar, Cengage Learning Nutrition and the Athlete.
© 2012 Delmar, Cengage Learning Chapter 30 Oxyfuel Welding and Cutting Equipment, Setup, and...
-
Upload
karissa-coleman -
Category
Documents
-
view
222 -
download
3
Transcript of © 2012 Delmar, Cengage Learning Chapter 30 Oxyfuel Welding and Cutting Equipment, Setup, and...
© 2012 Delmar, Cengage Learning
Chapter 30
Oxyfuel Welding and Cutting Equipment, Setup, and Operation
© 2012 Delmar, Cengage Learning
Objectives
• Describe how to maintain the major components of oxyfuel welding equipment
• Explain the method of testing an oxyfuel system for leaks
• Demonstrate how to set up, light, adjust, extinguish, and disassemble oxyfuel welding equipment safely
© 2012 Delmar, Cengage Learning
Introduction
• Oxyfuel welding, cutting, brazing, hardsurfacing, heating, etc. – Use the same basic equipment
• Cylinders• Regulators• Hoses• Hose fittings• Safety valves• Torches• Tips
© 2012 Delmar, Cengage Learning
Introduction (cont'd.)
• All oxyfuel processes use a high-heat, high-temperature flame– Produced by burning a fuel gas mixed with pure
oxygen
– Gases are supplied in pressurized cylinders
– Regulators reduce gas pressure from the cylinder
– Gas flows through flexible hoses• Torch controls flow
– Acetylene is the most widely used fuel gas
© 2012 Delmar, Cengage Learning
Pressure Regulators
• Reduce a high pressure to a lower working pressure– Kept constant over a range of flow rates
• Various types– Low-pressure regulators, high-pressure regulators,
single-stage regulators, dual-stage regulators, cylinder regulators, etc.
• Not interchangeable
© 2012 Delmar, Cengage Learning
Regulator Operation
• Regulators work by holding the forces on both sides of a diaphragm in balance– Gas pressure on back side of diaphragm is reduced
• Two-stage regulators – Keep pressure constant at very low or high flow
rates
– Two sets of springs, diaphragms, and valves
© 2012 Delmar, Cengage Learning
FIGURE 30-1 Force applied to the flexible diaphragm by the adjusting screw through the spring opens the high-pressure valve. © Cengage Learning 2012
© 2012 Delmar, Cengage Learning
Regulator Gauges
• One or two gauges on a regulator– One regulator gauge shows working pressure
• Shows pressure at regulator and not at the torch
– Second gauge shows cylinder pressure
• Line drop – Caused by resistance of a gas flow
© 2012 Delmar, Cengage Learning
Regulator Safety PressureRelease Device
• Safety release valve or safety disc– Prevent excessive pressure from damaging the
regulator
• Safety release valve – Made of a ball held against a seat by a spring
• Safety disc – Thin piece of metal held between two seals
• Must be replaced if used
© 2012 Delmar, Cengage Learning
Cylinder and Regulator Fittings
• Ensure regulator is not connected to wrong gas or pressure– Common adapters
• Left-hand male acetylene cylinder fitting to a right-hand female regulator fitting
• Argon or mixed gas male to a female flat washer-type CO2 fitting
– Considerations• Keep fittings free of dirt and oil• Screw together freely by hand• Replace damaged connections
© 2012 Delmar, Cengage Learning
Regulator Safety Precautions
• Key points– Back off adjusting screw at shut down to prevent
damage
– Creep is rising pressure on working side of regulator
– If leakage at the seat is severe: maximum safe pressure can be exceeded on working side
• Results in damage to diaphragm, gauge, hoses, etc.
– Do not use regulators that creep excessively
© 2012 Delmar, Cengage Learning
Regulator Care and Use
• Considerations– No internal or external moving parts on a regulator
or a gauge require oiling
– Adjusting screw becomes tight and difficult to turn: remove and clean with a dry, oil-free rag
– Replacing adjusting screw: be sure it does not become cross-threaded
– Welding is finished and cylinders are turned off: gas pressure must be released and adjusting screw backed out
© 2012 Delmar, Cengage Learning
Welding and Cutting Torches: Design and Service
• Oxyacetylene hand torches – Most common type of oxyfuel gas torch used
• Combination welding and cutting torches – More flexible
• Straight or dedicated cutting torches– Longer than combination torches
• Most manufacturers make torches in a variety of sizes for different types of work
© 2012 Delmar, Cengage Learning
Mixing the Gases
• Two methods for mixing oxygen and fuel gas– Two gases mixed completely before leaving tip
• One method uses equal pressures– Gases are mixed in a mixing chamber
• Second method uses higher oxygen pressure– Gases are mixed in an injector chamber
© 2012 Delmar, Cengage Learning
FIGURE 30-18 Schematic drawing of an oxyacetylene welding torch. © Cengage Learning 2012
© 2012 Delmar, Cengage Learning
Torch Care and Use
• Considerations– Torch body contains threaded connections for the
hoses and tips
– Wrench should never be used on one nut unless the other connection is protected
– Hose connections should not leak after they are tightened
– Valves should be easily turned on and off
– Bubbles around the valve stem indicates a leaking valve packing
© 2012 Delmar, Cengage Learning
FIGURE 30-22 One hose-fitting nut will protect the threads when the other nut is loosened or tightened. Larry Jeffus.
© 2012 Delmar, Cengage Learning
Welding and Heating Torch Tips
• Key points– No industrial standard tip size identification system
• Students must learn various tip sizes
– Tip sizes: comparable to numbered drill sizes
– On some torch sets: each tip has its own mixing chamber
© 2012 Delmar, Cengage Learning
Torch Tip Care and Use
• Considerations– Tips may have metal-to-metal seals or an O-ring or
gasket between the tip and the torch seat• Tighten metal-to-metal seal tips with a wrench• Tips with an O-ring or gasket can be tightened by
hand
– Dirty tips can be cleaned with tip cleaners
– Damaged tips or tips with cleaners broken in them can be reconditioned
© 2012 Delmar, Cengage Learning
Backfires
• Backfire – Flame goes out with a loud snap or pop
– Causes:• Touching the tip against the workpiece• Overheating the tip• Flame settings are too low• Loose tip• Damaged seats• Dirt in the tip
© 2012 Delmar, Cengage Learning
Flashbacks
• Flame is burning inside the tip, torch hose, or regulator– Produces a high-pitched whistle
• Close oxygen valve and then close fuel valve • Allow torch to cool
– Usually indicates a serious problem with the equipment
© 2012 Delmar, Cengage Learning
Reverse Flow and Flashback Valves
• Reverse flow valve – Prevents gases from flowing through the torch into
the wrong hose• If gases are allowed to mix in the hose or regulator
they might explode
• Flashback arrestor – Will do the job of a reverse flow valve
– Will also stop the flame of a flashback
© 2012 Delmar, Cengage Learning
Care of the Reverse Flow Valve and Flashback Arrestor
• Considerations– Both devices must be checked on a regular basis
• Internal valves may become plugged with dirt
– Test reverse flow valve: blow air backwards through the valve
– Test flashback arrestor: follow manufacturer's recommended procedure
– Replace of not functioning correctly
© 2012 Delmar, Cengage Learning
Hoses and Fittings
• Characteristics– Siamese hoses are molded together as one piece
• Other hoses may be taped together
– Fuel gas hoses must be red and have left-hand threaded fittings
– Oxygen hoses must be green and have right-hand threaded fittings
– Hoses are available in four sizes
© 2012 Delmar, Cengage Learning
Hose Care and Use
• Considerations– Hoses not in use: gas must be turned off and
pressure bled off
– Hoses are resistant to burns: not burn-proof
– Hoses should be checked for leaks
– Hose fitting can be changed if damaged
– To replace hose end: hose is cut square
© 2012 Delmar, Cengage Learning
Types of Flames
• Oxyacetylene flame settings– Carburizing flame
• Excess of fuel gas
– Neutral flame• Balance of fuel gas and oxygen
– Oxidizing flame• Excess of oxygen
© 2012 Delmar, Cengage Learning
Leak Detection
• Leak-detection solution – Premixed or concentrate
– Must be free flowing
– Good quantity of bubbles without film
• Solution can be:– Dipped
– Sprayed
– Brushed
© 2012 Delmar, Cengage Learning
Figure 30-36 Safety chain cylinder. Larry Jeffus.
© 2012 Delmar, Cengage Learning
FIGURE 30-42 Connect the free ends of the oxygen (green) and the acetylene (red) hoses to the welding torch. Larry Jeffus.
© 2012 Delmar, Cengage Learning
FIGURE 30-43 Select the proper tip or nozzle and install it on the torch body. Larry Jeffus.
© 2012 Delmar, Cengage Learning
FIGURE 30-44 Back out both regulator-adjusting screws before opening the cylinder valve. Larry Jeffus.
© 2012 Delmar, Cengage Learning
FIGURE 30-45 Stand to one side when opening the cylinder valve. Larry Jeffus.
© 2012 Delmar, Cengage Learning
FIGURE 30-48 Adjust the regulator to read 5 psig (0.35 kg/cm2g) working pressure. Larry Jeffus.
© 2012 Delmar, Cengage Learning
FIGURE 30-50 Identify any cylinder that has a problem by marking it. Larry Jeffus
© 2012 Delmar, Cengage Learning
Manifold Systems
• Used when there are a number of work stations or a high volume of gas will be used– Must be located at least 20 feet or more from work
– Rooms used for manifolds can be also used for cylinder storage
– Piping for high-pressure side of the manifold must be steel, stainless steel, or alloyed copper
– Should be tested for leaks at a half times operating pressure
© 2012 Delmar, Cengage Learning
Manifold Operation
• Considerations– Clean pipes with oil-free, noncombustible fluid
before regulators are attached
– Install regulators and purge the system with nitrogen
– Fill pipes with oxygen or fuel gas
– Set line pressure as low as possible
© 2012 Delmar, Cengage Learning
Summary
• You will work with experienced welders– After you have developed skills and found a
welding job• These welders have developed many good shortcuts
– Safe way of setting up and testing a system should always be followed
• Always refer to the manufacturer's operating instructions and safety recommendations