19_welding and cutting

8/16/2019 19_Welding and Cutting

1/78

Welding, Cutting, and Brazing أع الحم والق

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%& C'( )&%.+/* - %& C'( )&%.+/0


2/78

Introduction

•123

78 49: ال 56ع 4ل

@Aأ ? ال ; =9DالحمEF 9 لا

•

GH? Dلحم وو 12الNOPQR EF 9 ام الح =ا LMأو ال IJKأو•9A G=T2 D EN9 لا @A @U9

V Dلحم AN5 ع

•EN9 لا @A 3V أ محلا E3XD YTZ[ F=\ ع 4U الحم

D 7 2]ا


3/78

General Hazards• ^eneral _azard` b

celding inlude• fletrial

_azard`Y

R=TX لا = OA• _arhbul 'uhe` 45F]اLM K لا

• _eat and jigkt LM ا= حلا

=T لا Y3K لاو (adiatin• 'ire and f!l`in`

m اM \Zoاو p: ا= حلا


4/78

Welding _ealtk _azard`

ح 4Uلحم

=ال 6

O لا)+ Ckehial qgent`4U:

U UX لا F ا3 لا

•الحم

@Xال


5/78

Cadhiuhم3UAF X لا

•1?€ لاو أN6

ال 5 ل EF 9 ل YH

? NOxDم ال 3UAF Xم

• @Aأ L=ORال 3UAF Xم ع U?=

=9ل =ا 4 UxR mل

لا

| {5 لا pU | @U:= ل LNDN‚ 4UP x wxD E أ @X

D +L83 لا mƒحلا „9R 78 و

•

4 D3 m ا= ل م3UAF X لا L=OR] „O5A U?= ل =9

لا

wxD NV eh!k…`ehaLMN

ال =: ˆ 6Ao @Uا[و ? @U\Uxو @Aال @X أ wxD Eو =†‡D =A 3GعA 7 ق@UU

X لا ‰

• 78


6/78

• Skin irritation

• Eye irritation

• Inhalation

4f

Acute health hazards


7/78

Acute health hazards

• Inestion

• !"ser#a"le e$$ects

4g


8/78

%hronic health hazards

• %arcinoen

• &idney da'ae

• (es)iratory da'ae

4h


9/78

Ber…lliuhم3U D= لا

•Š ح5 لا s: P A 4XUx? NOxDم

•@A @Aأ L=ORال 3U D=م ع U?= ل 7‹ حلا =9 لا3:= لا Œ T لoا wxD E أ @X لا

•L=OR أ @A „O5A U?= ل 4 D3 m ا= ل =9 لا 9x لا | {5 لا pU wxD E أ @X لا @A ال 3U D=م

E3 لا 78 Ž او قZ | @A لا


10/78

*luorides + ,-./

•YR=TX لا محل 78 NOxDم ل YHل ل =Xو Fال NOxD م @U\Ux?]ا 5 ل محلا 3 4 ل ع 4 ق @D3X ل s ل‘ و

ال EN9 و • ‰ الحم A 1 ع لا @A •M و لاو ‰Z]او @U9 ل 4UP x wxD

@Aال M3 ا 78 NDال \3• ع U?= ل M=X لا =9 لا

ل =ا @A 4 D3 mال @X أ 3P wxD Eا : 78 1ال =:4 ?ل ‰ • sال ‹9م


11/78

0hosene12324-/

•M3 X لا 7 ع 3 ح• 7 لا 4D3K9 لا m D لا 1 ح• wxR E3XD 3Rا 4 Pا[‚


12/78

56 0hysical Aents 78+92/ :;8


13/78

>y)es o$ ?eldin@8. B -CD

• Gas ?eldin oFy6acetylene as8

• Arc ?eldin SJA? K Shield Jetal Arc

?eldin K JIG K Jetal Inert Gas K >IG K >unsten Inert Gas

• !Fyen and Arc %uttin


14/78

5L %*( MLMNO5P5General (eQuire'ents

8= R8.T U •

E XA Œ=V @Aالحم 9‚ ل 4 R قلا F ا3 لا U } F 9R[

’• ƒ 48 x R /ق 1ع @ NV))“=Aم•D 9‚ ل 4 R قلا F ا3 لا F 9R[ 4UZ XA[ 78ل 4ع Nم

+9‚ ل 4 R V =U~ LF A 4 P ا3R TU J•

•E XA @A Œ= قلR pD= حلا 4 ح8 XA m اN9A و LM و= الحم


15/78


16/78

%ontinued

•E XA @A Œ= قلR N} ا3D pD= حل wV ا=A ‰U X• LM و= =D و RMNA E3XDع8 XA 7 ح 4 لا M=; لا 49R ل محلا

+p: ا= حلا•E XA 78 pD= حلا wV ا=A 1‹D YTZ[ N9Rع 4U الحم

• ƒ LNAق 1ع @ Pع 4ل 4‹H أ = 4Dا :pالحم

+=D لا M=; لا 4\UZ –N ح• NV 4—U R


17/78


18/78


19/78

?eldin or %uttin %ontainers

V2 : W R8+W8 XY ZT W @8. •

~ ˜3 xA =Uع 7 ا


20/78

0rotection o$ 0ersonnel

2[\] +8^- R8 _

•LM ا= حل 4A وقA m ا V

•LM ا= حل 4A وقA {RHA

EN9 لاو M=; لا @A 4D حل@ x لا

•4AHP Yا

•š3Z wx = R @U9 ل 7V او

الحم


21/78

*il ` Sh d " G id


22/78

*ilter èns Shade u'"er GuideWelding ›!eratin Skade œuher

Skield etal qr Welding u! t 0 hh eletrde )*

Skield etal qr Welding “0+ž t .+0 hh’ eletrde` )%Skield etal qr Welding “.+0 hh’ eletrde )0

â` etal qr Welding “œnberru`’ ))

â` etal qr Welding “berru`’ )%

â` Ÿung`ten qr Welding )%

Carn qr Welding )* - )0

Ÿrk Sldering %

Ÿrk Brazing / r 0

jigkt utting u! t % hh / r 0

ediuh utting % t )* hh 0 r

_ea… utting er )* hh r .

â` celding “ligkt’ u! t /+% 0 r

â` celding “hediuh’ /+% t )%+¡ r .

â` celding “kea…’ er )%+¡ . r ž

H l h 0 i d b il i


23/78

Health 0rotection and bentilation

2[ +8^- W +-_U

• = W @8. 8f 2f2C8f2 +-_g :2Y-g ,W: 1j V + +-_U 5NNN


24/78

Jo#a"le Hoods

2=- +-_U •D 4?= حA 4U93A 4D3T•

E XA @A Œ= قلR T9 و

LM K لا L=OR]ا I; ل محلا 4 P ا3R TV ;5P[ 1V +1A 9 لا

•yG 78 Yا3T لا I‚ 4 ع=P

ال ; w\D m أ• ƒق 1ع @ Rل UVNق 4**( NVم


25/78


26/78

5L *( MLMN 5P~


27/78

5L *( MLMNO5P~Gas ?eldin and %uttin

8 8m Z T W @8. • qn …aet…lene celding utbit` i` aìall… hade u!

b …linder` b …gen and aet…lene, regulatr`,kè`, and a trk+

• ›…gen and qet…lene are `tred in è!arate…linder` in a kigk !re`ùre, ckik i` ntrlled …tke regulatr`+

• _è` arr… tke gaè` brh tke …linder` t tke trk+Ÿke green kè arrie` ›…gen+ Ÿke red _è arrie`

qet…lene+• Ÿke gaè` are hied inìde tke trk+ Wken urnedtke… !rdue a er… kt blahe+ Ÿke blahe i` regulated… interkangeale trk ti!` and … tke trkale`+


28/78


29/78

'la`k Ba¢ qrre`trn tke aet…lene and…gen regulatr`


30/78

Gas ?eldin *lash"ack Arresters

• 'la`ka¢ during …£buel celding, utting an auèèriu` in¤ur…+

• qll ga` celding r ga` utting e¥ui!hent hu`t ebitted citk bla`k arre`ter`+

• 'la`ka¢ egin` cken tke blahe he` a¢ brhtke celding ti! and int tke lc!i!e, uùall… citk alud ¦ang§ r a `krill ki`ìng ùnd+

•Witkut a bla`ka¢ arre`ter, tke blahe an traeletrehel… ba`t aut )/ heter a ènd - u! ga`ù!!l… kè` t tke regulatr and !`ìl… int tkega` …linder` ckere it uld auè an e!lìn+


31/78

on6return bal#es on the >orch

! t l ? ldi


32/78

!Fyacetylene ?eldinEQui)'ent


33/78


34/78


35/78


36/78

General (eQuire'ents

• ¨nder n nditin `kall aet…lenee generated r utilized at a

!re`ùre in ee`` b ) !ìg+• ¨ìng aet…lene at a !re`ùre inee`` b ) !ìg i` a kazardu`!ratie+ 'ree gaèu` aet…lene i`

!tentiall… un`tale at !re`ùreae ) !ìg and ulddeh!è citk e!lìeilene+


37/78

%ontinued

• Ÿke deh!ìtin karateri`ti` baet…lene ga` are aided … ¢ee!ing

tke ga` in li¥uid `lutin and `tringit in …linder` b uni¥uen`trutin+ Ÿkeè …linder` ntain!ru` aliuh ìliate biller

“hillin` b hir`!i !re`’ and aùitale `lent uùall… aetne+ “ka`tke ailit… t a`r er 0** tiheìt` cn luhe b aet…lene at ¡*© '+


38/78

AcetyleneCylinders are

flled withCalcium Silicate


39/78


40/78


41/78

%ontinued

• ?hen a"sor"ed in this $iller the acetylene isdi#ided into such s'all units that shouldacetylene deco')osition take )lace in one

)ore the heat released is not enouh to raisethe te')erature o$ the acetylene in thesurroundin )oresO

• Acetylene is usually su))lied in cylinders

€hich ha#e the ca)acity o$ u) to ~NN cu"ic$eet o$ dissol#ed as under )ressure o$ 5PN )si at N‚ *O


42/78

%ontinued

• %ylinders shall "e ke)t $ar enouh a€ay$ro' the actual €eldin or cuttin o)erationso that s)arks hot sla or $la'e €ill notreach the'O ?hen this is i')ractical shieldsshall "e )ro#idedO

• %ylinders containin !Fyen or Acetyleneor any $uel as shall not "e taken into

con$ined s)acesO• !Fyen cylinders and $ittins shall "e ke)t

a€ay $ro' oil or rease and shall not "ehandled €ith oily hands or lo#esO


43/78

%ontinued

• %rackinƒ „e$ore a reulator #al#e isconnected the #al#e shall "e o)ened

slihtly and closed i''ediatelyO >o clearthe #al#e o$ dust or dirtO• >he )erson crackin the #al#e shall stand to

one side o$ the outlet not in $ront o$ itO• *uel as cylinder #al#es shall "e o)ened MOP

turns and the €rench shall "e le$t in )osition on the ste' o$ the #al#eO


44/78

Sabet… ªreautin`


45/78

%heck €ith a leaks)ray or soa)solution that thereis no leakae

AdeQuate bentilation

*lash"ack Arrestor (e'o#e $la''a"le 'aterials

?ork)lace$ree $ro'co'"usti"le'aterials

e#er eF)ose the acetylene

cylinder to stron heat

A "urnin torch 'ustnot "e hun on thereulator or eF)ose

the cylinder


46/78

%ylinders and %ontainers

• %o')ressed as cylinders shall "e lei"ly'arked $or the )ur)ose o$ identi$yin the

as contentOstencilin K sta')in• %ylinders should "e stored a€ay $ro'

ele#ators stairs or an€ays or other areas

€here they 'iht "e knocked o#er orda'aed "y )assin or $allin o"…ectsO


47/78


48/78


49/78

%ontinued

• ?here the cylinder is desined to acce)t aca) shall al€ays "e in )lace hand6tiht

eFce)t €hen cylinders are in use orconnected $or useO >he #al#e )rotection ca)is desined to take the "lo€ in case o$

cylinder $allsO• Acetylene cylinders shall "e stored #al#eend u)O


50/78

!Fyen %ylinders

• !Fyen cylindersin storae shall

"e se)arated$ro' $uel6ascylinders orco'"usti"lecylinders a

'ini'u'distance o$ 5N$eet vOM 'O


51/78

!Fyen %ylinders

• !r "y a non6co'"usti"le

"arrier at least P$eet MOP' hihha#in a $ireresistance ratin

o$ at least M†5hourO


52/78

q(C Wfj«¬œ^


53/78

5L %*( MLMNO5P

Arc ?eldin and %uttin• Jost o$ the electric €elder are ty)icallyA%†‡% 5N #olt trans$or'er ty)es usin

electricity as the enery sourceO• Arc €eldin uses the heat $ro' an electric

arc to 'elt and $use "ase 'etals and

€eldin6rod 'etal into one )ieceO >he heat$ro' the arc 'elts the $luF coatin on therodO


54/78


55/78

q(C Wfj«¬œ^

• In arc €eldin theintense heat needed to'elt the 'etal is

)roduced "y anelectric arcO

• >he arc is $or'ed

"et€een the actual€ork and an electrode€ireO


56/78


57/78

So'e >y)es o$ A(% ?eldin

• SJA? Shielded Jetal Arc ?eldin

• GJA? Gas Jetal Arc ?eldin

• G>A? Gas >unsten Arc ?eldin


58/78

SqW “Skielded etal qr

Welding’• %onsists o$ an A%†‡% arc "urnin "et€een

a consu'a"le electrode and the €ork)iece

to 'elt the …oint areaO• >he arc and the €eld )ool are shielded "y

ases and slas €hich result $ro' the

deco')osition o$ the electrode coatinO


59/78

qr Skielding

• etal` at kigk teh!erature`tend t reat kehiall… citkelehent` in tke air “…gen -nitrgen’ ide` and nitride`brh ckik de`tr… tke`trengtk and tugkne`` btke celd ¤int+

• ªrtetie ering citk!rtetie `kield b ga`,a!r, r `lag+

^qW “^a` etal qr Welding’


60/78

^qW “^a` etal qr Welding’“¬^’ etal ¬nert ^a`

• Jeans the use o$ an inert iOeO non acti#e asO

• >he )rocess consists o$ a ‡% arc "urnin

"et€een a thin "are 'etal €ire electrode and the€ork)ieceO

• >he arc and €eld area are en#elo)ed in a

)roacti#e as shieldO• >he €ire electrode is $ed $ro' a s)ool throuh a€eldin torch €hich is connected to the )ositi#e

ter'inal into the €eld zoneO


61/78


62/78

^ŸqW “^a` Ÿung`ten qr Welding’


63/78

^ŸqW “â` Ÿung`ten qr Welding’Ÿ¬^ “Ÿung`ten qr Welding’

• Cnì`t` b an qC«C ar urning etceen a nn£

nùhale eletrde and tke cr¢!iee t helt tke ¤int area+

• Ÿke area b tke ar i` enel!ed in a !rtetie ga` `kieldckik !rtet` tke celd !l and eletrde` brhntahinatin ckile allcing a `tale ar t ehaintained+

• Ÿke biller cire i` added … kand, r in tke hekanièd!re``, … beed rller` attaked t tke trk+

• 'r kigk ¥ualit… celding n `tainle`` `teel`, aluhiniuhO

> t I t G


64/78

>unsten Inert Gas

• «C h`t nrhall… uèd br Ÿ¬^ celding b `tainle```teel`, hild and lc all… `teel`, !!er+• Ÿke eletrde hu`t e nneted t tke negatie

terhinal, ckere ne tkird b tke keat i` generated+

Ÿc tkird` b tke keat b tke ar i` generated at tke!ìtie !le+• q tung`ten eletrde nneted t tke !ìtie !le

culd erkeat and helt auìng ntahinatin b

tke celd and ra¢` in tke erahi `krud+• qC i` uèd nl… br celding b aluhinuh,hagneìuh+ Surbae idatin i` rehedauthatiall… … tke atin b tke ar eak tihe tke

eletrde ehe` !ìtie+


65/78

Sa$ety Jeasure

• Ÿke tung`ten eletrde` ntain `hall ahunt`b tkriuh “le`` tkan 0®’ ckik readil…urning in air brhing tkriuh ide+

• Ÿkriuh i` a radiatie hetal and !`e` aninkalatin and inge`tin kazard+

• ^d in`ulatin b all !cer ale`+

• Seure celding return lah!` and !rtetinagain`t ar radiatin+


66/78


67/78


68/78

I t lli th A ? ld


69/78

Installin the Arc ?elder

• Ÿke brahe r aè bcelder `kall e !r!erl…grunded+

• q ̀ abet… t…!e

di`nneting ̀ citk`kall e lated near tkehakine+

• Ÿke celder `kall e

!rteted … !r!erl…ìzed buè r iruitrea¢er n aninde!endent iruit+


70/78

%ontinue

• A round return ca"le shall ha#e a sa$ecurrent carryin ca)acity eQual to or

eFceedin the s)eci$ied out)ut ca)acity o$the arc €eldin or cuttin unit €hich itser#icesO

• 0i)elines containin ases or $la''a"leliQuids or conduits containin electricalcircuits shall not "e used as round returnO


71/78

%ontinue

• All arc €eldin and cuttin ca"les shall "eo$ the co')letely insulated $leFi"le ty)es

ca)a"le o$ handlin the 'aFi'u' currentreQuire'ents o$ the €ork in )roressO

• !nly ca"le $ree $ro' re)air or s)lices $or a

'ini'u' distance o$ MN $eet $ro' the ca"leend to €hich the electrode holder isconnected shall "e usedO

Sa$ety Jeasures


72/78

Sa$ety Jeasures

• Sine tke inert£ga` hetal£ar celding !re``

inle` tke !rdutin b ultra£ilet radiatin nintenìtie` b t /* tihe` tkat !rdued duringhetal£ar celding, tke bllcing àbet… heaùre` te bllced

)+ Ÿke uè b klrinated `lent` `kall e ¢e!t at lea`t%** beet, unle`` `kielded+ ¨ltrailet ra…` gien bb… celding an reat citk klrinated k…drarn`lent`, ùk a` triklretk…lene, ),),),£triklretkane, t brh !k`gene ga` “deadl…’

%+ fh!l…ee` in tke area nt !rteted brh tke ar …`reening `kall e !rteted … !r!er bilter lenè`+

/+ Wet cr¢ing nditin` hu`t e aided eauècater i` an eellent ndutr and eletriit… cill

alca…` bllc tke !atk b lea`t reì`tane+


73/78

5L %*( MLMNO5PP

(esistance ?eldin• Ÿke celd i` hade … ahinatin b keat,!re`ùre, and tihe+

• ¬t i` tke reì`tane b tkehetal t e celded turrent blc tkat auè`lalized keating in tke !art+

• Ÿke !re`ùre i` eerted …tke tng` and ti!`+

• Ÿke tihe i` kc lng

urrent blc` in tke ¤int


74/78


75/78


76/78

5L %*( MLMNO5PP

(esistance ?eldin• All doors and access )anels o$ all resistance€eldin 'achines and control )anels shall

"e ke)t locked and interlocked to )re#entaccess to li#e )ortions o$ the eQui)'entO

• All )ress €eldin o)erations shall "e

e$$ecti#ely uarded "y use o$ a de#ice suchas an electronic eye sa$ety circuit t€o handscontrols ˆO


77/78

%ontinued

• >he hazard o$ $lyin s)arks shall "eeli'inated "y installin a shield uard o$

sa$ety lass or suita"le $ire6resistant )lasticat the )oint o$ o)erationO• >€o or 'ore sa$ety e'erency sto) "uttons

shall "e )ro#ided on all s)ecial 'ultis)ot

€eldin 'achinesO• ?ear sa$ety oles or a $ace shield and

heat resistance lo#esO


78/78

19_welding and cutting

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