HDES-P1107

Standard Operating Procedure Of Gas Cutting Statute: 1982.10.30

Equipment Method Revision(No.): 2007.12.10(4)
page : 1 OF 14

Standard Operating Procedure Of

Gas Cutting Equipment Method
(CE Technical Standard:HDES-P1107)

2007 . 12 . 10

Manufacturing Engineering Team;

Construction Equipment BG;
Doosan Infracore
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982.10.30
Equipment Method Revision(No.): 2007.12.10(4)
page : 2 OF 14

Table of contents

1. Application Range

2. Purpose

3. Standard Procedure

3-1. Selecting Tip

3-2. Method of Pre-heating

3-3. AUTOMATIC GAS CUTTING

3-4. SEMI AUTOMATIC GAS CUTTING

3-5. MANUAL GAS CUTTING

3-6. CUTTING SURFACE

3-7. SELF-TEST OF CUTTING

3-8. Safety-inspection & Checking point after work

 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 3 OF 14

1. Application Range
This Standard should be used to make the goods be of good quality at the Construction
Equipment Business in Doosan Infracore. Workers should especially follow the standard
to operate Auto, Semi and manual cutting which uses O2-Acetylene or O2-LPG and
to grind the goods after cutting.

2. Purpose
The Standardization, Promptitude, Uniform Quality and Quality Guaranteed about
Cutting steel plate are the purpose of the revision.

3. Standard procedure
3-1. Selecting tip
3-1-1. The Standard of setting the tip, the pressure and the cutting speed by gas classification
* Tip Number means the standard features of the KOIKE SANSO

Acetylene (STRAIGHT TYPE) TIP TYPE : 102

Pressure(kg/cm²) cutting Flux (L/H)

Tip Thickness
speed
NO. (mm) O2
O2 for
Acetylene (mm/min) O2 for cutting preheating Acetylene

00 3~5 1.5 0.20 700~600 690 410 370

0 5~10 2.0 0.20 660~550 1,200 410 370
1 10~15 2.5 0.20 550~490 2,100 480 430
2 15~30 3.0 0.20 490~400 3,400 480 430
3 30~40 3.0 0.20 400~350 4,300 480 430
4 40~50 3.5 0.25 350~320 6,500 550 500
5 50~100 4.0 0.30 320~200 11,000 690 630
6 100~150 4.0 0.35 200~150 15,000 770 700
7 150~250 4.5 0.40 150~80 22,000 1,060 960
8 250~300 4.5 0.40 80~45 28,000 1,060 960
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 4 OF 14

LPG (Divergent Type) TIP TYPE : 106 - D7

Pressure(kg/cm²) cutting Flux (L/H)

Tip Thickness
speed
NO. (mm) O2
O2 for
LPG (mm/min) O2 for cutting preheating LPG

0 5~10 7.0 0.20 750~680 1,100 1,180 310

1 10~15 7.0 0.20 680~600 2,500 1,180 310
2 15~30 7.0 0.25 600~500 3,800 1,370 360
3 30~40 7.0 0.25 500~450 5,400 1,370 360
4 40~50 7.0 0.30 450~400 7,300 1,860 490
5 50~100 7.0 0.30 400~260 10,000 1,860 490
6 100~150 7.0 0.30 260~180 14,000 3,040 800
7 150~250 7.0 0.40 180~100 22,000 3,720 980
8 250~300 7.0 0.40 100~70 35,000 3,720 980

LNG (Divergent Type) TIP TYPE : 107 - D7

Pressure(kg/cm²) cutting Flux (L/H)

Tip Thickness
speed
NO. (mm) O2
O2 for
LNG (mm/min) O2 for cutting preheating LNG

0 5~10 7.0 0.10 750~650 1,100 1,350 800

1 10~15 7.0 0.15 680~600 2,500 1,500 900
2 15~30 7.0 0.15 600~500 3,800 1,500 900
3 30~40 7.0 0.15 500~450 5,400 1,700 1,000
4 40~50 7.0 0.15 450~400 7,300 1,700 1,000
5 50~100 7.0 0.15 400~275 10,000 1,850 1,100
6 100~150 7.0 0.20 275~200 14,000 2,200 1,300
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 5 OF 14

3-1-2. The Capacity of the standard tip

1) cutting condition for mild steel (ref. The fourth of welding series book)

Iron plate thickness The diameter of tip cutting speed flux(L/min)

(mm) (mm) (mm/sec) O2 for cutting Acetylene LNG
3.2 0.51~1.02 6.8~13.5 7.1~21.2 1.4~7.3 4.3~11.8
6.4 0.76~1.52 6.8~11.0 14.2~26.0 1.4~4.3 4.3~11.8
9.5 0.76~1.52 6.4~10.1 18.9~33.0 2.8~5.7 4.7~11.8
13 1.02~1.52 5.1~9.7 26.0~40.0 2.8~5.7 7.1~14.2
19 1.14~1.52 5.1~8.9 47.2~70.9 3.3~6.6 7.1~14.2
25 1.14~1.52 3.8~7.6 51.9~75.5 3.3~6.6 8.5~16.5
38 1.52~2.03 2.5~5.9 51.9~82.6 3.8~7.6 8.5~16.5
51 1.52~2.03 2.5~5.5 61.4~89.6 3.8~7.6 9.4~18.9
76 1.65~2.16 1.7~4.7 89.6~142 4.3~9.4 9.4~18.9
102 2.03~2.29 1.7~4.2 113~170 4.3~9.4 9.4~18.9
127 2.03~2.41 1.7~3.4 127~170 4.7~11.6 11.8~23.6
152 2.41~2.67 1.3~3.0 123~236 4.7~11.6 11.8~23.6
203 2.41~2.79 1.3~2.1 271~293 7.1~14.2 14.2~26.0
254 2.41~2.79 0.85~1.7 274~331 7.1~16.5 16.5~33.0
305 2.79~3.30 0.85~1.7 340~401 9.4~18.9 21.2~44.9

2) tip diameter (mm)

절단화구 NO. 00 0 1 2 3 4 5 6 7 8

STRAIGHT TYPE 0.8 1 1.2 1.4 1.6 1.9 2.3 2.7 3 3.4
DIVERGENT TYPE - 0.6 0.9 1.1 1.3 1.5 1.8 2.1 2.6 3.2
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 6 OF 14

3) The Capacity of the standard tip

TIP Tip diameter (mm) KERF (mm) PLATE THICKNESS

0 1.0 1.70 5 ~ 10

1 1.2 2.04 10 ~ 15
2 1.4 2.38 15 ~ 30
3 1.6 2.72 30 ~ 40
4 1.8 3.06 40 ~ 50
* Because automatic cutting program control the Kerf width automatically, we don't mention
it.

3-2. Method of Pre-heating

3-2-1. Pre-heating flame
1) Because a bit much hot flame generates surface-melting and slugs at the reverse-

side, it is very important to keep the fire in neutral type and follow the lead of '3-2-2.

Pre-heating time'.But if you want to grow up the cutting speed, you can employ

the oxygen rich frame sometimes.

2) If the Pre-heating flame is too weak, the cutting is failed and sometimes

a backfire happens.
3-2-2. Pre-heating time (SEC)

thickness of plate cutting gas

Tip NO.
(mm) O 2 - Acetylene O 2 - LPG O 2 - LNG

0 5~10 8 12 15

1 10~15 12 18 20

2 15~30 20 24 40

3 30~40 30 36 50

4 40~50 40 50 70
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 7 OF 14

3-2-3. Adjusting the frame <neutral frame> <oxygen rich

<fuel rich frame>
[figure]

The Frame has a sharp

point and the color is

2~3mm
very bright and white

The frame is white and

blue colored long tail type The Frame has a sharp
point and the light color.

2~3m
[picture]

* Keep the neutral or the oxygen rich state(for

speed up)
3-3. Automatic gas cutting

3-3-1. A working process

1) Confirm the condition of the panel and the other electronic and check

the leakage of the gas. And then set the buttons at their post.

2) Turn on NC CUTTING MACHINE S/W, PANEL S/W, OPERATING PANEL S/W

in the order named.

3) Choosing and loading the data file(cutting file) after Inserting the diskette in the driver
at machine.
4) Setting the steel plate on the cutting table.
* attention : A. Don't set the other plate during working.
B. Optimize setting plates by considering the number of torch and
sizes of plates.
5) Open the UTILITY VALVE and the other valves in the right upper side.
6) Choose the tip suitable for the CUTTING PLAN and plate thickness,
adjust the distance between tip and torch.
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 8 OF 14

7) The torch keeps 15~20mm from the steel plate.

Torch
15~20

steel plate

8) Open valves of each torch / operate the FUEL SWITCH and IGNITION BUTTON.
After igniting, adjust the size and colors of preheating frame by the REGULATOR.
* OVERRIDE : After choosing the tip (considering capacity of tip), the ratio of
the cutting speed has to reach 80% of target speed at least. If the plate
was oxidized seriously, the operator control the cutting speed.

(down the speed in generally)

9) At last, check the condition of the machine and solve any problems.

10) Handle panels and start cutting

11) While automatic cutting, mark the value of gap(plate-torch) on the other plate ready
to cut.
12) Move M/C to the other plate after cutting finished.
13) Recycle 6)~12) process.
14) As the machine cuts the other plate, transport the pieces of products to next-step.
15) After all processes are finished, turn off the power switch and close valves.

3-4. SEMI AUTOMATIC GAS CUTTING

3-4-1. A working process
1) Match the operating number with the size/thickness.
2) Check size, material and thickness of the steel plate before cutting.
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 9 OF 14

- the Tolerance of steel plate thickness (KS D 3500)

unit : mm

width
폭 under
1600미만 1600~2000 200~2500 2500~3150 3150~4000 4000~5000
thickness
두 께

~1.25 ±0.16 - - - - -

1.25~1.60 ±0.18 - - - - -

1.60~2.00 ±0.19 ±0.23 - - - -

2.00~2.50 ±0.20 ±0.25 - - - -

2.50~3.15 ±0.22 ±0.29 ±0.29 - - -

3.15~4.00 ±0.24 ±0.34 ±0.34 - - -

4.00~5.00 ±0.45 ±0.55 ±0.55 ±0.65 - -

5.00~6.30 ±0.50 ±0.60 ±0.60 ±0.75 ±0.75 -

6.30~10.0 ±0.55 ±0.65 ±0.65 ±0.80 ±0.80 ±0.90

10.0~16.0 ±0.55 ±0.65 ±0.65 ±0.80 ±0.80 ±1.00

16.0~25.0 ±0.65 ±0.75 ±0.75 ±0.95 ±0.95 ±1.10

25.0~40.0 ±0.70 ±0.80 ±0.80 ±1.00 ±1.00 ±1.20

40.0~63.0 ±0.80 ±0.95 ±0.95 ±1.10 ±1.10 ±1.30

63.0~100 ±0.90 ±1.10 ±1.10 ±1.30 ±1.30 ±1.50

100~160 ±1.30 ±1.50 ±1.50 ±1.70 ±1.70 ±1.90

160~200 ±1.60 ±1.80 ±1.80 ±1.90 ±1.90 ±2.10

200~250 ±1.80 ±1.90 ±1.90 ±2.00 ±2.00 ±2.20

250~300 ±2.00 ±2.10 ±2.10 ±2.20 ±2.20 ±2.50

300~350 ±2.10 ±2.30 ±2.30 ±2.40 ±2.40 ±2.80

 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 10 OF 14

3) Check the gap of rail and clean the rail.

4) Fix a proper tip to the torch, at this time you refer to the standard of tip.

5) Set the rail parallel with the cutting line to make a tip go through the cutting line.

Make the distance between a tip and plate 15~20mm.

6) Set the cutting speed and the pressure of gas. Then ignite a torch and adjust
the frame on neutral type.
7) While the electromotor idle after switch-on, move the torch near the cutting-start point,
preheat the plate.
8) Heat a plate just until the surface melts and then open the valve of O 2 gas for cutting.
As soon as the gas is emitted, turn on the S/W switch and make the cutting-
machine go ahead.
9) Turn off the power switch and valves of gas. Clean the workshop finally.

3-5. MANUAL GAS CUTTING

3-5-1. A working process

1) Grasp a torch lightly by the right hand and hold the O 2 valve to easily control

the volume of gas by the left hand.

2) Put your spread right forefinger on the valve of fuel gas.

- This pose can help to deal with the backfire or other emergency situation to close
the valve.
3) Aim the tip to the plate like the picture, make
the end of white fire and plate 1.5~2.5mm.
* the distance between the end of white fire and plate : 1.5mm~2.5mm (In case of the
Straight Type Tip and O2-Acetylene gas) If the tip or gas change, the distance
can change too.
4) Make the preheating-frame neutral. Preheat the point at a plate.
As soon as the plate melt, open O2 valve and move the torch to cut the plate.
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 11 OF 14

5) It is the most important point to keep up the distance between Tip and plate and continue

fixed cutting speed.

TORCH 1.5~2.5mm

steel plate

3-6. cutting surface

3-6-1. the Standard of cutting surface (KS B 0428('2005), WES : the Standard of the Japan
welding engineering society)

NO Defect type of defect test rule remark

Rework by
SLAG
1  non-permission grinder
BURR
(elimination)

class
등급 P (mm)
1 0.4
2 0.8 Rework by
2 flatness
3 1.5 grinder
4 4
class
비고 second
2등급 적용 class

Refer to the sample of  Cutting surface(by manual) : 300S

cutting standard Rework by
3 toughness
(make the standard  Cutting surface(by machine): 150S grinder
sample)
Refer to the sample of class
등급 shape
형상
cutting standard
(application the second 1 Rework by grinder
non- class)
(After rework, no
4 melting
2 curved surface
particle
has to exit.)
3
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 12 OF 14

(continue)

NO Defect type of defect test rule remark

Rework by grinder
Angle thickness A class B class
ex) 2 degree
(deviation 6~50 2 degree 5 degree th ic kn e ss gradie n t
5 from 51~100 1.5degree 4 degree 12t 0.6mm
perpendicul REMARK Apply the A class 14t 0.7mm
arities) 16t 0.8mm
Size must be same after reworking 19t 1.0mm

class A class B class Rework by grinder

length about 1000mm (when it is hard
straight ~3150 0.4 1 to rework, scrap
6
ratio 3150~6000 0.5 1.2 the plate.)
6000~10000 0.6 1.5 ※ the value of a
about 1000mm
REMARK apply B

thickness 6~50 51~100

b width A B A B Rework by grinder
ratio
~315 1 2 1.5 3 (when it is hard
(deviation
to rework, scrap
7 from 316~1000 1.5 3 2 4
the plate.)
perpendicul 1001~2000 2 4 2.5 5 ※ definition :
arities) b 2001~3150 2.5 5 3 6 ratio of b to a
a  Apply B class
NOTCH
(start Rework by grinder
8 point/end
 non-permission
(elimination)
point)
 non-permission
Rework by
9 chipping (especially external appearance
grinder
problem, Trouble to post step)

When cutting
10 Lamination  non-permission(product : disuse)
causes this.

(refer.) The allowable roughness standard for cutting plane (unit : mm)

roughness range the bound of application remark

125S less 0.125 as a rule, thickness is under 12mm

160S less 0.16 as a rule, thickness is under 28mm If the next treatment is
MCT, roughness is
200S less 0.20 as a rule, thickness is 32~50mm permitted to 500S.
500S less 0.50 as a rule, thickness is above 28mm
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 13 OF 14

3-6-2. No-dimensional tolerance of Gas cutting

1) No-dimensional tolerance of gas cutting

length(mm)
~400 401~1600 1601~4000 4001~
thickness(mm)

~19t ±1.5 ±2.0 ±2.5 ±3.5

19t ~ 33.5t ±2.0 ±2.5 ±3.0 ±4.0
33.5t ~ 67t ±2.5 ±3.0 ±3.5 ±4.5
67T ~ ±3.0 ±3.5 ±4.5 ±5.0

Comment) This standard applies to usual gas cutting goods except those of Boom, Arm.

2) No-dimensional tolerance of gas cutting part of BOOM and ARM (unit : mm)

SECTIO N Width Length REMARK

This value has to be applied regardless of length or

Tolerance Value 0 ~ -2.0 1.0 ~ -2.0
thickness of steel plate.

3) No-dimensional tolerance of usual bending (unit : mm)

Measurement 1 ~100 100 ~ 200 200 ~ 400 400 ~ 800 800 ~ 1600 1600 ~
Tolerance ±1.0 ±1.0 ±2.0 ±2.0 ±3.0 ±3.0

3-6-3. No-dimensional tolerance of beveling

beveling angle

root face

1) ROOT FACE (unit : mm)

Root Face 0 0~4.0 4~10
REMARK
tolerance tolerance deviation tolerance deviation tolerance deviation
Apply to machining
Thickness of Root Face +2.0~0 2.0 +1.0~-1.5 2.0 ±2.0 3.0 and automatic beveling

주) 1. deviation : A gap from Max value to Min value in all area. It means the degree of the uniformity.
2. If there are two stairs of beveling, this rule applies to each root-face.
 HDES-P1107
Standard Operating Procedure Of Gas Cutting Statute: 1982. 10.30
Equipment Method Revision(No.): 2007.12.10(4)
Page : 14 OF 14

2) Beveling ANGLE

The angle of beveling

~ 30° 30° ~ 45° 45° ~ REMARK
Thickness

~ 19T +2.0° ~ 0° +3.0° ~ -1.0° +3.0°~ -2.0°

19T ~ 32T +2.0° ~ 0° +3.0° ~ -2.0° +4.0° ~ -2.0°
32T ~ +3.0° ~ 0° +4.0° ~ -2.0° +4.0° ~ -3.0°

3-6-4. The Background to cause defective goods

1) Cutting speed is not fixed or too slow/fast.
2) Pressure of oxygen is not suitable.
3) Use the wrong cutting-tip or tip has defects.
4) While cutting the piece of steel plate, the distance between plate and tip changes.

3-7. Self-test of cutting process

3-7-1. Operator has to check for the proto-product by the sheet of the Self-test of cutting process.
3-7-2. All of products which are made by manual or semi-automatic cutting have to be checked.
In case of automatic cutting, examine the sample. Then record and store the sheets of self-test.
3-7-3. After accounting for the factor and mending to the senior, solve the problem
3-7-4. In case of need to welding repair products for incorrect cutting, discuss
what to do with the relevant departments(Q/C, Manufacturing Engineering Team, etc)

3-8. Safety-inspection & Checking the point after work

3-8-1. A person who complete the course of GAS Welding Class has to look after the process.
3-8-2. Check the leakage of the gas on the valves.
3-8-3. Inflammables and explosives strictly prohibited to be brought in.
3-8-4. Wear protective glasses to block off the intensive ultraviolet rays.
3-8-5. Wear the protective clothing and gloves.
3-8-6. Check valves, switches and fire-extinguisher can operate in emergency.
3-8-7. Pattern out the cutting goods for the safety.
3-8-8. Turn off switches and valves of gas tank after completing the cutting work.

- Additional Rule -

1. This standard is put in operation by January First, 2008.