Q-15427 Product Information

PRODUCT
INFORMATION
GAS WELDING DISTRIBUTION SYSTEM
VARD PROMAR
VESSEL NAME/HULL NO.: EP09
PROJECT NO.: Q-15427
REVISION NO.: 00
DATE: 14.04.2016
CHAPTER DESCRIPTION PAGES
• GENERAL INFORMATION 5 – 36
1 • SAFETY IN WELDING 37 – 58
• MAINTENANCE INSTRUCTION 61 – 62
2 • OPERATING INSTRUCTIONS 63 – 66
3 • TECHNICAL DESCRIPTIONS 69 – 96
4 • INSTALATION PROCEDURES 99 – 124
• MATERIAL SPECIFICATION 127 – 128

5 • DATA SHEET 129 – 186
6 • CERTIFICATES 189 – 210

CHAPTER 1
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CHAPTER 1
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Type of document Document No.
GENERAL INFORMATION 61-00-004-1-E

Issued by Date of issue Rev. No. Rev. date Approved by Page
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UNITOR AC & OX WELDING CENTRAL INSTALLATION FOR 6
GAS DISTRIBUTION SYSTEM 61-00-004
CYLS, 2 AC AND 4 OX
SYSTEM DESCRIPTION
This AC and OX gas distribution system consists of all items necessary for the gas central
room, including signs, racks, equipment and brackets to be screwed or welded to the deck and
bulkhead.
Gas cylinders, cylinder trolley, clamps, bushings and outlet station should be ordered
separately in necessary quantities.
The cylinders with cylinder valves, T-valves, closing valves and central regulators shall be
situated in a separated store on or above the upper continuous deck. The cylinders shall be
placed in an erect position. The regulators are secured with safety valves ventilated to open
air.
The outlet station is usually placed in the engine room or in the workshop. On special
purpose ships it may be placed on open deck.
SYSTEM LAYOUT
The system arrangement is built up by means of standard components, all individually

documented.
The system consists of the following main components:
Two acetylene cylinders and four oxygen cylinders are situated in an erect position in a
separated store on or above the upper continuous deck with free access direct to the open
deck. The door to the central store must be marked with a warning sign: "GAS UNDER
PRESSURE". Fastening arrangements for the AC and OX cylinders ARE to be welded to the
bulkhead.
From the cylinders the gas is transported through high pressure hoses to the T-valves. To
eliminate the possibility of incorrectly connecting the equipment, all connections are left-hand
threaded for acetylene and right-hand threaded for oxygen. An exeption to the acetylene
side are the cylinder valves and the closing valve with 3/4" right hand threads.
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CYLS, 2 AC AND 4 OX
To prevent gas from flowing back to the cylinders, non-return valves are fitted to the T-
valves. From the first T-valve the gas is led to a closing valve where the central regulator
are located.
The last T-valve is closed with a blind plug and connecting nut. The central regulators have a
combined closing and pressure regulation knobs. The regulators are fitted with safety
valves ventilated to open air. The end of the ventilation pipes must be located in open air,
and the outlet must be marked with a warning sign: "GAS DANGER. Fire, open lights and
smoking prohibited".
From the low pressure side of the regulators, the AC and OX gas are fed through low
pressure steel pipe coils which are connected to the fixed distribution pipes with unions.
The pipelines are colour-coded. Red pipelines are for acetylene and blue for oxygen.
On the acetylene side, a flashback arrestor is connected between the regulator and the low
pressure steel pipe coil. The arrestor is mounted as an extra safety,device if a flashback
occurs in the distribution pipe and/or because of a fault in the arrestor for acetylene
situated in the outlet station.
Where the pipelines pass through bulkheads or decks they must be led through by approved
bushings. The pipelines are to be fastened to the bulkheads with pipe clamps at intervals not
exceeding 2,5 metres.
The outlet station is to be installed in a protective cabinet at a suitable location which is well
ventilated and where the outlet station is protected from mechanical damage.
The outlet station is fitted with ball valves which should be closed during short interruptions
in work. The ball valves are fitted with filters to prevent particles passing into the outlet
fittings.
Connected to the ball valves are regulators with gauges that can be set the desired working
pressure, and flashback arrestors fitted with joints for welding hoses. Welding hoses are not
included in this system.
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CYLS, 2 AC AND 4 OX
SYSTEM OPERATION
COMMENCEMENT OF WORK
All valves and regulators are shut including the cylinder valves, T-valves and the closing
valves. Also shut the ball valves and the low-pressure regulators in the outlet station. The
regulators are shut when the adjusting knobs are screwed so far out that they run free.
Start the operation by connecting the torch handle with the right blowpipe and hoses,
normally 5 mm in 10 m length, to the outlet station.
Slowly open the cylinder valves, T-valves and the closing valves for acetylene and oxygen.
Set the right working pressure by screwing the adjusting knobs to the right until the low
pressure gauges show a little higher than 0.8 bar for acetylene and 8.0 bar for oxygen. It is not
necessary to touch the adjusting knobs. They can be locked with the lock nut.
Fully open the ball valves for acetylene and oxygen in the outlet station.
Fully open the torch oxygen needle valve and adjust the working pressure by means of the
regulator in the outlet station and then shut the torch oxygen valve.
Fully open the torch acetylene needle valve and adjust the working pressure by means of the
acetylene regulator in the outlet station.
Slightly the torch oxygen needle valve to provide a little extra oxygen to prevent
troublesome soothing when the burner is lit.
Hold the torch so that the nozzle points away from flammable objects. Light the torch, and
adjust the desired flame characteristic by means of the torch oxygen needle valve. The torch
is now ready for use.
TERMINATION OF WORK
The torch is normally extinguished by first closing the torch acetylene needle valve and then
closing the torch oxygen needle valve.
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CYLS, 2 AC AND 4 OX
After finishing the work, release the pressure in the pipelines and hoses by closing the
cylinder valves and empty one hose at a time, keeping the torch needle valve for the other
gas shut. Finally make sure that all torch valves are shut, close the T-valves, closing valves
and the ball valves and the regulators in the outlet station.
For shorter interruptions in the welding, close the outlet station ball valves and empty one
hose at a time, keeping the torch needle valve for the other gas shut.
REGULAR MAINTENANCE
Check the sealing rings at regular intervals for damage, deformation or wear. Replace them
if they are defective. To facilitate changes of torch or cutter tips, the sealing rings and
sealing surfaces in the torch connection head should be lightly smeared with a special
lubricant.
Warning! Oil or grease must never be used as lubricant or in any other place that might
get in contact with oxygen. Use of oil or grease as lubricant may cause fatal
accident.
EMERGENCY OPERATION
In the event of sustained backfire (which is recognised by a whistling or hissing sound) first
close the touch oxygen needle valve as quickly as possible, then the acetylene valve. Then
follow normal termination of work procedure and reset the flashback arrestors.
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UNITOR AC & OX WELDING
GAS DISTRIBUTION SYSTEM CENTRAL INSTALLATION 61-00-990
GENERAL
UNITOR AC AND OX GAS DISTRIBUTION SYSTEM is designed and developed

for safe storage, distribution and use of acetylene and oxygen onboard ships. This
central installation fulfils in every aspects the safety requirements set up by marine
authorities, and it is type approved in Norway, Sweden, Denmark and Germany.
The principle for the system is that the high pressure gas cylinders are located and
securely fastened in an erect position, in a storage room in the ships superstructure,
with free access to the open deck. The gas pressure are reduced in regulators and
carried at low pressures through fixed pipe lines to the point of usage.
An outlet station at the point of usage, whether that be in the workshop or the engine
room or the locations, contains all necessary components for gas pressure adjustment
and safety.
MAIN FEATURES
The central installations for acetylene and oxygen have these features:
 Safety
 Less physical damages to cylinders because of less dangerous internal transport.
 Easy removal of cylinders in case of fire.
 Location of cylinders known to everyone on board.
 Possible leakages from a cylinder or from the high pressure equipment will be ventilated
to open air.
 Effectiveness
 Fewer interruptions during large-scale operations due to change cylinders.
 Sufficient gas flow even when working with large-sized blowpipes for heating purposes.
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 Work can be performed in different areas without having to move cylinders (depending
on number of outlet stations installed).
 Space is released for other purposes.
 Economy
 Fewer cylinders required, as volume of gas can be easily checked at any time.
 Acetylene gas can be drawn from two or more cylinders simultaneously, which means
less gas drawn per unit per cylinder.
 Maintenance costs are reduced, as most of the equipment is bolted to the bulkhead.
 Expenses concerning internal transport reduced.
SAFETY PRECAUTIONS
All industrial gases have properties which may cause injury or death if proper
precautions are not followed. It should never be assumed that all possible hazards or
acceptable safety measures have been complied without the exercise of common sense
and prudence in the handling of any industrial product.
In most instances hazards are created because of improper application or the misuse of
the gas or its containers. Another major cause of accidents in the use of industrial gases
is improper installation and failure to provide adequate and working regulators,
valves, piping and tubing.
Always remember:
1. Never, under any circumstances allow oil, grease or dirt to come into contact with parts for
oxygen as this can result in spontaneous self ignition.
Hands, tools, work clothes and all other material must be thoroughly cleaned and free from
oil and grease before work begins. The same degree of cleanliness also applies to
equipment in operation or in storage.
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2. Acetylene makes explosive combinations in contact with silver and copper. Only metal
alloys with maximum 63% Cu is allowed on equipment.
3. Never disconnect any safety devices which are parts of this central. They are there to save
your life.
4. Always follow exactly the operation instructions of the gas equipment manufactures.
5. It is the responsibility of the user to be certain that all employees are familiar with the specific
properties and proper handling techniques applicable to each gas used.
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GAS DISTRIBUTION SYSTEM 40 LTR ACETYLENE CYLINDER 61-01-001
DESCRIPTION
The 40 ltr acetylene cylinders branded with UNITOR which are used in a central installation
are owned, inspected and maintained by WSS. These cylinders are approved by a Notified
Body (PI-mark) and the US DOT, for use on board ship. The cylinders are loaned by our
customers and can be returned to WSS or other authorised contractor when they are
empty.
LAYOUT
In UNITOR AC and OX gas distribution systems, acetylene cylinders are used one alone
or in sets of two which are connected with an expansion set for parallel operation. The
acetylene cylinders are filled with a porous mass, which is saturated with acetone.
An acetylene cylinder with a volume of 40 litres normally contains 16 litres of acetone.

The acetylene gas dissolves in the acetone. The content of acetone in the cylinders is
checked when the cylinders are filled with gas. At a pressure of 15 bar and a temperature
of 15°C the cylinder will contain approx.. 6.000 n/1 of dissolved acetylene.
OPERATION
Acetylene cylinders must be stored and used in upright position. Only open the hand wheel on
the cylinder valve by hand. Ensure the valves are closed when the cylinders are not in use.
Wrenches or other tools must never be used
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GAS DISTRIBUTION SYSTEM 40 LTR OXYGEN CYLINDER 61-01-002
DESCRIPTION
The 40 ltr oxygen cylinders branded with UNITOR which are used in a central installation
are owned, inspected and maintained by WSS. These cylinders are approved by a Notified
Body (PI-marking) and the US DOT, for use on board ship. The cylinders are loaned by
our customers and can be returned to WSS or other authorised contractor when they are
empty.
LAYOUT
In UNITOR AC and OX gas distribution systems, oxygen cylinders are used alone or in
sets of two which are connected with an expansion set for parallel operation.
OPERATION
Only open the hand wheel on the cylinder valve by hand. Ensure the valves are closed when
the cylinders are not in use.
Wrenches or other tools must never be used.
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UNITOR AC & OX WELDING HANDLING AND USE OF GAS
CYLINDERS
TRANSPORT
 Cylinders should be handled only by personnel who have been trained in proper
handling of gas cylinders.
 Always make sure that the cylinder cap that protects the cylinder valve is in place
and screwed down before moving the cylinder.
 Use racks, baskets or cylinder trolleys equipped with proper lifting lugs to lift gas
cylinders. Never use slings, chains, cargo nets or magnets.
 Gas cylinders must never be hoisted or dragged by the cylinder cap or the top valve.
 Do not subject the cylinders to unnecessary impacts or jolts during transport. Do not
allow the cylinders to fall or knock against each other.
 During transport, gas cylinders must always be handled as if they were full.
Empty acetylene cylinders contain a certain quantity of acetylene dissolved in the
acetone at atmospheric pressure.
HANDLING, USE AND MAINTENANCE
 Each cylinder must bear the label and marking required for the compressed gas
contained. The markings stamped into the cylinder collars shall not be removed or
changed. Content identification must always be present.
 Cylinder not bearing the legible label which is identifying the content, shall not
be used and shall be returned to UNITOR.
 If the cylinder valve cannot be opened by hand alone, put the cylinder aside and
inform the supplier. Never use wrenches or other tools to try to force open the
cylinder valves.
 Make sure that the threads on the cylinder valve outlet and the threads on the
equipment to be connected corresponds. Never force a connection that does not fit.
Make sure that seals are in good condition and of the correct type.
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UNITOR AC & OX WELDING HANDLING AND USE OF GAS
CYLINDERS
 Never use gas cylinders as rollers or props for other cargo, or for any purpose
whatever other to contain a specific gas.
 The information that is cast or stamped on the cylinder collars must not be
altered or removed.
 Avoid as far as possible to expose gas cylinders to moisture and salt water.
Never expose cylinders to chemicals or gasses.
 Never try to repair or modify any part of a cylinder.
 Take care that gas cylinders are not used or stored where there is a risk that they
may become part of an electric circuit. Never touch a cylinder with a electric welding
electrode.
 Never empty a gas cylinder complete. Return it with a positive pressure of 1

bar, with closed cylinder valve and top cap.
 Never try to fill cylinders or transfer gas from one cylinder to another on your
own. This may cause serious accidents.
 The cylinders and their appurtenances shall be marked only by UNITOR or

UNITORS representative.
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GAS DISTRIBUTION SYSTEM ACETYLENE GAS 61-99-991
PROPERTIES
Acetylene (C2H2) is a colourless reactive and highly inflammable gas, slightly lighter than air.
It has a typical garlic-like sweet smell and is non-toxic, but has an anaesthetic effect when
inhaled.
Acetylene alone bums in air with a very hot, bright and sooty flame. Mixed with air or
oxygen in the right proportion, acetylene gives a concentrated, soot-free flame. When mixed
with oxygen combustion is more intense than in air, and because of the acetylene's high carbon
content (97 % by weight) its maximum flame temperature is about 3100°C.
Because of its high temperature, thermal value and speed of combustion (11,6 m/s), acetylene
is the most suitable gasflame both for welding and for cutting.
Acetylene is produced industrially by the reaction of water with carbide in acetylene

generators. The gas is dissolved in acetone and stored in steel cylinders filled with a porous
mass. This mode of storage hinders decomposition and makes the cylinders safe against
impacts and transport handling.
TECHNICAL DATA
Chemical formula: C2 H2
Relative molecule mass: 26.04
Tripelpoint:
temperature: 192.3 K (-80.85°C)
pressure: 1.267 bar (0.308 ato)
heat of melting: 96.46 kJ/kg
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GAS DISTRIBUTION SYSTEM ACETYLENE GAS 61-99-991
Boiling point
1.013 bar: 189.12 K (-84.0°C)
heat of evaporation: 686 kJ/kg
density: 419.4 kg/m³
Critical point
temperature: 303.1 K (35.94°C)
pressure: 62.52 bar (62.75 ato)
density: 419.4 kg/m³
Highest combustion value: 503.70 kJ/kg
Spontaneous combustion temp.: 608 K (335°C)
Combustion speed in O2 : 13.5 m/sec.
Explosion limits: in air: 1.5-82 vol.%
in O2 : 1-100 vol.%
SAFETY RULES
Acetylene cylinders must be stored and used in an erect position. If the cylinders are used when
lying on their sides or sloping, some of the acetone will run out of the cylinder.
Acetylene makes explosive combinations (acetylides) with silver and copper. Therefore only
metal alloys with max. 63% Cu are allowed on equipment.
At an increase pressure acetylene can spontaneously fall apart in carbon and hydrogen
(dissociation), and heat can be released. This can lead to heavy explosions. Therefore
acetylene under pressure can only be stored safe in steel cylinder filled completely with
porous mass and acetone.
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GAS DISTRIBUTION SYSTEM OXYGEN GAS 61-99-992
PROPERTIES
Oxygen (02) is a colourless gas, without smell or taste, slightly heavier than air. The earth's
atmosphere at sea level consists of 20.9 vol.% oxygen. Oxygen is not poisonous and
passable water soluble.
Oxygen itself will not burn, but is the gas that maintain all human and animal life and
sustain all combustion in the normal sense of the word. Combustion- and oxidation-
processes pass much more rapidly in high oxygen concentration than in air and with
increasing pressure.
Even materials that are not normally combustible, or difficult to ignite, can catch fire
spontaneously or be set alight in pure oxygen.
Oxygen is produced industrially by rectification (distillation) of liquid air, from which the
oxygen boils off at minus 183°C, and can thus be separated from the other gasses, for
compression in steel cylinders.
TECHNICAL DATA
Chemical formula: O2
Relative molecule mass: 32
Tripelpoint
pressure:
heat of melting: 13.8kJ/kg
Boiling point
1.013 bar: 90.19 K (183.0°C)
heat of evaporation: 212.5 kJ/kg
density: 1141 kg/m3
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GAS DISTRIBUTION SYSTEM OXYGEN GAS 61-99-992
Critical point
pressure: 49.9 bar
density: 430 kg/m3
SAFETY RULES
Oxygen can lead to explosive ignition in contact with ordinary oil, grease or other
organic substances. Equipment or fittings for oxygen must never come into contact
with oil or grease. Only special lubricants may be used for oxygen equipment.
Oxygen that leaks out into the air increases the danger of combustible materials
igniting, or of body hair, clothes etc. catching fire. This can occur even with small
increases in the oxygen content of the air, and can cause serious burns.
For this reason a welder must never wear working clothes or use equipment that is
contaminated with oil or grease. If clothing has been accidentally exposed to an
increase in oxygen content, it may take a long time to get rid of the excess oxygen,
often several hours.
Oxygen instead of air must never be used to blow clean different equipment or to start
a diesel engine.
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ACETYLENE DISSOLVED
Revision: 10/7/2014
SAFETY DATA SHEET
SECTION 1 Identification of the substance/mixture and of the

company/undertaking
1.1 Product identifier

- Product Name: ACETYLENE DISSOLVED
- Product Part Number: ACETYLENE DISSOLVED
1.2 Relevant identified uses of the substance or mixture and uses advised against
- Use of the substance/mixture:
- Gas for welding and cutting
1.3 Details of the supplier of the safety data sheet
- Name of Supplier: Wilhelmsen Ships Service AS
- Address of Supplier: Willem Barentszstraat 50, 3165AB Rotterdam, The
- Netherlands
- Telephone: +31 4877 777 Fax: +31 4877 888
-
- Head office: Wilhelmsen Ships Service AS
- Strandveien 20, N1324 Lysaker
- Norway, Tel: (47) 6349 440 35
-
- Other suppliers SEE SECTION 16!!!
- For quotations contact your local Customer Services
-
- Responsible Person: Product HSE Manager,
- Email: Email: WSS.GLOBAL.SDSINFO@wilhelmsen.com
- Telephone: Tel.: +31 10 4877775
1.4 Emergency telephone number
- ****ONLY TO BE USED IN CASE OF AN INCIDENT****
-
- International 24hrs Emergency NCEC:+ 44 1865 407333
- American Chemistry Council 24hrs +1 703 527 3887
- American 24hrs Emergency CHEMTREC (800) 424 9300
- Greece: Poisoning emergency center, +30 210 7793777
- Norway: Poison information centre, +47 22591300
- Sweden: Poison information centre, +46 08 33 12 31
- China NRCC 24hrs emergency telephone number: +86-0532-8388 9090
- Wilhelmsen Ships Service, Melbourne, AUSTRALIA Emergency 24hrs: +61 3 9630 0998
SECTION 2 Hazards identification
2.1 Classification of the substance or mixture

- Counsil Directive 1999/45/EEC Classification, packing and labelling of dangerous
preparations.
- Dangerous Substances Directive (67/548/EEC). Classification, packaging and labelling
of dangerous substances
- Symbols: F+
- Heating may cause an explosion (R5)
- Explosive with or without contact with air (R6)
- Extremely Flammable (R12)
-
Datasheet Number C2H2-r - v2.0.0 1

Prometheus version 1.4.3.0
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ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 2 Hazards identification (....)
- Regulations 1272/2008/EEC. Classification, labeling and packing of dangerous
substances and preparations
- Symbols: GHS04, GHS02
- Flam. Gas 1
- Press. Gas
- Explosive with or without contact with air (EUH006).
2.2 Label elements
- Signal Word: Danger

- Hazard phrases
Extremely flammable gas (H220).
Contains gas under pressure; may explode if heated (H280).
Explosive with or without contact with air (EUH006).
- Precautionary Phrases
Keep away from heat/sparks/open flames/hot surfaces. – No smoking (P210).
Leaking gas fire: Do not extinguish, unless leak can be stopped safely (P377).
Eliminate all ignition sources if safe to do so (P381).
Store in a well-ventilated place (P403).
2.3 Other hazards
- Odour: Strong smell of garlic
- Appearance: Gas dissolved under pressure
- Contact with eyes: May cause irritation, Looking into the welding / brazing flame with
incorrect or insufficient eye protection may cause arc-eye.
- Contact with skin: May cause irritation
- Inhalation: Inhalation of fumes formed during welding and or cutting may be harmful.
SECTION 3 Composition/information on ingredients
3.1 Mixtures
- acetylene; ethyne
Concentration: >98 %
CAS Number: 74-86-2
EC Number: 200-816-9
R/H Phrases: H220, EUH006, R5,R6,R12
Symbols: GHS02,GHS04, F+
Categories: Flam. Gas 1 Press. Gas
SECTION 4 First aid measures
4.1 Description of first aid measures

- Rescuers should take suitable precautions to avoid becoming casualties
themselves
- Rescuers should put on approved respiratory protection before entering the area to
render first aid
- IF INHALED: If breathing is difficult, remove victim to fresh air and keep at rest in a position
comfortable for breathing (P304+P341).

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ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 4 First aid measures (....)
- Apply artificial respiration only if patient is not breathing
- Call a POISON CENTER or doctor/physician (P311).
4.2 Most important symptoms and effects, both acute and delayed
- Aspiration hazard
- In cases of severe exposure, breathing difficulty may develop
- In cases of severe exposure, dizziness, confusion, headache or stupor may develop
- In cases of severe exposure, nausea/vomiting may develop

- In cases of severe exposure, respiratory failure may develop
- In cases of severe exposure, unconsciousness may develop
4.3 Indication of any immediate medical attention and special treatment needed
- No information available
SECTION 5 Fire-fighting measures
5.1 Extinguishing media

- Leaking gas fire: Do not extinguish, unless leak can be stopped safely (P377).
5.2 Special hazards arising from the substance or mixture
- Inform Fire Brigade of potential danger of exploding and rocketing cylinders
- Pressurized container
5.3 Advice for firefighters
- In case of fire: Evacuate area. Fight fire remotely due to the risk of explosion
(P370+P380+P375).
- Leaking gas fire: Do not extinguish, unless leak can be stopped safely (P377).
- Vapours are heavier than air and may travel considerable distances to a source of ignition
and flashback
- Keep container(s) exposed to fire cool, by spraying with water
SECTION 6 Accidental release measures
6.1 Personal precautions, protective equipment and emergency procedures

- Shut off all ignition sources
- Do not smoke
- May form explosive vapour/air mixtures
- Evacuate the area
- Shut off source of leak if safe to do so
- In confined spaces, sewers, etc., the vapours may collect to form explosive
mixtures with air
6.2 Environmental Precautions
- No special precautions are required for this product
6.3 Methods and material for containment and cleaning up
- Ventilate area
6.4 Reference to other sections
- None
SECTION 7 Handling and storage
7.1 Precautions for safe handling

- Use proper hoisting equipment

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ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 7 Handling and storage (....)
- See information supplied by manufacturer
- (Unitor welding handbook)
- Keep away from heat/sparks/open flames/hot surfaces. – No smoking (P210).
- Do not subject to grinding/shock/ (P250)
- Use only outdoors or in a well-ventilated area (P271).
7.2 Conditions for safe storage, including any incompatibilities
- Keep in a cool, dry, well ventilated place
- Pressurised container: protect from sunlight and do not expose to temperatures
exceeding 50 deg C
- Keep away from open flames, hot surfaces and sources of ignition.
7.3 Specific end use(s)
- Contact supplier for further information
SECTION 8 Exposure controls/personal protection
8.1 Control parameters

- TLV (TWA) 5 mg/m3 (Welding fumes)
8.2 Exposure controls
- No special requirements
8.3 Occupational exposure controls
- In case of insufficient ventilation, wear suitable positive pressure respiratory

protection equipment
- Wear safety boots when handling cylinders.
- Wear suitable filter lenses when welding / cutting.
- Wear leather gloves, boots and apron
SECTION 9 Physical and chemical properties
9.1 Information on basic physical and chemical properties

- Odour: Strong smell of garlic
- Appearance: Gas dissolved under pressure
- pH - not applicable
- Boiling point - 84 °C to 760 °C
- Vapour density (air = 1) 0.9
- Freezing point -84 °C to 760 °C
- Melting point - 81 °C to 760 °C
- Water solubility 1.2 g/l
- Density
- Auto-ignition point 305 deg C at 760 mm Hg
- Lower explosive limit 2.2 % (in air)
- Upper explosive limit >85 % (in air)
9.2 Other information
- No information available
SECTION 10 Stability and reactivity
10.1 Reactivity

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ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 10 Stability and reactivity (....)
- This article is considered stable under normal conditions
10.2 Chemical stability
- Sensitive to shock
10.3 Possibility of hazardous reactions
- May form explosive dust/air mixtures
10.4 Conditions to avoid
- Keep away from naked flames, incandescent or hot surfaces
- Keep away from heat and sources of ignition
- Keep away from static electricity
10.5 Incompatible materials
- Incompatible with silver, mercury, copper and their alloys containing more than 67%
copper.
10.6 Hazardous Decomposition Products
- No hazardous decomposition products known
SECTION 11 Toxicological information
11.1 Information on toxicological effects

- Non-toxic
- Asphyxiant
11.2 Contact with eyes
- May cause irritation
11.3 Contact with skin
11.4 Ingestion
- Not regarded as a potential route of exposure.
11.5 Inhalation
- Inhalation of fumes formed during welding and or cutting may be harmful.
- In cases of severe exposure, breathing difficulty may develop
- Asphyxiant
SECTION 12 Ecological information
12.1 Toxicity
- On available data, substance is not harmful to aquatic life
12.2 Persistence and degradability
- Not applicable
12.3 Bioaccumulation Potential
- Not applicable
12.4 Mobility in soil
- This substance is volatile
12.5 Results of PBT and vPvB assessment
- Not a PBT according to REACH Annex XIII
12.6 Other Adverse Effects
- Presents no hazard to the environment
SECTION 13 Disposal considerations
13.1 Waste treatment methods

WTS Page 25
ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 13 Disposal considerations (....)
13.2 Classification
- Not applicable
SECTION 14 Transport information
14.1 UN
- UN No.: UN1001
- Proper Shipping Name: Acetylene, dissolved
- Hazard Class: 2.1
- Packing Group: N/A
14.2 Environmental hazards
- On available data, substance is not harmful to the environment
14.3 Special precautions for user
- Gas cylinders must be equipped with valve protection caps during transport.
14.4 Transport in bulk according to Annex II of MARPOL 73/78 and the IBC code
- Not applicable
14.5 Road/Rail (ADR/RID)
- ADR UN No.: UN1001
- ADR Hazard Class: 2.1
- ADR Packing Group: N/A
14.6 Sea (IMDG)
- IMDG UN No.: UN1001
- IMDG Hazard Class: 2.1
- IMDG Pack Group.: N/A
- IMDG EmS: F-D, S-U
14.7 Air (ICAO/IATA)
- ICAO UN No.: UN1001
- ICAO Hazard Class: 2.1
- ICAO Packing Group: N/A
14.8 DOT / CFR (US Department of Transportation)
- Identification Number: UN1001
- DOT Proper Shipping Name: Acetylene, dissolved
- DOT Labels: 2.1
- Product RQ (lbs): Not applicable
SECTION 15 Regulatory information
15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture

WTS Page 26
ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 15 Regulatory information (....)
- Regulations 1272/2008/EEC. Classification, labeling and packing of dangerous
substances and preparations
- This Safety Data Sheet has been prepared in accordance with article 31 and annex II
in REACH and Directive 453/2010/EU.
- Dangerous Substances Directive (67/548/EEC). Classification, packaging and labelling
of dangerous substances
- Counsil Directive 1999/45/EEC Classification, packing and labelling of dangerous
preparations.
15.2 Chemical Safety Assessment
- None
SECTION 16 Other information

Text not given with phrase codes where they are used elsewhere in this safety data sheet:-
EUH006: Explosive with or without contact with air. H220: Extremely flammable gas. R12:
Extremely Flammable. R5: Heating may cause an explosion. R6: Explosive with or without contact
with air.
The information provided about the product on this Safety Data Sheet has been compiled from
knowledge of the individual constituents
The data given here only applies when product used for proper application(s). The product is not
sold as suitable for other applications - usage in such may cause risks not mentioned in this sheet.
Do not use for other application(s) without seeking advice from manufacturer
The data given here is based on current knowledge and experience. This Safety Data Sheet
describes the product in terms of safety requirements and does not signify any warranty with
regard to the product's properties
The most up-to-date version of this MSDS can be found on www.wilhelmsen.com/shipsservice
OTHER CONTACT INFORMATION MAJOR CHEMICAL OFFICES
Wilhelmsen Ships Service Level 17, 636 St Kilda Road Melbourne Vic 3004 AUSTRALIA
Tel: +61 3 9630 0900 Emergency 24hrs: +61 3 9630 0998
Wilhelmsen Ships Service INC 210 Edgewater Street US-10305 Staten Island New York United
States Telephone daytime: (+1) 718 815 1310 Fax: (+1) 718 233 3268
Wilhelmsen Ships Service INC 2200 W. Pacific Coast Highway US-90810 Long Beach California,
United States Tel (+1) 562 624 8888 Fax (+1) 562 624 1011
Wilhelmsen Ships Service INC 701 Ashland Ave. Ashland Center Two, Bay 12 US- 19032 Folcroft
Pennsylvania United States Tel (+1) 610 586 7801 Fax (+1) 215 701 0646
Wilhelmsen Ships Service INC. 9400 New Century Drive US-77507 Pasadena Texas United States
Telephone daytime: (+1) 281 867 2000 Fax: (+1) 281 867 2800
Wilhelmsen Ships Service Ltd. Unit 3A NewtonsCourt Crossways DA2 6QL Dartford, Kent United
Kingdom Tel (+44) 1322 282 412 Fax (+44) 1322 284 774
Wilhelmsen Ships Service Ltda Rua Bispo Lacerda nos.61/67 Del Catilho BR 21051120 Rio de
Janeiro Brazil Tel (+55) 21 25 82 8000 Fax (+55) 21 25 82 8001
Wilhelmsen Ships Service (S) Pte Ltd 186 Pandan Loop Singapore 128376 Tel (+65) 6395 4545
Wilhelmsen Ships Service Co., Ltd 12-31 Torihama-cho Kanazawa-ku Yokohama-shi JP-236 0002,
Japan Tel (+81) 45 775 0012 Fax (+81) 45 775 0070
Wilhelmsen Ships Service Hellas SA 100, D. Moutsopoulou & Serifou str GR-185 41 Piraeus Greece
Tel (+ 30) 210 4239100 Fax (+ 30) 210 4212480
Wilhelmsen Ships Service AS U.A.E . Fl 24 Executive Heights, Tecom C Sheikh Zayed Road (East)
Dubai United Arab Emirates Tel (+971) 4 382 3888
Wilhelmsen Ships Service AS, Willem Barentszstraat 50 3165 AB Rotterdam-Albrandswaard,
the Netherlands. Tel (+31) 10 4877 777

WTS Page 27
ACETYLENE DISSOLVED
Revision: 10/7/2014
SECTION 16 Other information (....)

WTS Page 28
OXYGEN
SAFETY DATA SHEET
1 Identification of the substance or preparation and of the company/undertaking
1.1 Product identifier

Product Name:
Datasheet Number: O2-r 1. 0. 0
Head Office:: Wilhelmsen Ships Service AS
Address: Strandveien 20, N1324 Lysaker, Norway, Tel:(+47) 67 58 45 50
1.2 Relevant identified uses of the substance or mixture and uses advised against
Gas for welding and cutting
1.3 Details of the supplier of the safety data sheet
Name of Supplier: Wilhelmsen Ships Service AS
Address of Supplier: Willem Barentszstraat 50
3165AB Rotterdam
The Netherlands
Telephone: +31 10 4877 777
Fax: +31 10 4877 888
Responsible Person: Patrick Rijsdijk, Product HSE Manager, Tel.:+31 6 349 440 35
Email: patrick.rijsdijk@wilhelmsen.com
1.4 Emergency telephone number
-ONLY TO BE USED IN CASE OF AN INCIDENT-
NCEC: +44 1865 407333, CHEMTREC (800) 424 9300
American Chemistry Council +1 703 527 3887,
Greece +30 210 7793777
Australia: +61 3 9630 0998
Giftinformasjonsentralen in Norway Tel.: +47 22591300
2 Hazards identification
2.1 Classification of the substance or mixture

- Regulations 1272/2008/EEC. Classification, labeling and packing of dangerous substances and
preparations
- Press. Gas
- Ox. Gas 1
- May cause or intensify fire; oxidizer.
2.2 Label elements
- Signal Word: Danger

- Symbols: GHS03, GHS04
Hazard phrases
- May cause or intensify fire; oxidizer.
Date of Last Change 01/06/2012 1
WTS Page 29
OXYGEN
2 Hazards identification (....)
- Contains gas under pressure; may explode if heated.
Precautionary Phrases
- Keep/Store away from clothing/.../combustible materials.
- Protect from sunlight. Store in a well-ventilated place.
- In case of fire: Stop leak if safe to do so.
- Keep reduction valves free from grease and oil.
- Do not breathe dust/fume/gas/mist/vapours/spray.
Risk Phrases
- Contact with combustible material may cause fire (R8)
Safety Phrases
- Keep away from combustible material (S17)
2.3 Other hazards
- Odour: Odourless
- Appearance: Compressed gas
- Contact with eyes: May cause irritation, Looking into the welding / brazing flame with incorrect or
insufficient eye protection may cause arc-eye.
- Contact with skin: May cause irritation
- Inhalation: Inhalation of fumes formed during welding and or cutting may be harmful.
3 Composition/information on ingredients
3.1 Mixtures
Chemical Name Concentration CAS Number EC Number R/H Phrases* Symbols

Oxygen >99 % 7782-44-7 231-956-9 R8 O
CLP CLASSIFICATION: H270 GHS03, GHS04
Press Gas. Ox Gas 1
*See Section 16
4 First aid measures
4.1 Description of first aid measures

- IF ON SKIN: Wash with plenty of soap and water.
- Contaminated clothing should be laundered before reuse
-
- IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses, if present and easy to
do. Continue rinsing.
- When in doubt or symptoms persist, seek medical attention
-
- IF INHALED: Remove victim to fresh air and keep at rest in a position comfortable for breathing.
- IF INHALED: If breathing is difficult, remove to fresh air and keep at rest in a position comfortable for
breathing.
- Rescuers should take suitable precautions to avoid becoming casualties themselves
-
WTS Page 30
OXYGEN
4 First aid measures (....)
4.2 Most important symptoms and effects, both acute and delayed
4.3 Indication of immediate medical attention and special treatment needed
5 Fire-fighting measures
5.1 Extinguishing media

- Not flammable. In case of fire use extinguishing media appropriate to surrounding conditions
5.2 Special hazards arising from the substance or mixture
- Pressurized container
- Oxidising
5.3 Advice for firefighters
- Keep container(s) exposed to fire cool, by spraying with water
- Fight fire remotely due to the risk of explosion.
6 Accidental release measures
6.1 Personal precautions, protective equipment and emergency procedures

- Do not smoke
- Avoid contact with combustible material
6.2 Environmental Precautions
- No special precautions are required for this product
6.3 Methods and material for containment and cleaning up
- Ventilate area
6.4 Reference to other sections
- None
7 Handling and storage
7.1 Precautions for safe handling

- Use proper hoisting equipment
- Use only outdoors or in a well-ventilated area.
7.2 Conditions for safe storage, including any incompatibilities
- Keep in a cool, dry, well ventilated place
- Pressurised container: protect from sunlight and do not expose to temperatures exceeding 50 deg C
7.3 Specific end use(s)
WTS Page 31
OXYGEN
8 Exposure controls/personal protection
8.1 Control parameters

- Oxygen
TLV (TWA) 5 mg/m3 (Welding fumes)
8.2 Exposure controls
- No special requirements
Occupational exposure controls
- In poorly ventilated areas or confined spaces, use an airline respirator or self-contained breathing
apparatus
- Avoid oxygen enrichment in confined spaces or in poorly ventilated areas.
- Wear safety boots when handling cylinders.
- Wear suitable filter lenses when welding / cutting.
- Wear leather gloves, boots and apron
Boots Gloves Visor No Smoking
9 Physical and chemical properties
9.1 Information on basic physical and chemical properties

- Odour: Odourless
- Appearance: Compressed gas
- pH - not applicable
- Boiling point - 183 °C at 760 mm /Hg
- Vapour pressure - not applicable
- Vapour density (air = 1) 1.1
- Melting point - 218 °C at 760 mm /Hg
- Water solubility 0.04 g/l
- Not flammable but will support combustion
- Strong oxidising agent, Contact with other material may cause fire
9.2 Other information
10 Stability and reactivity
10.1 Reactivity
10.2 Chemical stability
10.3 Possibility of hazardous reactions
- Reacts violently with combustible material
- Reacts violently with reducing agents
WTS Page 32
OXYGEN
10 Stability and reactivity (....)
10.4 Conditions to avoid

- Avoid contact with combustible material
10.5 Incompatible materials
- Incompatible with combustible material
10.6 Hazardous Decomposition Products
- No hazardous decomposition products known
11 Toxicological information
11.1 Information on toxicological effects

- Non-toxic
Inhalation
Contact with skin
Contact with eyes
Ingestion
- Not regarded as a potential route of exposure.
Carcinogenicity
- No evidence of carcinogenic effects
12 Ecological information
12.1 Toxicity
- On available data, substance is not harmful to aquatic life
12.2 Persistence and degradability
- Not applicable
12.3 Bioaccumulation Potential
- Not applicable
12.4 Mobility in soil
- This substance is volatile
12.5 Results of PBT and vPvB assessment
12.6 Other Adverse Effects
- Presents no hazard to the environment
13 Disposal considerations
13.1 Waste treatment methods

WTS Page 33
OXYGEN
14 Transport information
Non-Flammable Compressed Gas Oxidizing Agent

14.1 UN Number
- UN1072
14.2 UN Proper Shipping Name
- Oxygen, Compressed
14.3 Transport hazard class(es)
- 2.2 (5.1)
14.4 Packing group
- n/a
14.5 Environmental hazards
- On available data, substance is not harmful to the environment
14.6 Special precautions for user
- Gas cylinders must be equipped with valve protection caps during transport.
14.7 Transport in bulk according to Annex II of MARPOL 73/78 and the IBC code
- Not applicable
Other information
Road/Rail (ADR/RID)
Proper Shipping Name: Oxygen, Compressed
ADR UN No.: UN1072 ADR Hazard Class: 2.2
ADR Packing Group: n/a ADR subrisk: 5.1
ADR Flashpoint: n/a
Sea (IMDG)
IMDG UN No.: UN1072 IMDG Hazard Class.: 2.2
IMDG Pack Group.: n/a IMDG EmS: F-C, S-W
IMDG subrisk: 5.1 IMDG Flashpoint: n/a
Air (ICAO/IATA)
ICAO Un No.: UN1072 ICAO Hazard Class.: 2.2
ICAO Packing Group.: n/a ICAO subrisk: 5.1
ICAO Flashpoint: n/a
DOT / CFR (US Department of Transportation)
DOT Proper Shipping Name: Oxygen, Compressed
Hazardous Material: Oxygen
Hazard Class: 2.2 Identification Number: UN1072
Product RQ (lbs): n/a DOT subrisk: 5.1
DOT Flashpoint: n/a
WTS Page 34
OXYGEN
15 Regulatory information
15.1 Safety, health and environmental regulations/legislation specific for the substance or mixture
- This Safety Data Sheet has been prepared in accordance with article 31 and annex II in REACH and
Directive 453/2010/EU.
15.2 Chemical Safety Assessment
NONE
16 Other information
Text of R and S phrase codes used in this safety data sheet:- H270: May cause or intensify fire; oxidizer.; R8:
Contact with combustible material may cause fire.
The information provided about the product on this Safety Data Sheet has been compiled from knowledge of the
individual constituents
The data given here is based on current knowledge and experience. This Safety Data Sheet describes the product in
terms of safety requirements and does not signify any warranty with regard to the product's properties
The data given here only applies when product used for proper application(s). The product is not sold as suitable for
other applications - usage in such may cause risks not mentioned in this sheet. Do not use for other application(s)
without seeking advice from manufacturer
The most up-to-date version of this MSDS can be found on WWW.WILHELMSEN.COM
OTHER CONTACT INFORMATION MAJOR CHEMICAL OFFICES

For addresses of other Wilhelmsen Ships Service offices, please refer to www.wilhelmsen.com/shipsservice
Wilhelmsen Ships Service Level 1, 39 Park Street South Melbourn, Vic 3205 Australian Tel:+61 3 9630 0900
Emergency 24hrs: +61 3 9630 0998
Wilhelmsen Ships Service INC 210 Edgewater Street US-10305 Staten Island New York United States Telephone
daytime: (+1) 718 815 1310 Fax: (+1) 718 233 3268
Wilhelmsen Ships Service INC 2200 W. Pacific Coast Highway US-90810 Long Beach California, United States
Tel (+1) 562 624 8888 Fax (+1) 562 624 1011
Wilhelmsen Ships Service INC 701 Ashland Ave. Ashland Center Two, Bay 12 US- 19032 Folcroft Pennsylvania
Wilhelmsen Ships Service INC 701 Ashland Ave. Ashland Center Two, Bay 12 US- 19032 Folcroft Pennsylvania
Wilhelmsen Ships Service INC. 9400 New Century Drive US-77507 Pasadena Texas United States Telephone
daytime: (+1) 281 867 2000 Fax: (+1) 281 867 2800
Wilhelmsen Ships Service Ltd. Unit 3A NewtonsCourt Crossways DA2 6QL Dartford, Kent United Kingdom Tel
(+44) 1322 282 412 Fax (+44) 1322 284 774
Wilhelmsen Ships Service Ltda Rua Bispo Lacerda nos.61/67 Del Catilho BR 21051120 Rio de Janeiro Brazil Tel
(+55) 21 25 82 8000 Fax (+55) 21 25 82 8001
Wilhelmsen Ships Service (S) Pte Ltd 186 Pandan Loop Singapore 128376 Tel (+65) 6395 4545
Wilhelmsen Ships Service Co., Ltd 12-31 Torihama-cho Kanazawa-ku Yokohama-shi JP-236 0002, Japan Tel
(+81) 45 775 0012 Fax (+81) 45 775 0070
Wilhelmsen Ships Service Hellas SA 100, D. Moutsopoulou & Serifou str GR-185 41 Piraeus Greece Tel (+ 30)
210 4239100 Fax (+ 30) 210 4212480
WTS Page 35
OXYGEN
16 Other information (....)
WMS AS U.A.E. Fl 24 Executive Heights, Tecom C Sheikh Zayed Road (East) Dubai United Arab Emirates Tel
(+971) 4 382 3888
WTS Page 36
SAFETY IN WELDING
Introduction
1.00 Welding and related thermal proc- performed by qualified personnel
esses utilize compressed gas and/or under proper supervision.
electric current to provide a con- In this chapter as well as in other parts
centrated heat source which melts of the handbook, you will find guide-
or burns away steel and other met- lines on safe handling of equipment,
als. Proper safety precautions are how to protect yourself, and safety
required to avoid accidents related precautions that should be observed
to the gas and power supplies, to the when welding and related thermal
sparks, heat, fumes, and visible and processes are used on board a ship.
invisible rays from the heat source.
You will also find extensive informa-
Authorities in most countries have tion on how and where to use filler
laid down regulations and guidelines materials, and some guidelines as to
related to welding and other hot work identifying metals.
processes, their application onboard
ships, the equipment to be used and This handbook, however, cannot be
the protection of the operator. considered to be a complete manual
for each of these areas, dealing in
These regulations must be available detail with all the aspects of the vari-
onboard, and be known and adhered ous items.
to when hot work is to be done.
Additional information
A welded component that fails may
represent a safety hazard to crew, should be sought in other publications
ship and cargo. Classification soci- from Wilhelmsen Ships Service, from
eties and other authorities have authorities and others and by attend-
consequently issued regulations and ing training courses. Approved Unitor
welding procedures for a number of welding courses will deal in detail
applications onboard. These should not only with the technique required
be known and followed wherever for a successful weld, but also with
applicable, and welding should be the safety aspects around welding
onboard.
SAFETY DEPENDS ON YOU
Do not install, operate or repair equipment for welding or related thermal

processes unless you are thoroughly familiar with:
– The Instruction Manual for the equipment to be used.
– Rules and regulations relating to the handling and installation of the
equipment.
– Rules and regulations relating to hot work onboard.
– Proper use of protective equipment and accessories related to the hot
work, like fire extinguishers, fume extraction equipment, etc.
– Proper use of the filler material and fluxes for the job.
10
WTS Page 37
SAFETY IN WELDING
How to use the Handbook

1.00
Read this first
Familiarize yourself with the chapter you are now reading, and follow the
advice given here whenever you weld. If you know little about welding and your
objective is to become familiar with the welding processes on a self-study basis,
start with the chapters at the back of the book and follow the processes from gas
to flame, from primary power to arc and then through consumables to solutions. If,
on the other hand, you have a basic understanding of welding, read the book from
the beginning, starting with the chapter on solutions.
When facing a problem

Consult the solutions chapter. Here you will find quick guides to cutting,
joining, rebuilding and coating, as well as information on how to identify
metals, descriptions of the most common metals, and a number of examples on
welding applications. You will also find tables for calculating filler material
consumption.
Use the consumables correctly

When a solution is found you should check the specifics of the consuma-
bles you are going to use. The descriptions given in the chapter on consumables
will not only give you technical information on the consumables, but also advise if
special procedures should be followed for the particular product at hand.
The process
Before commencing work, take the time to check the details of the equip-
ment and the technique you should use from the section on processes. You should
also read through the special instruction manuals for the process and equipment
you are going to use.
Power and gas supply

Safe operation and successful results depend on you being familiar with
these chapters, and also the instruction manual on the specific power
source you have onboard. Ensure that the gas supply is in proper order and
correctly maintained, that the welding machine is suited for the process at hand,
and that the cables are of correct size.
Cold repair components require no outside energy. The energy is built into
the products and is released when the base and activator is mixed together.
In order for the chemical reaction to take place, the temperature must be above
+5°C.
The remaining questions

Reading through the handbook you will come across terminology and
abbreviations you may not be familiar with. These are explained in an exten-
sive “Abbreviations and welding terminology” section in the “Miscellaneous
Information” chapter. In this chapter you will also find a number of useful tables
and comparisons.
11
WTS Page 38
SAFETY IN WELDING
Welding instruction and training

1.00 As the world’s leading welding supplier to the marine industry, Wilhelmsen Ships Service has designed and
certified a number of well recognised welding academies around the world. These academies offer tailor made
solutions for maintenance and repair welding onboard vessels.
It is crucial that pressurised gases and arc welding equipment are handled in a safe and secure way, and
safety related issues are always a top priority for running the vessel. The consequences of not adhering to
correct safety procedures can be both hazardous for the crew and damaging to the vessel. Therefore, health
and safety issues are an essential and an important part of the welding training offered.
Welding and related processes are complex and require hands-on training, which teaches skills that are
otherwise difficult to obtain. By attending the our approved training academies, the vessel’s crew will be
certified and trained to perform quality welding repairs onboard.
Working in the ship’s operating environment, in awkward positions, and with the numerous kinds of metals
onboard, can be very challenging. These are all elements the crew must take into consideration in order to
work effectively. The Wilhelmsen Ships Service approved academies offer both practical and theoretical
training as to how to select the correct welding methods and filler materials. These courses aim to help
shipboard welders overcome the daily maintenance challenges onboard.
In order to meet world fleets logistical time challenges and requirements, we endeavour to offer flexible
solutions, and can therefore arrange courses throughout the year. The pupils can be enrolled and trained at
short notice, and courses may be tailor-made to fit the pupil’s individual needs.
Over the years, thousands of seafarers have completed our courses, ensuring that high quality workmanship is
carried out onboard the world’s fleets.
The courses offer training in the following processes:
• Stick electrode welding Materials:
• TIG (Tungsten Inert Gas) welding • Steel
• MIG (Metal Inert Gas) welding • Stainless Steel
• MAG (Metal Active Gas) welding • Copper and copper alloys
• Plasma cutting • Cast iron
• Gas welding, brazing, soldering and cutting • Cast steel
• Cold repairs using cold repair components • Aluminium
Throughout the years thousands of seafarers have completed our courses, ensuring that good quality
workmanships is carried out onboard the world’s fleet.
To sign up or to obtain more information please contact your local Wilhelmsen Ships service office or the below
academies.
Unitor Welding Centre – Piraeus, Greece Toplis Ofshore Training Center – Manila, The Philippines
Contact: wss.greece.cs@wilhelmsen.com Contact: jbbacolod@toplistraining.com
Phone: + 30 210 4239 100 Phone: +632 5237070
Internet site: www.wilhelmsen.com/shipsservice Internet site: www.toplistraining.com
International Maritime Training Centre – Mumbai, India Maritime Academy of Asia and the Pacific – Bataan,
Contact: imtc.mumbai@wilhelmsen.com The Philippines
Phone: +91 22 2570 5570 Contact: info@maap.edu.ph
Internet site: www.imtcmumbai.org Phone: + 632 7849100
Internet site: www.maap.edu.ph
Norwegian Training Centre – Manila, the Philippines
Contact: training.manager@ntcm.com.ph People Soft Inc. – Antipolo, the Phillippines
Phone: +632 8120 742 Contact: dbjaurigue@sourceasia.biz
Internet site: www.ntcm.com.ph Phone: + 632 4210994 & 421-0998
12
WTS Page 39
SAFETY IN WELDING
Personal protection
Why do you need protective equipment? 1.00
Protection against electric shocks

Electric shocks can be the cause of two types of accidents:
– Direct accidents caused by the shock itself can be anything from
minor burns to heart failure.
– Indirect accidents caused by falls from scaffolding and platforms.
Protection against burns

Burns may be caused by hot work pieces, sparks, molten metal, red-hot
electrodes etc.
Protection against ultraviolet and infrared light

Many welders have experienced the discomfort of arc-eye or “sun-
burnt” skin on unprotected parts of the body, usually due to insufficient
or incorrect protective equipment.
Protection against chemicals

Most of the products in the Unitor Cold Repair Component range are to
be considered harmless. Nevertheless we always recommend that one
does the mixing and application in a ventilated area and always wear
the gloves supplied with the set, when handling polymer products.
Protection against flying chips

When using a chipping hammer to remove slag from the weld, there is always
a risk of flying chips which are a potential danger. The chips are sharp and can
cause serious damage to the eyes.
General body protection

A welder at work is isolated from his surroundings. He must concentrate on the
welding operation and cannot see what may be happening in the surrounding
area. He must therefore always wear a safety helmet, safety shoes etc. which
will offer him protection against accidents beyond his control.
A welder must always use complete personal protection equipment – but
it is also important that he uses the correct type of equipment for the job.
Wilhelmsen Ships Service, who supply a full range of welding equipment all
over the world, can offer correct and complete protection equipment which will
provide maximum safety for the welder in all situations.
Work site protection

In order to protect the surrunding area from sparks and spatter, ultra violet and
infrared light, welding curtains and/or blankets should be used.
13
WTS Page 40
SAFETY IN WELDING
1.00
Arc welding face shields and glasses
A welder should bear in mind that proper protection is absolutely necessary to
guard himself against the danger of electric shocks, burns, ultra-violet rays and
bits of welding slag in the eye.
Unitor face shields for welding are made from a lightweight, robust plastic
material which is unaffected by heat, cold or moisture, and both glasses and
shields conform to relevant EN standards.
The Autovision Plus Fresh Air Welding Shield

This Shield is the AutoVision Plus with respiratory unit. It gives the user
clean, filtered air inside the helmet, and prevents inhalation of welding
fumes. The airflow will keep the user fresh and let him concentrate on
the work. The kit is CE approved and conforms to EN 12941:2009.
The fan battery recharges in 2-4 hours and will provide up to 220 liters
per minute for at least 8 hours.
Fresh air kit for face shield
The AutoVision Plus Welding face shield

The basis is a lightweight well designed shield which allows good air
flow for the welder, and a head band that allows unique possibilities
for adjustment:
• Distance to face
• Angle in relation to face
• Height on head
The AutoVision Welding • Head diameter
face shield
• Stay-up friction
Replaceable inside and outside protective lenses, headband and sweatband for
the headband is available as spares. The shield is equipped with a light powered
quick automatic darkening glass that switches from low shade (4) to selected
shade within to selected dark state within 0,4 milliseconds (0,0004 sec)The low
shade state allows for good vision while chipping slag, grinding and repositioning
for next arc striking.Dark mode is adjusted with a knob at the side of the shield,
from shade 9 to 13 which is from the lowest TIG welding settings (5-10A) to
extreme processes at + 400A arc current. Conforms to EN 175: 1997-08.
The Flip-Vision Welding face shield

This is the AutoVision face shield with headband where the AutoVision cassette
is replaced with a flip-up front frame. A clear safety glass is placed in the fixed
frame under the flip-up frame protecting the eyes when chipping slag. The flip-up
front frame is fitted with a filter shade glass with shade selected according to
14
WTS Page 41
SAFETY IN WELDING
welding current used. The filter shade glass is

protected against spatter by a clear protection 1.00
glass fitted in front of it. Shade 11 glass is
supplied as standard with the shield. The
glasses have dimension 60 x 110 mm.
Safety helmet with face shield

The Flip-Vision Welding
The Flip-Vision face shield is also available with face shield
safety helmet instead of headband.
Face Shield with handle

The face shield with
handle is also supplied
with shade 11 dark
glass and clear
Safety helmet w/face shield
protection glass as
standard. It is designed
to also protect the
hand holding it from
radiation. Face shield w/handle
The shields are CE approved and conforms to DIN/EN 175: 1997
Face shields
Description Product no.

Autovision Plus FreshAir Weldshield with respiratory unit 196 767000
AutoVision Plus Welding Face Shield with Adjustable Shade 9 To 13 196 767001
FlipVision shield with flip-up frame, head band and shade 11 glass 196 709485
Safety helmet with face shield, flip-up front frame and shade 11 glass 196 619114
Face shield with handle and filter shade 11 glass 196 619098
Spares for AutoVision Plus
Autovision Plus Outside Cover Lens10 pcs and 2 frames 196 766997
Autovision Plus Headband complete with nuts and bolts 196 766998
Autovision Plus FreshAir Headgear without hose and fan 196 766999
Autovision Plus FreshAir Face seal with attachment screws 196 767002
Autovision Plus FreshAir Filter 196 767003
Spares and accessories for Autovision (old model)
Autovision Outside Cover Lens 10 pcs 112 X 93mm 196 709469
Autovision Inside Cover Lens 10 pcs 97 X 47mm 196 709477
Headband Complete For Autovision 196 709493
Sweat Band For Autovision 196 709501
15
WTS Page 42
SAFETY IN WELDING
Glasses for Arc Welding Items to be mounted into Unitor face

1.00 The glasses have dimension 60 x shield in the following manner:
110 mm and are manufactured in
accordance with DIN standard and
are CE approved. When ordering face A B C
shields, filter shade glass of correct
shade should be ordered in addition
to the filter shade 11 glasses which is
included.
The filter glasses are supplied in A. Safety glass (Polycarbonate)
sets consisting of 5 safety glasses, 5 The glass should be placed near-
protection glasses and 5 filter shade est to the eyes to protect against
glasses. slag or other particles while chip-
ping/grinding. When using a shield
with a flip-up front frame, the
safety glass shall be placed in the
fixed frame.
B. Filter shade glass
Filters out harmful infra-red and
ultra-violet rays from the welding
arc, and reduces visible light to a
level which is sufficient to see the
welding process without straining
the welder’s eyes. Filter Shade
Glass should be selected after
consulting the welding process
and amperage (see table). The
glasses are marked Protane Shade
SO 1 DIN 0196 CE
C. Protection glass
Is placed in front of the filter shade
glass to protect against spatter.
The protection glass should be
Guide to arc welding glasses replaced at regular intervals.
Amperage Filter Quantity Product
Shade in number
Unit unit
< 20 A 8–9 5 sets 196-633230
20–40 A 9–10 5 sets 196-633248
40–80 A 10 5 sets 196-633255
80–175 A 11 5 sets 196-633263
175–300 A 12 5 sets 196-633271
300–500 A 13 5 sets 196-633289
Safety Glass 10 pcs 196-633222
Protection Glass 10 pcs 196-633214
16
WTS Page 43
SAFETY IN WELDING
Safety spectacles clear for eye

1.00 protection
Comfortable protective spectacles
with integrated side guards. The lens
is made of scratch-resistant anti glare
material. The temple arm length and
angle is adjustable. For use during
Product Pcs. Product no. daily maintenance work in workshop
Safety Spectacles –
1 176-632943 and on site for protection against
Clear
flying objects.
Comply to:
EN 166:2001
Safety spectacles Shade 5 for brazing

and welding
Same modern lightweight design
and features as the Clear version.
Fitted with Shade 5 lens. For use when
doing brazing and light duty gas
Product Pcs. Product no. welding and cutting work. Not for
Safety Spectacles –
1 176-632950 use when doing arc welding.
Shade 5
Comply to:
EN 166:2001
Welding and grinding goggles

Lightweight goggles with soft and
comfortable surfaces against the
face. The ventilation slots are
designed to prevent entry of sparks
and spatter, at the same time ensuring
sufficient air circulation to prevent
Product Pcs. Product no. dampness and fogging of the glasses.
Welding/Grinding 1 176-175273 The filter shade glass are mounted
Goggles w/flip-up-frame
in a flip-up front frame. A protection
glass must be placed in front of the
filter shade glass in order to protect
against spatter. One more protection
glass must be placed in the fixed
frame.
Comply to:
DIN EN 1598:2002–04
Safety grinding goggles

Product Pcs. Product no. Half mask goggle of clear soft
Safety grinding synthetic none-mist material. For
goggles non mist 1 176-653410
grinding only.
Comply to:
EN 166:2001
18
WTS Page 44
SAFETY IN WELDING
Glasses for gas welding and cutting Items to be mounted into Unitor face
The Unitor gas welding glasses shield in the following manner: 1.00
have a diameter of 50 mm and fit
the goggles. They are available in A B A
different grades of shade for various
types of work. All glasses come in
sets of 10 pcs.
A. Protection glass
When using goggles with a flip-up
front frame, the protection glass
should be placed in the fixed
frame.
B. Filter shade glass

In order to filter out the strong
glare of the flame.
A. Protection glass
One protection glass must be
placed in front of the filter shade
glass in the flip-up front frame in
order to protect against spatter.
Guide to gas welding glasses The protection glass should be
replaced at regular intervals.
Application Filter Pcs/ Product
Shade set number
Glass
Silver
Brazing 3 10 176-633305
Gas Welding 5 10 176-633313
& Cutting –
General 6 10 176-633321
Gas Welding
& Cutting – 7 10 176-633354
Thick material
Protection Glass 10 176-633297
19
WTS Page 45
SAFETY IN WELDING
1.00
E
C
A B
F
G
Welder’s protective clothing Protective clothing

Made from specially treated leather, Pos. Product Pcs/set Product no.
these protective clothes are heat and A Welders gloves for electric arc welding 6 pairs. 196-632786
wear resistant. They provide protec- B TIG and gas welding gloves 6 pairs. 196-632794
tion during welding, especially when Working gloves 12 pairs 196-633057
the welder has to work close to the C Leather jacket, Large for welding pcs 196-510438
workpiece or where movement is C Leather jacket, Extra large for welding pcs 196-510446
restricted. It is specially important D Leather trousers with belt pcs 196-633016
that the welding jacket is worn when E Arm protector pair 196-184184
welding overhead, to protect the body F Leather apron pcs 196-510420
and arms against falling sparks and G Leather spats pair 196-510453
slag. Heat resistant mitten pcs 176-233148
In addition to protection against
sparks and molten metal, the task
of the protective leather clothing is
also to protect against electric shock.
When dry the leather acts as an elec-
tric insulator. Therefore always wear
dry protective clothing when doing
arc welding.
20
WTS Page 46
SAFETY IN WELDING
Electric arc welding gloves

Gloves must always be worn when 1.00
arc welding. Special welding gloves
with long gauntlets are necessary.
These must be of leather.
Long lined welding gloves are
recommended for welding with
coated electrodes.
TIG and Gas welding gloves

Thick welding gloves will hamper the
control of the torch or rod. Special
softskin gloves are available for this
purpose. They will protect fully from
sparks and the radiation from an arc,
but will give less protection than the
thicker welding gloves when touching
hot metal.
Gloves for Arc and TIG welding
Comply to NEN-EN 12477 type A/B
Protection:
EN 388 3232
EN 407 332222.
Heat resistant mitten

This is a special mitten with a heat
and fire resistant woven kevlar outer
layer, and further insulation against
heat in the inner layers. It is designed
to make it possible to close an acety-
lene cylinder valve even if the escap-
ing gas is on fire, and should always
be kept by acetylene cylinders as a
safety precaution. It is also suitable
for handling hot work pieces.
Comply to:
EN 388:2003
EN 407:2004
Working gloves
This type of glove is not designed
for hot work; just for handling of
equipment and consumables.
21
WTS Page 47
SAFETY IN WELDING
Work site protection

1.00
Welding Curtain
The purpose of the Welding Curtain
is to avoid other personnel being
harmed by the welding work taking
place. The curtain blocks out all
hazardous ultraviolet and infrared
light from the welding arc, but still
enables one to see trough the curtain.
It is made of self-extinguishing
material, but is not heat resistant
to direct exposure to hot slag/iron
spatter from the arc. Size: 2 m high
and 1,3 m wide. The top of the curtain
has 7 holes and the curtain comes
complete with 7 heavy-duty hooks.
With the hooks the curtain can be
put in a frame, or hooked up on an
existing pipe or wire. Maximum pipe
diameter the hooks will fit on is 41
mm. In order for the curtain to be
drawn freely the pipe should be less
than 30 mm. It is possible to join two
or more curtains together by the use
of snap on buttons along the side. The
curtain with hooks is supplied in
a plastic bag. The curtains are in
accordance with EN 1598: 2002-04.
Product Pcs. Product no.

Welding curtain w/ 1 196-633065
hooks, orange 1,4 x 2 m
Welding spatter blanket

Non-asbestos woven glass fabric
with a fire retardent weavelock, for
protecting combustible materials and
delicate machinery from spatter and
spark during welding and cutting.
Available in a roll 1m x 10m. Nom.
Thickness 0,82mm. Max operating
temperature 550 °C. The welding
blanket is supplied in a carton box.
Produced according to
EN-ISO 25980: 2012
Product Pcs. Product no.
Welding spatter blanket 1 196-646067
22
WTS Page 48
SAFETY IN WELDING
Fire extinguisher
Always keep a fire extinguisher ready 1.00
when welding outside workshop. The
PP3P is a lightweight ABC dry powder
fire extinguisher.
Technical Properties
This device was designed using
highly reliable materials and the
latest corrosion-resisting protection
technologies In order to be ideally
suited to the requirements of the
maritime environment.
It complies with European AENOR
- EN 3 standard, and is of the hightest
performance in its category. Weight: 4,7 kg.
Efficiency
Classes A, B or C Instructions for use
The multi-purpose nature of the ABC
powder extinguisher ensures that it
is effective against these three types
of fire. For solid material fires (class
A), it replaces the conventional water
products, which are sometimes not
recommended for use with electrical Temperature limits: -20 °C to +60 °C
currents. For liquid, liquefiable solid
and gas fires, it acts in the same
conditions as the BC powder and is Product Pcs. Product no.
ideally suited for Industrial hazards. PP3P 1 291-667394
Extinction Mechanism
The multi-purpose ABC powder acts:
-on the flames, by negative catalysis,
-on the embers, by cooling and
forming a layer of heat insulating and
fireproof “varnish”, which coats the
fire, preventing it from re-igniting.
When sprayed, the ABC powder forms
an insulating screen, which protects
the user from heat radiation.
Easy to use pressing on the striking handle. The

flow rate is controlled by the tap on
0peration the final control valve. The fact that it
Once the safety pin has been is so simple to use means that risks of
removed, the device is pressurised by incorrect use are greatly reduced.
23
WTS Page 49
SAFETY IN WELDING
Welding fumes fumes is kept at a reasonable level.

1.00 Welding fumes, or smoke consists When the base metal has been sur-
of a mixture of gases and dust par- face-treated, the smoke may contain
ticles. The composition of the fumes substances which could constitute
depends on: a health risk.
1. The filler material and method of Welding of galvanized materials
welding. or materials surface treated with
substances containing zinc, gives
2. The base material. off fumes which contain zinc oxide.
Different welding methods and dif- Inhalation of these fumes can result
ferent metals, means that the fumes in zinc poisoning with very unpleas-
given off may contain numerous com- ant effects. It should be avoided by
ponents which can be dangerous if the use of a good extraction unit, or
inhaled. The best protection is the use the use of a face shield with fresh air
of a smoke extraction unit. When cor- connection.
rectly positioned, this unit will protect Cadmium plating is sometimes used
the welder against fume inhalation instead of zinc plating. Welding or
and also prevent the smoke spreading cutting cadmium-plated material can
in the surrounding area and contami- produce fumes which contain cad-
nating the area for others. mium oxide. Lung damage can result
If it is not possible to use a smoke from the inhalation of this substance.
extraction unit, the welder can mini- When welding or cutting old steel
mize the risk of fume inhalation by plating, remember that the surface
positioning himself so that the smoke coating may contain lead or mercury.
rises some distance from his nose Fumes from these substances can
and mouth or by using a welding face result in serious health damage if
shield with fresh air supply. For on inhaled.
board use a self contained unit with
filter is a safe and flexible solution. When welding or cutting any type
of material that has been plated or
Electric arc welding with coated elec- surface coated, precautions must
trodes, may comprise several different be taken against dangerous fumes
components depending on the type before welding commences.
of electrode. The composition of the
smoke will therefore vary depending Welding of stainless or acid-resist-
on the type of electrode. Electrodes ant steel produces smoke containing
are divided into smoke classes 1 to 7, nickel and chrome. Copper alloys (tin
which indicates the degree of smoke bronze, leaded gun metal, leaded tin
pollution. See the Coated Electrodes bronze and brass) contains items such
section on smoke classes. as tin, zinc, lead, etc. Welding temper-
ature tends to vaporise these items.
Risks Inhaling these substances can seri-
The fumes given off when welding ously affect the respiratory system.
unalloyed or low-alloyed steel which When weIding these types of steel or
has not been surface treated, are not materials plated or coated with sub-
considered to be particularly danger- stances containing chrome, cadmium,
ous as long as inhalation of these nickel lead or mercury, it is essential
24
WTS Page 50
SAFETY IN WELDING
that a smoke extractor unit is used. If

this is not possible, the welder must 1.00
be equipped with, and must use a
face shield with fresh air connection.
Welding, cutting and brazing with a
gas torch can produce smoke which
may contain several toxic substances.
Of the gases given off, it is primarily
the nitrous gases (NO2 + NO) that are
a health hazard. The amount of nitrous
gases in the smoke depends on sev-
eral conditions. The use of large size
torches in confined spaces can quick-
ly produce dangerous concentrations.
No warning is given of the presence
of these gases in the form of irritation Avoid direct inhalation of welding fumes.
of the muceous membrane in eyes,
nose or throat. Proper ventilation must
be arranged, and when working in
confined spaces, the welder must not
leave the torch alight when he is not
actually using it.
Carbon monoxide may be given off due
to incomplete combustion of the gases
or if the material being welded or cut
is plastic surfaced, varnished, painted
or oily. High concentrations, which
constitute a health risk, can be formed
Use fume extraction.
in confined spaces, tanks, pipes etc.
Inhalation of large quantities of carbon
monoxide can lead to suffocation.
This section points out some of the
more usual risks connected with weld-
ing smoke. There are special books on
the subject, and welding smoke is also
undergoing continuous research. The
result of this research work may bring
new important factors to light and all
those involved in welding should keep
themselves informed of the develop-
ment in this area, so precautions can Use Fresh Air supply.
be taken to protect against health risks
which may, as yet, be unknown.
25
WTS Page 51
SAFETY IN WELDING
Welding fumes
1.00 All Unitor Electrodes are issued a fume Class number according to Danish
standard. These are the recommended precautions .
Fume Class 1: Ensure sufficient ventilation when welding in confined
spaces. Other protective measures are normally not needed
in larger well ventilated spaces.
Fume Class 2: Spot extraction is always recommended when welding in
confined spaces. Larger spaces shall be well ventilated.
Fume Class 3: Spot extraction is recommended when welding indoors.
Special protective measures are normally not needed
outdoors if there is enough wind or draught to keep fumes
and gases from the welders breathing zone.
Fume Class 4–7: Spot extraction shall be used when welding indoors. For
outdoor welding see Fume Class 3.
The standards state the connection between Fume Class and NHL* that is a
theoretical value to describe the amount of fresh air needed to dilute the fumes
to "safe" concentrations. It is important to understand that NHL* is a theoretical
value and should not be used for calculating ventilation capacities:
Fresh air needed to dilute the fumes

Fume Class NHL* (m3/h)
1 0 – <3000
2 3000 – < 7500
3 7500 – < 15000
4 15000 – < 35000
5 35000 – < 60000
6 60000 – < 100000
7 >100000
* NHL = Nominelt hygenisk luftbehov i m3/t

Nominal hygene air supply in m3/h
26
WTS Page 52
SAFETY IN WELDING
FumeClean 230 welding fume

extractor 1.00
With this unit a welder is easily protected
against inhaling welding fumes that might have
harmful effects. It is compact and lightweight
and can be used anywhere a welder can work.
Four-stage filtration system

When the welding fumes enter the unit they first
pass a metal pre-separator, then the fumes flow
through a aluminium pre-filter and into the main
filter which has a total area of 12m2. The large
area of the main filter provides a long life and
a constant high efficiency since filter cleaning
does not have to take place very frequently.
The last stage is a High Efficiency Particle
Arrestor HEPA 12 which guarantees a filtration
efficiency of 99.9% under all circumstances.
Active carbon filter

If required an optional activated carbon filter
can be placed on top of the main filter to remove
smell. It is also possible to add hoses on the
exhaust side to completely remove the filtered air
from the area if required.
Two powerful motors

The two motors guarantee an adequate extrac-
tion capacity under all conditions. At low welding
fume concentrations, the extraction capacity can
be halved, in which situation both motors oper-
ate at half speed, thus providing a lower noise
level and reduced maintenance.
Automatic start
When the welding cable is placed in a slit on top
of the unit the automatic start/stop function can
be used and the unit will automatically switch on
when welding starts and off when welding stops.
27
WTS Page 53
SAFETY IN WELDING
Technical Data
1.00 Number of motors 2
Motor power consumption 2x1kW
Power supply 1phase 230V 50/60Hz Dimmensions
Noise level 70dB
High vacuum suction 22 000 Pa
Extraction volume speed setting 140 m3/h
‘low’
Extraction volume speed setting 230m3/h
‘high’
Filter surface main filter 12 m2
Filter surface HEPA filter 0,4 m2
Filter efficiency incl. HEPA filter 99,9%
Min. operating temperature 5°C
Max. operating temperature 40°C
Max. relative humidity 80 %
IP class 50
Net weight 16 kg
Ordering information
Description Product no.
FumeClean 230 complete with 2,5 m 196 735878
hose and nozzle with magnet foot
Optionals
Bulkhead Bracket 196 740399
Hose Connection Outlet Side 196 740381
Active Carbon Filter 196 740431
Spare parts
Disposable Cartridge Filter 196 740415
High Efficiency Particle Filter H12 196 740423
Funnel Nozzle With Magnetic Foot 196 740373
Extract/Exhaust Hose 2,5 M, 196 740449
Ø 45 mm
Connection Piece For Two Hoses 196 740456
Ø 45 mm
Carbon Brushes 2 Sets W. Seals 196 740407
230V
28
WTS Page 54
SAFETY IN WELDING
Safety check list for welding

1.00 and related processes
Preparation for hot-work onboard
should include, without being limited
to the points below:
Equipment
✓ Check that the power source
functions correctly, is correctly
connected to mains, and that you
are familiar with its operation.
✓ Ensure that gas cylinders are
Keep your welding equipment well properly secured, in upright
maintained. position, and fitted with correct
and properly functioning
regulators for the gas. Acetylene
and oxygen regulators shall be
fitted with flashback arrestors.
Protect cylinders against heat and
mechanical damage.
✓ The valve opening of the acetylene
cylinder shall point away from
other compressed gas cylinders,
and a heat resistant mitten shall be
available.
✓ Hoses shall be in good condition,
without leaks or damage, and with
correct colour coding for the gas.
(Red for acetylene, blue for oxygen,
black for shielding gases and filt
ered air). Use correct hose conn
ectors and hose clamps. Pieces of
Never use defective welding cables. pipe and twisted wire must never
be used. Never use oil or grease in
connection with welding gases and
never use copper in connection
with acetylene.
✓ Cables shall be of oil resistant
type with undamaged insulation
and properly mounted cable
connectors. Use safety cable
connectors where both halves are
protected to prevent contact with
deck when disconnected.
30
WTS Page 55
SAFETY IN WELDING
✓ Check that torches and electrode

holders are in good working order, 1.00
including check of blowpipes
(AC/ OX), nozzles (AC/OX, Flame
Spray, TIG, Plasma), electrodes
(TIG, Plasma), and insulation (TIG,
Plasma, GMAW, MMAW).
✓ Check all gas connectors for leaks,
including torch valves. Even Argon
may be a safety risk if it replaces
air in a confined area due to
excessive leaks. Replace defective
gaskets with original gaskets only.
Keep cables and hoses clear of passage

✓ Keep hoses and cables clear of passage ways and
ways. protected from sparks, hot metal and mechnical
damage e.g. in doorways, hatches, etc.
✓ Both welding and return clamp cables should be
stretched to the work place, and the return clamp
should be fastened with good electrical contact
directly on the work piece.
Work place
Tidy up the work place and remove any flammable
materials, liquids and gases from workplace and adja-
cent spaces including spaces above/below decks,
behind bulkheads and inside pipes or containers. Cover
any openings through which sparks may be led to other
areas onboard which have not been prepared for hot
work.
✓ Shield the work place to protect others from sparks

and radiation from the arc, and post a warning sign
that welding is in progress.
✓ Ensure that sufficient and correct fire fighting
equipment is available at the workplace, and that
personnel familiar with its use is present. Ensure that
Place return clamp (return clamp) directly the work place is properly ventilated, if necessary
on the work piece, know where the return with special fume extraction equipment. This is
current goes.
especially important when working on galvanized or
coated surfaces which may produce harmful fumes
when heated.
31
WTS Page 56
SAFETY IN WELDING
1.00
Cover openings! Sparks may travel far!
Hot work procedure

✓ Ensure that all relevant check lists, certificates and
permits for hot work have been issued.
✓ If work is being done outside the ship’s workshop, an
assistant protected in the same manner as the welder
should accompany him.
✓ If work has been done inside a confined space the
assistant should be placed outside, within view of the
welder and with possibility to cut off gas and power
supply. (Gas quick couplings and an unlocked safety
cable connector may act as emergency cut-offs).
Operator / assistant protection

✓ When working, wear safety shoes and a proper boiler
suit with long sleeves. Do not wear clothes of highly
combustible materials or wet clothes, and do not carry
combustible material, e.g. matches, lighters, oily rags. Ensure proper ventilation.
✓ Welding gloves should always be used, and when
necessary also use additional leather clothing for
protection against sparks, heat and electric shock.
✓ Use head and face protection (helmet, shield,
goggles). Ensure that filter glasses are unbroken and
have the correct shade.
32
WTS Page 57
SAFETY IN WELDING
1.00
For light duty work (200 Amps or lower)

• Working overall w/long sleves (flame
retardent material). Preferably without
too many pockets that easily catch
For work in vertical and overhead position
sparks. For same reason avoid zips.
• Working overall
Avoid synthetic materials, including
• Safety boots with steel toes.
nylon, rayon and polyester.
• Face shield w/head band
• Safety boots with steel toes.
• Welders gloves
• Face shield w/handle or face shield w/
• Arm protector
head band
• Leather spats
• Welders gloves
✓ Where necessary use a fresh air unit or breathing

apparatus to avoid inhaling fumes and dust from the
welding process.
✓ Never use acetylene or oxygen to blow away dust
from yourself or the workplace. Always keep dry and
keep the workplace dry, especially when arc welding.
When work is paused or completed

✓ Always remove coated electrodes from the electrode
holder and switch/close off gas and current at the
source (welding machine, cylinder valve, gas outlet)
For heavy duty work (above 200 Amps) also during short breaks for meals etc.
• Working overall ✓ Do not leave the workplace unattended. When hot
• Safety boots with steel toes work is completed the work place shall be inspected
• Face shield w/head band at regular interval to ensure that no risk of fire
• Welders gloves
remains. Only when this has been assured should
• Leather jacket
• Leather trousers fire fighting equipment be retumed to its normal
storing place.
Available wall chart:

ID No. 811053 Wall Chart Safety Checklist.
33
WTS Page 58
CHAPTER 2
WTS Page 59
CHAPTER 2
WTS Page 60
MAINTENANCE INSTRUCTION 61-00-990-6-E

PBA 30.05.14 00 WLE Page 1 of 2

System Subject Ref.

GAS DISTRIBUTION SYSTEM CENTRAL INSTALLATION
LEAKAGE TEST
Leakage test of the system shall be carried out at least ones a year by the Chief Engineer or
the person he authorises.
The leakage test shall be carried out as follows:
• Normal working pressure for acetylene and oxygen on the system.

• The gas supply to the pipe line shall be stopped, the central regulators for
acetylene and oxygen are closed.
• The pressure in the pipe lines shall be kept constant for at least 8 hours.
• Leak detection spray should be used for this purpose. Spray on the surface
(joints) to be controlled. Leakages will develop clearly visible bubbles.
If a pressure drop should occur in the acetylene or the oxygen pipe lines, the central
installation shall be inspected and repaired by the installer, and a new Installation Certificate
shall be issued.
The annual test shall be entered on the Installation Certificate in the cylinder Central.
PRIOR TO LEAKAGE TEST
Prior to the leakage test the following must be checked:
1. Oxygen equipment free of fat, grease, oil and dirt.

2. Safety and instruction signs in place.
3. All equipment in the cylinder room, which is not a part of the central installation, is
removed.
4. Cylinder racks are in good condition and cylinders securely fastened.
5. High pressure hoses are without mechanical damage on couplings and
braiding. UNITOR recommends that high pressure hoses are replaced with new
ones at least every 5th. year, due to the risks involved if such hoses should
rupture. If the hoses are damaged or there is suspicion thereof, the hoses must be
replaced before the system is taken into use.
WTS Page 61
MAINTENANCE INSTRUCTION 61-00-990-6-E

PBA 30.05.14 00 WLE Page 2 of 2

System Subject Ref.

6. Regulators must be function tested. Damaged gauges must be replaced.

UNITOR recommends that oxygen regulators are replaced with new ones at least
every 5th. year, due to the risks involved for self ignition when pure oxygen is
present. If the regulators are damaged or there is suspicion thereof, the regulators
must be
replaced before the system is taken into use.
7. Expansion pipes, both high pressure and low pressure are without leakages and that
the inside of the pipes is free from corrosion products and moisture.
8. Outlet station must be checked according to the "Outlet station instruction".
9. For all repairs UNITOR original spare parts must be used and all repairs
should be made by authorised personnel only.
CERTIFICATION
After completed installation or repairs of the AC and OX gas distribution system, and
otherwise at 5th. years intervals, the system shall be tested and controlled by authorised
personnel.
For ship registered NIS or NOR the control shall be carried out in the presence of a ship
control surveyor. A new installation certificate shall be issued.
WTS Page 62
OPERATING INSTRUCTION 61-00-990-7-E

PBA 02.06.14 00 WLE Page 1 of 4

System Subject Ref.
UNITOR AC & OX WELDING OPERATING INSTRUCTION FOR

GAS DISTRIBUTION SYSTEM
CENTRAL INSTALLATION
BEFORE USE
Read, understand and follow the instructions in the Regulations for the use of AC AND OX
GAS DISTRIBUTION SYSTEM and for the gases acetylene and oxygen on board all kind
of ships laid down by the relevant Statutory Body.
GENERAL WARNINGS
• Compressed gases, liquefied or gaseous, should only be handled by fully skilled personnel.
• High-pressure acetylene and oxygen must never be used before they first have been
brought down to a lower pressure in the regulators.
• The cylinder valves must always be fully open when using cylinders.
• It is very important to make sure that the outlet threads on the cylinder valves correspond
to those on the equipment to be connected. Never force a connection which will not fit.
• Make sure that the ventilation to open air works.
• Do not attempt to charge acetylene or oxygen into any cylinder.
• Regulators and other equipment for oxygen must never be lubricated with ordinary oil,
grease and readily combustible substances, as this brings a great risk of explosion. Only special
lubricants may be used.
• Always ensure that safety devices, such as flashback arrestors and non-return valves are
installed and in good condition.
• Always ensure that maintenance procedures as given are followed.
• Remember :
Warning! FAILURE TO OBSERVE THESE WARNINGS

MAY RESULT IN FATAL ACCIDENTS.
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CYLINDER OPERATION
• Check that the cylinders bear the stamps ACETYLENE or OXYGEN. Confusing with other
gases may be dangerous.
• Handle the cylinders with great care. Do not push or strike. Follow the rules and safety
precautions for transporting and handling of gas cylinders.
• Never remove the protection cap from the cylinder until everything is ready for connecting the
high pressure hose to the cylinder valve.
• Never use pliers or a similar tool to open the cylinder valves. It is dangerous to force the valve
open by knocking or heating.
• Always clean the cylinder valve outlet before connecting it to the high pressure hose. This
can be done by briefly opening the cylinder valve in open air and in a non-explosive area.
Do not stand in front of the gas outlet.
• Make sure that gaskets are free from faults and that they are made of the correct material.
Copper gaskets must never be used.
• Open the cylinder valves slowly with both hands.
• Close the cylinder valves after finishing the work.
• Prior to disconnecting the high-pressure hose the cylinder valve must be closed and the
pressure relieved.
• The cylinders shall always be returned with positive pressure, valves closed and the
protection cap screwed on.
COMMENCEMENT OF WORK
1. All valves and regulators shall be shut including the cylinder valves, the closing valves
and the T-valves. Also make sure that the closing valves and the low-pressure regulators
in the outlet station are shut. The regulators are shut when the adjusting wheel an the
central regulators and the adjusting knob on the low-pressure regulators are screwed so
far out that the runs free.
2. Start the operation by connecting the torch handle with the right blowpipe and hoses, normally
2 x 1/4" in 10 m length, to the outlet station.
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3. Slowly open the cylinder valves, the T-valves and the closing valves for acetylene and
oxygen.
4. Loosen the low pressure tubes off the AC and OX regulators so they leaks gas. Set the
right working pressure by screwing the adjusting knob to the right until the low pressure
gauges show a little higher than 0.8 bar for acetylene and 8.0 bar for oxygen. Then
tighten the low pressure tubes to the regulators. From now on it is not necessary to touch
the adjusting wheels and they can be locked with the lock nut.
After connection, check each connection for leakages with leak detection spray.
5. Fully open the closing valves for acetylene and oxygen in the outlet station.
6. Fully open the torch oxygen needle valve and adjust the working pressure by means of
the regulator in the outlet station and then shut the torch oxygen valve. Working pressure
is 0.3 bar for welding and 1.7 bar for cutting.
7. Fully open the torch acetylene needle valve and adjust the working pressure by means of
the acetylene regulator in the outlet station. Working pressure are 0.3 bar for welding
and 0.2 bar for cutting.
8. Slightly open oxygen needle valve to provide a little extra oxygen to prevent
troublesome shooting when the burner is lit.
9. Hold the torch so that the nozzle points away from the flammable objects. Light the
torch, and adjust the desired flame characteristic by means of the torch oxygen needle
valve. The torch is now ready for use.
TERMINATION OF WORK
1. The torch is normally extinguished by first closing the torch acetylene needle valve
and then closing the torch oxygen needle valve.
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2. After finishing the work, release the pressure in the pipelines and the hoses by closing
the cylinder valves and empty one hose at a time, keeping the touch needle valve for the
other bar shut. Finally shut the T-valves, the closing valves, the closing valves and the
regulators in the outlet station and the torch needle valves.
3. For shorter interruptions in the welding or cutting work, shut the closing valves in the
outlet station and empty one hose at a time by keeping the torch needle valve for the other
gas shut. Shut the regulators in the outlet station and the torch needle valves.
REGULAR MAINTENANCE
Check the sealing rings at regular intervals for damage, deformation or wear. Replace
them if they are defective. To facilitate changes of torch or cutter tips, the sealing rings
and sealing surfaces in the torch connection head should be lightly smeared with a
special lubricant.
Warning! Oil or grease must never be used.
WTS Page 66
CHAPTER 3
WTS Page 67
CHAPTER 3
WTS Page 68
TECHNICAL DESCRIPTION 61-01-001-2-E

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System Subject Ref.
UNITOR AC & OX WELDING UNITOR A-40 ACETYLENE

CYLINDER
APPLICATION
The UNITOR branded A-40 ACETYLENE CYLINDER is used in the AC and OX

distribution system. The customer orders the necessary quantity of cylinders and pays
for the gas and filling and a deposit for the cylinders. Cylinders and fillings must be
ordered separately for the distribution system.
The AC and OX gas distribution system is built up to contain any desired number of
acetylene cylinders by using several high pressure hoses and T-valves connected by
connection tubes.
Prior to the installation drawings and documentation of the cylinder store shall be
submitted to the classification society for approval.
DESIGN
The UNITOR branded A-40 ACETYLENE CYLINDER is designed for marine use. The
cylinder is seamless and built up by steel. The wall thickness is minimum 4.8 mm.
The cylinder surface is sandblasted, primed and painted.
The cylinder is filled with a high porous mass based upon a special calcium silicate
material. The porosity is approximately 92%. This mode of storage hinders
decomposition and makes the cylinders safe against impacts and transport handling.
The porous mass is saturated with approximately 16 1 acetone. The acetylene gas is
absorbed by the acetone. At a pressure of 15 bar and a temperature of 15°C a
UNITOR branded A-40 ACETYLENE CYLINDER will contain 6000 normal litre
of dissolved acetylene.
A neck-ring marked with UNITOR is mounted on the collar of the cylinder. All
necessary technical data and specifications are stamped on the shoulder of the cylinder.
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CYLINDER
FUNCTION
When the cylinder top valve is opened the pressure in the cylinder falls and the
acetylene is released from the acetone. The cylinder shall not be emptied more rapidly
than by about one-eight of the contents of the cylinder per hour.
The content of 6000 normal litre acetylene in A-40 ACETYLENE CYLINDER is

sufficient for most normal welding and cutting work with one operator during a day.
An A-40 CYLINDER should normally not be emptied faster than 750 1. per hour. This
process must not proceed too quickly because "boiling" can occurs in the cylinder and
some of the acetone will emerge with the gas resulting in an instable flame.
Acetone burns, but with a very different characteristics from acetylene. This can be very
damaging both to the cylinder and the weld. However, for a short-while, maximum
30 minutes, extraction from a full cylinder at about 15°C may be increased to 2500 1/h.
After that the cylinder must not be used for a while.
If the gas consumption is greater than a single acetylene cylinder can deliver, two or more
cylinders must be connected to the gas central distribution system.
The gas contents of an A-40 ACETYLENE CYLINDER is sufficient for a minimum of 9

hours of brazing or welding (650 1/h), 7 hours of cutting (810 1/h) or 3.5 hours of heating
(1650 1/h).
TECHNICAL SPECIFICATION
Material: Steel CM or MnH
Surface treatment: Sand blasting, priming and painting
Colour: Red, RAL 3011
Specification to: ISO9809-1 and ISO3807-1
Filled with: calcium silicate porous mass 92% porosity, 12.4 kg, Acetone
(approx.. 161itre acetone).
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CYLINDER
Filling pressure: 15 bar at 15°C
Min water capacity: 40.2 1
Gas capacity: 5.6 Nm3
Nominal weight: 42.5 kg (Without cap, valve, porous mass and acetone)
Weight of cap: 1.1 kg
Test pressure: 60 bar
WTS Page 71
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GAS DISTRIBUTION SYSTEM UNITOR 0-40 OXYGEN CYLINDER 61-01-002
APPLICATION
The UNITOR branded 0-40 OXYGEN CYLINDER is used in the AC and OX

distribution system. The customer orders the necessary quantity of cylinders and pay for
the gas and filling and a deposit for the cylinders. Cylinders and filling must be ordered
separately for the distribution system.
The AC and OX gas distribution system is built up to contain any desired number of oxygen
cylinders by using several high pressure hoses and T-valves connected by connection
tubes.
Prior to the installation, drawings and documentation of the cylinder store shall be
submitted to the classification society for approval.
DESIGN
The UNITOR branded 0-40 OXYGEN CYLINDER is designed for marine use. The
cylinder is seamless and built up by alloy steel. The wall thickness is minimum 5.6 mm.
The cylinder surface is sandblasted, primed and added with blue top coat, RAL 5000.
At a pressure of 150 bar and a temperature of 15°C a UNITOR branded 0-40 OXYGEN
CYLINDER will contain approximately 6400 normal liters of oxygen.
A neck-ring marked with UNITOR is mounted on the collar of the cylinder. All necessary
technical data and specifications are stamped on the shoulder of the cylinder.
FUNCTION
The UNITOR branded 0-40 OXYGEN CYLINDER is connected to the gas distribution
system one alone or in parallel operation with other 0-40 CYLINDERS.
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GAS DISTRIBUTION SYSTEM UNITOR 0-40 OXYGEN CYLINDER 61-01-002
For normal welding work the oxygen consumption is about the same as the acetylene
consumption.
For cutting work the oxygen consumption is 3 to 4 times more than the acetylene
consumption.
As the average oxygen consumption is twice that of acetylene, the corresponding

number of oxygen cylinders should be two times the acetylene cylinders to ensure full
work flexibility.
The gas content of an 0-40 OXYGEN CYLINDER is sufficient for minimum of 8.5 hours
of brazing or welding (710 1/h) or 2.75 hours of cutting (2150 1/h).
Material: Alloy steel CM

Surface treatment: Primer + top coat
Colour: Blue, RAL 5000
Specification to: ISO9809 Part 1 and US DOT 3AA
Filling pressure: 150 bar at 15°C
Min. water capacity: 40 L
Gas capacity: 6.4 Nm3
Nominal weight: 52 kg (without cap and valve) depending on manufacturer
Weight: Cap: 1.1 Kg
Gas: 7.8 Kg
Cyl. gross: approx. 60.5 Kg.
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System Subject Ref.

GAS DISTRIBUTION SYSTEM RACK FOR TWO CYLINDER 61-02-002
APPLICATION
The RACK FOR TWO CYLINDERS is designed for safe and vibration-free storing of
two 40 1. or two 50 1. Gas cylinders on board ships.
DESIGN
The RACK FOR TWO CYLINDERS is made of galvanized steel, and consists of three
major parts: the bulkhead bracket, the fastening clamp, and the foot bracket. The screw
and nut in the clamp assembly are made of stainless steel.
The brackets are to be welded to the bulkhead so that the cylinders are placed in erect
position.
FUNCTION
The RACK FOR TWO CYLINDERS fits both 40 1. and 50 1. cylinders. When the
cylinder rack is correctly mounted and the cylinders conscientiously fastened, the
cylinders will be protected against vibration and other strains.
The screw and nut in the fastening clamp is made for fast removal of the cylinders in case
of fire.
Material: Brackets: Mild Steel

Securing screws
and nuts: Stainless Steel
Surface treatment: Galvanized
Weight: 8.5 kg
Mounting: Brackets: Welded to supporting structure
Support: Welded to deck
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System Subject Ref.
UNITOR AC & OX WELDING CLOSING VALVE ACETYLENE WITH

BRACKET
APPLICATION
The CLOSING VALVE FOR ACETYLENE is designed for use in connection with the
acetylene regulator to close the high pressure side of the acetylene gas distribution pipe
line.
DESIGN
The CLOSING VALVE FOR ACETYLENE has a solid brass body and is easy to operate.
The CLOSING VALVE COMPLETE is mounted on a bracket made of stainless steel.
FUNCTION
The CLOSING VALVE FOR ACETYLENE is on the inlet side connected to a high-
pressure hose in a system consisting of one acetylene cylinder or to a high-pressure tube
where two or more acetylene cylinders are connected to each other with T-VALVES.
Under normal conditions the regulator for acetylene is set on a previous desired pressure
and there for always open. The CLOSING VALVE is designed to close the high pressure
pipe line for acetylene when the equipment is not in use and to prevent any escaping gas
from the cylinders to leak into the low pressure pipe line.
Material: T-valve: Brass body and piston CuZn39Pb3, DIN

17660 Stainless steel
Bracket: Steel
Treatment:
Normal working pressure: 18 bar
Weight: 0.7 kg
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System Subject Ref.
UNITOR AC & OX WELDING CLOSING VALVE OXYGEN WITH

BRACKET
APPLICATION
The CLOSING VALVE FOR OXYGEN is designed for use in connection with the oxygen
regulator to close the high pressure side of the oxygen gas distribution pipe line.
DESIGN
The CLOSING VALVE FOR OXYGEN has a solid brass body and is easy to operate with
a hand wheel.
The CLOSING VALVE COMPLETE is mounted on a bracket made of stainless steel.
FUNCTION
The CLOSING VALVE FOR OXYGEN is on the inlet side connected to a high-pressure
hose in a system consisting of one oxygen cylinder or to a high-pressure tube where two
or more oxygen cylinders are connected to each other with T-VALVES.
Under normal conditions the regulator for oxygen is set on a previous desired pressure
and there for always open. The CLOSING VALVE is designed to close the high pressure
pipe line for oxygen when the equipment is not in use and to prevent any escaping gas
from the cylinders to leak into the low pressure pipe line.

17660
Bracket: Stainless steel
Treatment:
Weight: 0.7 kg
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System Subject Ref.
UNITOR AC & OX WELDING T-VALVE ACETYLENE WITH NON-

RETURN VALVE AND BRACKET
APPLICATION
The T-VALVE ACETYLENE WITH NON-RETURN VALVE is design for use where any
desired number of cylinders supplies the UNITOR AC AND OX GAS
DISTRIBUTION SYSTEM with acetylene gas.
DESIGN
The T-VALVE ACETYLENE WITH NON-RETURN VALVE, has a solid brass body and
is easy to operate with a hand wheel.
The T-VALVE is mounted on a bracket made of stainless steel and fitted with a non-return
valve made of brass.
FUNCTION
By using several T-VALVES FOR ACETYLENE connected by high pressure connection

tubes, it is possible to connect any desired number of acetylene cylinders.
The last T-VALVE in the series is closed with a blind plug and a connection nut. The
first T-VALVE in the series is leading to the closing valve and the central regulator for
acetylene.
The none-return valves which are fitted to the T-VALVES prevent gas from flowing
back through the valves to the gas cylinders. This makes it possible to remove any of the
cylinders in the central and still continue to use the remaining cylinders.

17660
None-return valve: Brass body
Weight: 0.75 kg
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System Subject Ref.
UNITOR AC & OX WELDING T-VALVE OXYGEN WITH NON-

RETURN VALVE AND BRACKET
APPLICATION
The T-VALVE OXYGEN WITH NON-RETURN VALVE AND BRACKET, is design

for use where any desired number of cylinders supplies the UNITOR AC AND OX
GAS DISTRIBUTION SYSTEM with oxygen gas.
DESIGN
The T-VALVE OXYGEN WITH NON-RETURN VALVE AND BRACKET has a solid
brass body and is easy to operate with a hand wheel.
The T-VALVE is mounted on a bracket made of stainless steel and fitted with a non-return
valve made of brass.
FUNCTION
By using several T-VALVES FOR OXYGEN connected by high pressure connection

tubes, it is possible to connect any desired number of oxygen cylinders.
The last T-VALVE in the series is closed with a blind plug and a connection nut. The
first T-VALVE in the series is leading to the closing valve and the central regulator for
oxygen.
The none-return valves which are fitted to the T-VALVES prevent gas from flowing
back through the valves to the gas cylinders. This makes it possible to remove any of the
cylinders in the central and still continue to use the remaining cylinders.

17660
None-return valve: Brass body
Weight: 0.75 kg
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System Subject Ref.
UNITOR AC & OX WELDING CENTRAL REGULATOR R-520

ACETYLENE
APPLICATION
The CENTRAL REGULATOR R-520 FOR ACETYLENE is specially designed for use
as central regulator and fits directly into the UNITOR AC AND OX GAS DISTRIBUTION
SYSTEM, AC side.
The capacity of the regulator is sufficient for all normal demands, also when more than one
outlet station is supplied from the central installation.
DESIGN
The CENTRAL REGULATOR R-520 FOR ACETYLENE is easily connected to the

closing valve on the high pressure side with a 3/4" BSP RH fittings and to a connection
tube on the low-pressure distribution line with a 3/8" BSP LH fittings. The regulator is
fitted with a safety valve connected to a ventilation pipe to open air.
The CENTRAL REGULATOR is easy to operate with a large comfortable adjustment

wheel.
FUNCTION
The CENTRAL REGULATOR R-520 FOR ACETYLENE is designed for adjusting

maximum 15 bar inlet pressure down to maximum 3.0 bar outlet pressure and for keep the
working pressure constant when several welders are welding or cutting at the same time,
supplied from the same regulator.
When the desired working pressure has been set on the regulator, the setting is locked with a
locknut. It shall under normal conditions, only be necessary to reset the regulator when
exchanging the cylinders.
In case of any leak of gas in the CENTRAL REGULATOR a pipeline will carry the
escaping gas out to the open deck.
Correct use is an important part of the safety aspect. The regulator is therefore delivered with
an instruction manual for the user.
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System Subject Ref.

GAS DISTRIBUTION SYSTEM CENTRAL REGULATOR 520 OXYGEN 61-03-014
APPLICATION
The CENTRAL REGULATOR R-520 FOR OXYGEN is specially designed for use as
central regulator and fits directly into the UNITOR AC AND OX GAS DISTRIBUTION
SYSTEM, OX side.
The capacity of the regulator is sufficient for all normal demands, also when more than one
outlet station is supplied from the central installation.
DESIGN
The CENTRAL REGULATOR R-520 FOR OXYGEN is easily connected to the

closing valve on the high pressure side with a W21.8x1/14" fittings and to a connection
tube on the low- pressure distribution line with a 3/8" BSP fittings. The regulator is fitted
with a safety valve connected to a ventilation pipe to open air.
The CENTRAL REGULATOR is easy to operate with a large comfortable adjustment

wheel. The valve sealing materials are of special composition to minimize self ignition
risk.
FUNCTION
The CENTRAL REGULATOR R-520 FOR OXYGEN is designed for adjusting

maximum 150 bar inlet pressure down to maximum 10 bar outlet pressure and to keep
the working pressure constant when several welders are welding or cutting at the same
time, supplied from the same regulator.
When the desired working pressure has been set on the regulator, the setting is locked with a
locknut. It shall, under normal conditions, only be necessary to reset the regulator when
exchanging the cylinders.
In case of any leak of gas in the CENTRAL REGULATOR a pipeline will carry the
escaping gas out to the open deck.
Correct use is an important part of the safety aspect. The regulator is therefore delivered with
an instruction manual for the user.
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System Subject Ref.

GAS DISTRIBUTION SYSTEM CENTRAL REGULATOR 520 OXYGEN 61-03-014
CAPACITY GRAPH
TECHNICAL INFORMATION
Material: Body: Brass CuZn39Pb3, DIN 1660

Capacity: 3
40m /h
Max. inlet pressure: 150 bar
Inlet pressure: Gauge: 0 - 400 bar
Max. outlet pressure: 10 bar
Outlet pressure: Gauge: 0 - 16 bar
Safety valve setting: 20 bar
Inlet thread: W21.8x1/14"
Outlet thread: 3/8" BSP
Weight: 1.4 kg
WTS Page 82

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System Subject Ref.
UNITOR AC & OX WELDING FLASHBACK ARRESTOR 85-10 AC

FOR CENTRAL REGULATOR
APPLICATION
The FLASHBACK ARRESTOR 85-10 AC FOR CENTRAL REGULATOR is a safety

device for use on the distribution pipe line for acetylene in the central station. The
FLASHBACK ARRESTOR 85-10 AC is connected between the regulator and the low
pressure pipe line coil and is a standard component delivered with all central
installations. Flashback arrestors for acetylene are required by most of the marine
authorities for use on board ships.
DESIGN
The FLASHBACK ARRESTOR 85-10 AC is particularly designed for fuel gasses

as acetylene and propane. The FLASHBACK ARRESTOR has a high pressure tested
body and the main parts consists of brass. It is completely enclosed when mounted in
the central station.
The ARRESTOR 85-10 AC incorporates an inlet filter, a non-return valve, a flashback

arresting element and a temperature operated cut-off valve.
FUNCTION
The FLASHBACK ARRESTOR 85-10 AC allows a gas flow of 7.5 m3/h with a minimum
pressure drop at 1.5 bar maximum working pressure.
The FLASHBACK ARRESTOR 85-10 AC is designed to fulfil the following safety

functions:
In case of a flashback the flame will be arrested. The non-return valve will close and the
gas-supply will be shut off automatically.
A single flashback will normally cause the cut-off valve to operate.
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System Subject Ref.
UNITOR AC & OX WELDING FLASHBACK ARRESTOR 85-10 AC

FOR CENTRAL REGULATOR
In the event of repeated flashbacks, the arrestor will be overheated, the cut off valve will
close the gas-supply. The cut-off valve will also operate if the flame stabilize undetected
inside the arrestor or when overheated by an external fire.
Note! If the cut-off valve has been operated, the complete

unit must be replaced.
Material: Body: Brass, CuZn38Pb3, DIN 17660

Connection threads: Inlet: 3/8" BSP LH
Outlet: 3/8" BSP LH
Standards: Complies with DIN/EN 730, ISO 51751 and BS 6158
Max working pressure: 1.5 bar
Capacity: 7.5 m3/h
Weight: 0.42 kg
WTS Page 84

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System Subject Ref.
UNITOR AC & OX WELDING HIGH PRESSURE HOSE AC WITH

ELBOW
APPLICATION
The HIGH PRESSURE HOSE COMPLETE FOR ACETYLENE is the connection

between the cylinder valve and the closing valve on the high pressure side in the acetylene
gas distribution system, or the cylinder valves and the T-valves where the gas distribution
system consists of more than one acetylene cylinder.
DESIGN
The HIGH PRESSURE HOSE COMPLETE FOR ACETYLENE is built up of three major
parts, the high pressure hose, the coupling elbow and a 3/4" right hand thread connection nut.
The rest of the connections are left hand threads.
The high pressure hose is built up of a double spun steel cord with hytrel coating. The coat
is red for acetylene. The coupling elbow consists of a stainless steel tube with brass
connection nuts.
In the connection between the high pressure hose and the coupling elbow there is a washer of
aluminium and in the connection between the coupling elbow and the cylinder valve there is a
washer of teflon.
FUNCTION
The HIGH PRESSURE HOSE COMPLETE FOR ACETYLENE is connected to the cylinder
valve with the 90 degrees coupling elbow and to the closing valve or to the T-valve with the
high pressure hose. The high pressure hose makes it very easy to disconnect the cylinder.
WTS Page 85

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System Subject Ref.
UNITOR AC & OX WELDING HIGH PRESSURE HOSE AC WITH

ELBOW
Material: Hose: Double Spun Steel cord. AISI 302

Jacket: Hytrel
Inner tube: Teflon
Connection nuts: St. steel AISI 303
Coupling elbow: St. steel AISI 316 L
Connection nuts: Brass CuZn38PB3
Washer: Aluminium or Teflon
Colour: Hose: Red
Hose bending radius: Min. 50mm
Test pressure: 300 bar (air) + 600 bar (water)
Burst pressure: min. 800 bar
Nominal working pressure: 0 – 15 bar
Weight: 0.53 kg
WTS Page 86

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System Subject Ref.
UNITOR AC & OX WELDING HIGH PRESSURE HOSE OX, WITH

ELBOW
APPLICATION
The HIGH PRESSURE HOSE COMPLETE FOR OXYGEN is the connection between
the cylinder valve and the closing valve on the high pressure side in the oxygen gas
distribution system, or the cylinder valves and the T-valves where the gas distribution
system consists of more than one oxygen cylinder.
DESIGN
The HIGH PRESSURE HOSE COMPLETE FOR OXYGEN is built up of three major
parts, the high pressure hose, the coupling elbow and a 21,8x1/14" right hand thread
connection nut.
The high pressure hose is built up of a double spun steel cord with hytrel coating. The
coat is blue for oxygen. The coupling elbow consists of a stainless steel tube with brass
connection nuts.
In the connection between the high pressure hose and the coupling elbow there is a washer of
aluminium and in the connection between the coupling elbow and the cylinder valve there
is a washer of teflon.
FUNCTION
The HIGH PRESSURE HOSE COMPLETE FOR OXYGEN is connected to the

cylinder valve with the 90 degrees coupling elbow and to the closing valve or to the T-
valve with the high pressure hose. The high pressure hose makes it very easy to
disconnect the cylinder off the high pressure gas distribution pipe line.
Material: Hose: Double Spun Steel Cord. AISI 302

Jacket: Hytrel
Inner tube: Teflon
Connection nuts: St. steel AISI 303
Coupling elbow: St. steel AISI 316 L
WTS Page 87

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System Subject Ref.
UNITOR AC & OX WELDING HIGH PRESSURE HOSE OX, WITH

ELBOW
Connection nuts: Brass CuZn38PB3

Washer: Aluminium or Teflon
Colour: Hose: Blue
Hose bending radius: Min. 50mm
Test pressure: 300 bar (air) + 600 bar (water)
Burst pressure: min. 800 bar
Nominal working pressure: 0 – 150 bar
Weight: 0.53 kg
WTS Page 88

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System Subject Ref.
UNITOR AC & OX WELDING EXPANSION PIPE AC, HIGH

PRESSURE
APPLICATION
The EXPANSION PIPE AC, HIGH PRESSURE is the connection between the T-valves
and the first T-valve and the closing valve on the high pressure side in the acetylene gas
distribution pipe line.
DESIGN
The EXPANSION PIPE AC, HIGH PRESSURE has a stainless steel pipe with brass
connection nuts which are fitted to the tube as swivels to enable easy connections. The
EXPANSION PIPE has a 360 degrees loop which makes the connections between the
different parts vibration-free.
FUNCTION
The EXPANSION PIPE AC, HIGH PRESSURE fits both the closing valve and the
T-valve and makes the connection between these parts.
It is only necessary to use the EXPANSION PIPE in a gas distribution system consisting of
more than one acetylene cylinder.
Material: Pipe: Stainless steel AISI 316 L

Connection nuts: Brass
Wall thickness: 1 mm
Nominal working pressure: 18 bar
Weight: 0.14 kg
WTS Page 89

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System Subject Ref.
UNITOR AC & OX WELDING EXPANSION PIPE OX, HIGH

PRESSURE
APPLICATION
The EXPANSION PIPE OX, HIGH PRESSURE is the connection between the T-valves
and the first T-valve and the closing valve on the high pressure side in the oxygen gas
distribution pipe line.
DESIGN
The EXPANSION PIPE OX, HIGH PRESSURE has a stainless steel pipe with brass
connection nuts which are fitted to the tube as swivels to enable easy connections. The
EXPANSION PIPE has a 360 degrees loop which makes the connections between the
different parts vibration-free.
FUNCTION
The EXPANSION PIPE OX, HIGH PRESSURE fits both the closing valve and the
T-valve and makes the connection between these parts.
It is only necessary to use this EXPANSION PIPE in a gas distribution system consisting of
more than one oxygen cylinder.

Wall thickness: l mm
Weight: 0.14 kg
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UNITOR AC & OX WELDING EXPANSION PIPE AC, LOW

PRESSURE
APPLICATION
The EXPANSION PIPE AC, LOW PRESSURE is the connection between the central
regulator and the fixed low pressure gas distribution pipe line for acetylene.
DESIGN
The EXPANSION PIPE AC, LOW PRESSURE has a stainless steel pipe with brass
connection nuts. The connection nuts are fitted to the stainless steel pipe as swivels to
enable tight connections. The EXPANSION PIPE has a 360 degrees loop which makes
the connections between the different parts free of vibration.
FUNCTION
The EXPANSION PIPE AC, LOW PRESSURE makes the connection between the fixed gas
distribution pipe line free of vibrations.
Note: The expansion pipe is delivered with a pre-welded union for easy connection to the
fixed low pressure gas distribution pipe line.

Wall thickness: l mm
Nominal working pressure: 0.8 bar
Inlet thread: 3/8" BSP LH
Outlet thread: 3/8" BSP LH
Weight: 0.22 kg
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UNITOR AC & OX WELDING EXPANSION PIPE OX, LOW

PRESSURE
APPLICATION
The EXPANSION PIPE OX, LOW PRESSURE is the connection between the central
regulator and the fixed low pressure gas distribution pipe line for oxygen.
DESIGN
The EXPANSION PIPE OX, LOW PRESSURE has a stainless steel pipe with brass
connection. The connection nuts are fitted to the stainless steel pipe as swivels to enable easy
connections. The EXPANSION PIPE has a 360 degrees loop which makes the connections
between the different parts free of vibration.
FUNCTION
The EXPANSION PIPE OX, LOW PRESSURE makes the connection between the fixed gas
distribution pipe line free of vibrations.
Note: The expansion pipe is delivered with a pre-welded union for easy connection to the
fixed low pressure gas distribution pipe line.

Wall thickness: 1 mm
Inlet thread: 3/8" BSP RH
Outlet thread: 3/8" BSP RH
Weight: 0.22 kg
WTS Page 92
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UNITOR AC & OX WELDING OUTLET STATION 700 COMPLETE

W/SG5 AND CABINET
APPLICATION
The GAS OUTLET STATION 700 for bulkhead mounting is used in connection with
the AC and OX gas distribution system and must be ordered separately.
According to the NMD regulations, in general, only 2 OUTLET STATIONS are

permitted in every AC and OX gas distribution system. On special purpose ships additional
OUTLET STATIONS may be accepted. The number will be approved in each
individual case.
GAS OUTLET STATIONS are in general, only permitted in engine room and/or
workshop. They shall be positioned in a well-ventilated place and in such a way that they
are protected against mechanical load. On special purpose ships outlet stations are also
permitted on open deck. The location shall be approved in each individual case.
DESIGN
The GAS OUTLET STATION MODEL 700 is designed to obtain a high degree of safety
together with ease of operation.
The GAS OUTLET STATION MODEL 700 consists of the following main
components:
• Twin valve unit for bulkhead fastening. The ball-type closing valves for AC
and OX are fitted with pre-welded connection unions.
• Regulators type R-700+ for adjusting the working pressure. Alternatively
the outlet station can be delivered with regulator R530.
• Flashback arrestors SG-5 for AC and OX. These are the standard arrestors
for this outlet station. Alternatively the outlet station can be delivered with
flashback arrestors type W66S.
• Stretch-relief bracket for the welding hoses.
• The standard protective cabinet made of 1.5mm mild steel plate.
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W/SG5 AND CABINET
FUNCTION
The UNITOR GAS OUTLET STATION MODEL 700 is delivered with installation
instructions and directions for use and maintenance.
On the inlet side of the OUTLET STATION the low pressure distribution pipes are
connected to the twin valve unit with two pre-welded unions and connection nuts. All
connections between the distribution pipes and the pre-welded unions is done by butt
welding.
The center distance between the pipes is 150 mm. There is a detachable filter in the
adapter on the inlet end of the ball valve. It shall remain there the first year of use, to
collect possible scales and rust particles.
The central regulators are set at a little higher pressure than 0.8 bar for acetylene and 8.0
bar for oxygen. The exact working pressure are to be set with the regulators in the outlet
station. The pressures depend on the type of work. Welding, cutting, plate/material
thickness, etc.
The flashback arrestors, one for each gas, are connected between the regulators and the
welding hoses. They shall, in case of a flashback, prevent the flash to reach the central.
The model SG-5 are standard supply with the outlet station. Alternatively W-66S can be
delivered on request.
Material: Cabinet: Mild steel

Mounting: Cabinet: 6 screws M6, yard supply
Twin valve unit: 4 screws M6, yard supply
Stretch reliefer: 2 screws M6, yard supply
Colour: Cabinet: Blue, RAL 5010
Weight: 10.8 kg
WTS Page 96
CHAPTER 4
WTS Page 97
CHAPTER 4
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INSTALLATION PROCEDURES 61-00-004-3-E

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UNITOR AC & OX WELDING CENTRAL INSTALLATION FOR

6 CYLS, 2 AC AND 4 OX
GENERAL
This installation procedure for CENTRAL INSTALLATION FOR 2 AC AND 4 OX

CYLINDERS is meant as a general line for the installer. Prior to the installation, drawings
and documentation of the central installation with piping shall be submitted to the
classification society for approval.
Before the central installation is brought into use it must be inspected, de-greased,
blown through and pressure tested in compliance with the rules of the statutory Authorities.
When the installation is found to be in order an installation certificate is issued.
INSTALLATION
Prior to the installation all the equipment, piping as well as connections, shall be
cleansed for all grease, oil and other combustible substances. For degreasing,
trichloroethane or another equally effective degreasing agent shall be used. Petrol must
not be used.
WARNING FOR CONSEQUENCE OF OIL AND GREASE
Prior to, as well as after the installation, pipe lines and connections shall be blown clean
with nitrogen. Compressed air from an oil lubricated compressor, or oxygen, shall
not be used.
The central gas cylinder store shall be a separate room on or above the upper
continuous deck. The three fastenings racks for the cylinders are to be welded to the
bulkhead. The racks are made of steel and the surface threated with zinc for good
corrosion protection. Screws and nuts in the clamps assembly are of stainless steel to
ensure easy and fast removal of the cylinders.
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To eliminate the possibility of the equipment being incorrectly connected, all

connections are left-hand threaded for acetylene and right-hand threated for oxygen.
An exception to the acetylene side are the cylinder valve and the closing valve with
3/4" right hand threads.
The six high pressure hoses, two for acetylene and four for oxygen, are coloured coded.
Red for acetylene and blue for oxygen. They are fitted with coupling elbows and nuts
for connections to the cylinder valves.
In the other end each high pressure hose shall be connected to a T-valve. Two for
acetylene and four for oxygen. Each T-valve is fitted with a non-return valve. The non-
return valves prevent back flow of gas to the cylinders.
The first T-valve for each gas shall be closed in the left end with a blind plug and a
connection nut. The T-valves shall be connected with each other with high pressure
expansion pipes. The last T-valve for each gas shall be connected to the inlet side of the
closing valve with a high pressure expansion pipe. This pipe must be formed to a loop
that fits between. The high pressure expansion pipes also serves the purpose to make
the connections free of vibrations.
The T-valves and the closing valves are mounted on brackets made of steel, and
recommended mounting of the valves are on the same bulkhead as the cylinders, above
and a little to the right of each cylinder.
The R-520 gas regulators are fitted directly to the closing valves. The safety valve
on the R-520 gas regulators are supplied with 06 mm and 100 mm long pipes (steel for
acetylene and copper for oxygen) for connection to ventilation pipes leading to open
deck. The ventilation pipes must terminate in open air according to the regulations.
The low pressure side of the regulators shall be connected to the low pressure
expansion pipes. On the acetylene side a flashback arrestor shall be connected between
the regulator and the expansion pipe. The low pressure expansion pipes also serves the
purpose to make the connection free of vibrations between the regulators and the fixed
low pressure pipe lines.
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The low pressure expansion pipes shall further be connected to the fixed distribution
pipe lines with prewelded unions and connection.
All connections between the unions and the fixed distribution pipes shall be done by
butt welding. The expansion pipes must be formed to loops that fits between the
regulators and the distribution pipes.
The fixed distribution pipes should be seamless steel pipes of ST 35 or of equivalent or

better quality, with minimum wall thickness of 2.0 mm and 2.5 mm on open deck.
Standard size is outer diameter 20-22 mm. On request such pipes are available from
Unitor.
Optional accessories are clamps for 20 mm diameter pipes, which should be fitted at
maximum 2.5 metres intervals. Bushings for ducting and sealing of the distribution pipes
trough decks and/or bulkheads are available from Unitor.
SIGNS MOUNTING
The signs are printed in black on yellow PVC-plastic. They may be attached to the bulkhead
by means of screws or glue.
1. Signs for entrance doors:
1. " ACE T YL E NE "

2. "OXYGEN"
3. "Gas under pressure"
4. "Gas danger"
5. "No admittance"
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2. Instruction signs for gas central:
6. "Acetylene instruction"
7. "Oxygen instruction"
8. "Pipeline pressures"
3. Signs for outlet station:
9. "Cl ose va l ve s "

10 . "Working pressure"
4. Sign for outlet point of the ventilation pipes:
11. "Gas danger"
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GENERAL
Before installation, read, understand and follow the instructions in the Regulations on welding
equipment, etc. for the welding gases acetylene and oxygen in ships, mobile drilling
platforms and special purpose ships in offshore activity, laid down by the Norwegian
Maritime Directorate on 5 March 2000 by virtue of § 1 and 42 in the act of 9 June 1903
relating to state control of the seaworthiness of ships, with subsequent amendments, cf,
Royal Decree of 5 April 1963, which describes the gas bottle central-, piping- and outlet
point installation together with the testing and control of central plants etc.
PRIOR TO INSTALLATION
Piping as well as connections shall be cleansed of all grease, oil and other combustible
substances. For degreasing, trichloroethane or another equally effective degreasing agent
shall be used. Petrol must not be used.
Warning! Prior to, as well as after the installation, pipe lines and
connections shall be blown clean with nitrogen.
Compressed air from an oil lubricated
compressor, or oxygen, shall not be used.
THE GAS CENTRAL
Requirements to the gas central and cylinder stores:
• It shall be located in the ship's superstructure, above the upper through-going

deck, and have direct access to open deck.
• Deck, bulkheads and roof in the central room shall be of steel.
• It shall be gas-tightly separated from adjacent rooms/spaces.
• It shall have separate ventilation, not connected to the ship's other ventilation
system. The ventilation (natural or forced) shall be so an-anged that the
temperature in the gas central shall not normally exceed 40° Celsius.
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• All electrical installation in the gas central shall be of explosion-proof

type.
• The gas central shall be used for n other purpose than storage of gas
cylinders.
CYLINDER RACKS
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The cylinder racks shall be welded or bolted to the bulkhead and they are to be in sufficient
number to accommodate all the ship's acetylene and oxygen cylinders. Additional racks to
accommodate spare cylinders must be ordered separately.
HIGH PRESSURE COMPONENTS
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Pos. component:
1. High pressure hose with elbow

2. T-valve with non-return valve
3. Blind plug
4. Co n ne c ti on nut
5. Expansion pipe, high pressure
6. Closing valve
To eliminate the possibility of the equipment being incorrectly connected, all connections
are left-hand threaded for acetylene and right hand threaded for oxygen. An exception to the
acetylene side are the cylinder valve and the closing valve with 3/4" right hand threads.
HIGH PRESSURE HOSES
The high pressure hoses are supplied in 1 mtr. lengths, complete with coupling elbow and
nut for the cylinder valves. Couplings are of stainless steel. Each hose is degreased and
pressure tested and labelled with test pressure, 300 bar. The high pressure hoses are coloured
red for acetylene and blue for oxygen.
Correct connection of the high pressure hose will considerably extend its service life.
Therefore the hose must be connected without any turns or sharp bends.
First connect the straight end of the hose to the non-return valve and then the elbow to the
cylinder valve.
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T-VALVES WITH NON-RETURN VALVE
The T-valves close the vertical inlet from the high pressure hose, while the horizontal gas
flow remains open. The non-return valves are gravity operated and they are fitted to the T-
valves in vertical positions. This makes it possible to remove any of the cylinders in the
central without interrupting the gas flow from the remaining cylinders.
The T-valves are mounted on brackets made of steel, and recommended mounting is
welding or bolting to the bulkhead.
BLIND PLUG
The last T-valve in a series requires a blind plug to close the valve side inlet. The blind plug
is held in place on the T-valve by a connecting nut. When the connecting nut is tightened,
the cone of the blind plug firmly blocks the opening.
EXPANSION PIPE
These serve as expansion loops to ensure flexibility in the individual spacing between the
T-valves, and between the last T-valve and the closing valve. They also give maximum
resistance against vibrations.
CLOSING VALVE
This valve is found in all central installations. It closes the connection between the
cylinder(s) and the regulator.
When the central plant is not in use, the closing valves, T-valves and cylinder top valves
shall be closed.
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LOW PRESSURE COMPONENTS
ACETYLENE COMPONENTS:
Pos. components:
1. Central regulator
2. Flash back arrestor
3. Low pressure expansion pipe
4. 12mm union Prewelded and supplied with
5. Connection nut LP-exapansion pipe (3)
6. 16-20mm. union
7. Pipe clamp
8. Bushing
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OXYGEN COMPONENTS
Pos. components:
1. Central regulator
2. Flash back arrestor
3. Low pressure expansion pipe
4. 12mm union Prewelded and supplied with
5. Connection nut LP-exapansion pipe (3)
6. 1 6-2 0m m un io n
7. Pipe clamp
8. Bushing
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CENTRAL REGULATOR
The regulators R-520 for acetylene and oxygen is specially designed for use in central
installations. The R-520 is fitted with hand wheels and lock nuts. When the pressure is
set to the correct values; 0.8 bar for acetylene and 8.0 bar for oxygen, the lock nut is
tightened, and further pressure adjustment in the central is unnecessary when the central
installation is in use. Further adjustments in the pressures for welding and cutting
operations is done on the outlet station regulators.
The safety valve on R-520 is supplied with a 06 mm and 10 cm. long pipe (steel for
acetylene and copper for oxygen) for connection to the ventilation pipe to open deck. The
pipe should terminate in open air according to the regulations. The ventilation pipe is yard
supply.
LOW PRESSURE EXPANSION PIPE
The low pressure expansion pipes make the connections between the regulators and the
fixed pipe line. The pipe loop may be formed to the exact shape and make the connection
free of vibrations.
The low pressure expansion pipe should be connected to the fixed pipe line with and
prewelded union and a connection nut. The prewelded union should be welded to the fixed
pipe line by buttwelding.
FLASHBACK ARRESTOR
The 85-10 flashback arrestor shall be mounted between the regulator and the low pressure
expansion pipe on the acetylene side. The arrestor is fitted as an extra safety device if a
flashback occurs in the distribution pipe line and/or because of a function fault in the
arrestor for acetylene in the outlet station.
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LOW PRESSURE DISTRIBUTION PIPE (FIXED PIPE LINE)
The NMD has the following stipulation concerning the fixed low pressure distribution pipe:
"Pipes shall be seamless, made of ST35 or equivalent material, and have a wall thickness of
minimum 2.0 mm". On special purpose ships the wall thickness of pipe lines on open
deck shall be at least 2.5 mm.
Recommended outer diameter is 20 mm.
Installing (NMD rules):
• Pipeline not to be carried through unventilated rooms or through accommodation

spaces for crew or passengers.
• Where pipeline passes bulkhead or deck, protective bushings to be used.
• Pipeline to be securely fastened by approved clamps. Max. distance between
fastening 2.5 m.
• Pipe joints to be buttwelded (end to end). Unions, muffs, flanges or similar
couplings are not accepted.
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ACETYLENE
GENERAL
The CENTRAL REGULATOR R-520 FOR ACETYLENE fits directly into the closing valve
for acetylene in the UNITOR welding gas central.
The special safety valve on R-520 is equipped with a 100 mm long steel pipe for connection
to the ventilation pipe leading to open deck.
Connection from the regulator R-520 to the fixed distribution pipe is done with the stainless
steel low pressure expansion pipe. The low pressure expansion pipe is connected to the
distribution pipe by an outlet union with the LP-expansion pipe.
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OXYGEN
GENERAL
The CENTRAL REGULATOR R-520 FOR OXYGEN fits directly into the closing valve for
OXYGEN in the UNITOR welding gas central.
The special safety valve on R-520 is equipped with a 100 mm long copper pipe for
connection to the ventilation pipe leading to open deck.
Connection from the regulator R-520 to the fixed distribution pipe is done with the stainless
steel low pressure expansion pipe. The low pressure expansion pipe is connected to the
distribution pipe by an outlet union which is delivered with the LP-expansion pipe.
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W/SG-5 AND CABINET
GENERAL
The UNITOR OUTLET STATION MODEL 700 for bulkhead mounting is delivered
complete with installation instructions and instructions for use and maintenance.
The complete outlet station model 700 consists of the following main components:
• Twin valve unit for bulkhead fastening. Ball-type closing valves for acetylene
and oxygen are fitted.
• Prewelded connection pipes and reducing tubes (20 mm to 16 mm).
• Regulators type R-700+ for adjusting the working pressure, with working
manometers. Alternatively it may be fitted with regulator R-530.
• Flashback arrestors SG-5 for acetylene and oxygen. These are the standard
arrestors for this outlet station. Alternatively it may be fitted with flashback
arrestors type W66S.
• Stretch-relief bracket for the welding hoses.
• Protective cabinet, made of 1.5 mm mild steelplate
INSTALLATION
The OUTLET STATION shall be positioned in a well-ventilated place in such a way that
it is protected against mechanical load.
Use the enclosed mounting plan for outlet station, and then mark on the bulkhead
where the outlet station is to be placed and finish the necessary pipe work. Centre
distance between pipes is 150 mm.
Weld the low pressure distribution pipes to the connection stubs on the outlet station.
All welds shall be buttwelds. Note that there are detachable filters in the adapter on
the inlet end of the ball valves. It shall remain there the first year of use, to collect possible
scales and rust particles.
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W/SG-5 AND CABINET
Fit the connection pipes to the ball valves. Fasten the outlet station and the cabinet on the
bulkhead and mount the stretch relief bracket.
INSTALLATION TEST
Leak test according to the regulations of the National Authorities.
Use nitrogen and pressure of 12 bar for oxygen and 12 bar for acetylene side for 8 hours.
Maximum permitted pressure drop of 0.4 bar.
Classification Society and/or National Authority must be present.
MAINTENANCE
The model 700 outlet station has two filters for each gas, located directly above and
below the ball closing valve in the connections.
To get at the filter above the ball closing valve, unscrew the nut holding the filter from
the valve. With the ball valve removed you can unscrew the filter unit, using a 6 mm
Allen key.
To get at the filter below the ball valve, unscrew and remove the regulator key. The filter
may then be unscrewed downwards with the 6 mm Allen key.
We recommend that the upper filter nut is unscrewed after the plant has been in
operation for five years, and the filter removed from it and discharged. Before
reassembling the outlet station, make a leak test of the unit.
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W/SG-5 AND CABINET
SIGNS
The signs are printed in black on yellow plastic. They may be attached to the bulkhead
by means of screws or glue.
Signs for outlet station:
1. "Close valves"
2. "W orking pressure"
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UNITOR AC & OX WELDING SIGNS FOR CENTRAL

INSTALLATION
GENERAL
There is a number of signs in the UNITOR AC AND OX GAS DISTRIBUTION SYSTEM to

be mounted at various locations. The signs are in accordance with NMD regulations and
Norwegian Standard 6033.
The text of warning notices and prohibition signs shall be in Norwegian as well as in English.
LOCATION
Entrance doors in gas cylinder centrals, gas cylinder cabinets or rooms where acetylene and
oxygen are stored, shall be marked with the following signs:
1. ACETYLENE
2. OXYGEN
The door shall also be fitted with the following prohibition signs:
3. ADGANG FORBUDT
NO ADMITTANCE
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INSTALLATION
4. GASSFARE
GAS DANGER
Further the door shall be fitted with the following warning sign:
5. GASS UNDER TRYKK
GAS UNDER PRESSURE
The "GAS DANGER" sign (4) should also be posted at the outlet point of the ventilation pipes
from the central regulators.
Inside the central room, or rooms where the acetylene and the oxygen cylinders are separated,
the following signs shall be used:
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INSTALLATION
6. ACETYLENE INSTRUCTION
7. OXYGEN INSTRUCTION
8. PIPELINE PRESSURE
Sign 8 should be placed close to the central regulators.

When two rooms are used, one sign 8 to be put in each
room.
Inside of the door of the protective cabinet for the outlet

station, or on the bulkhead close to the outlet if no cabinet
is mounted, should be fitted with the following signs:
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INSTALLATION
9. OUTLET STATION
10. WORKING PRESSURE
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INSTALLATION
SIGNS FOR ENTRANCE DOOR, CYLINDER CENTRAL
1.
2.
3.
4.
5.
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INSTALLATION
6.
7.
8.
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INSTALLATION
9.
10.
SIGN FOR GAS PRESSURE RELIEF PIPES OUTLET
11.
WTS Page 124

CHAPTER 5
WTS Page 125

CHAPTER 5
WTS Page 126

Q-15427 06/12/2015
Bill of Materials
Regulations compliant Bill of Materials
No. Item Description Qty UoM
1 510578 GAS DISTR. SYST. 6CYL. 2AC + 4OX 1 PCS
2 550277 OUTLET STATION 700 complete W/FLASHBACK ARRESTOR 5 PCS
Wilhelmsen Technical Solutions | 4

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CHAPTER 6
WTS Page 187

CHAPTER 6
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1
ApprdvalCertificate·
This is to certify, thatL undernoted products have been approved in accordance WITh·
the relevant reqUiremeilnts of the GL Approval System.
Certificate No. • 46726·12 HH
Company Wilhelmsen Technical Solutions Sp. zoo.
Stobno 74
72-002 Doluje, POLAND
Product Gas Welding Installation
Type AC and OX Gas Distribution System
I
Technical Data / SYSTEM ARRANGEMENTS: I
Application Gas Central Installation for 2 Cyl. 1 AC + 1 OX, No. 61-00-001
Gas Central Installation for 3 Cyl. 1 AC + 2 OX, No. 61-00-002
Gas Central Installation for AC and
OX Cylinders in separate rooms
Shielding Gas Central Installation with

No. 61-00-00
r
I
2 Cylinders for Argon or UNIMIX Ar+C02/80/20 No. 61-00-40~
Shielding Gas Central Installation with I
4 Cylinders for Argon or UNIMIX Ar+C02/80/20 No. 61-00-40f
Shielding Gas Central Installation with
2 Cylinders No. 61-00-41 1
I
Approval Standard VI-3-5 Guidelines for Design, Equipment and Testing of Gas Welding Installations
on Seagoing Ships, Ed. 2008 I
Documents Test report: 2011-R020 Oxygen, 2011-R023 Acetylene Habia Te1knofluor;
List of manufacturing standards and available approvals Unitor;
I
CONTINUATION see page 2
Remarks Prior to initial operation the gas welding system is to be surveyed and tested in the
presence of a GL-Surveyor.
Valid until 2017·10-30
File No. XI.O.01

II
Germanischet Lloyd
c~ ~----------------
~~~~--~~~-
Christian Kaemmer
Page 1 of 3 WTS Page 189

App rova I. Certificate
~ >,. -,' .' ',' ,'.
Certificate No.
, .
46726·12HH
Consisting of (only main components):
VALVES:
Cylinder Valve Acetylene No: 61·03·001
CylinderValveOx 150 bar No: 61~03·003
Closing VaiveAC with Bracket No. 61·03·009
Closing Valve OX with Bracket No.61~03·010
T ·ValveAC with Non-Return Valve and Bracket No. 61·03·011
T·Valve OX with Non-Return Valve and Bracket No. 61·03·012
Connection Nut AC114" for AC T·Valve No. 61·03·015
Connection Nut OX 114" for OX T-Valve No. 61·03"016
BlincfPlugfor T·Valve No: 01·03·0'17
Regulator R·700 +AC W/Hose Conn. for Outlet Station No. 61·03·018
RegulatorR·.100+0X W/Hose Conn. Tor Outlet Station No. 61·03·019
Non-Return Valve AC for T-Valve No. 61-03.020
Non-Return Valve OX for T-Valve No. 61·03·021
Flashback Arrestor FR·50 AC.F Acetylene Regulator No. 61·03-024
F,lashback Arrestor FR·SO OX F Oxygen Regulator No. 61·03·025
Twin Valve Unit for Outlet Station No. 61-03-026
Flashback Arrestor 85·10 F Acetylene on Central Regulator No. 61·03·027
Flashback Arrestor 85·10 F Oxygen on Central Regulator No. 61·03·028
Flashback Arrestor 5·55 AC for Regulator No. 61·03·029
Flashback Arrestor S·55 OX for Regulator No. 61·03·030
RegulatdrR~520 AC, physically same as R~510 No. 61·03·113
Regulator R·520 OX, physically same as R·5i0 No. 61·03·114
Regulator R·530 AC W1Hose Conn. for Outlet Station, No. 61·03·118
Regulator R·530 OX W/Hose Conn. for Outlet Station No. 61·03·119
Non Return Valve 1/4" No. 61·03·401
Closing Valve 12 mm for Regulator R 500 No. 61·03·402
Regulator R 500 + for Nitrogen No. 61·03·403
FLEXIBLE HOSES; PIPES AND FITTINGS:

High Pressure Hose AC with Elbow No. 61·04·001
High Pressure Hose OX with Elbow No. 61·04·002
Expansion Pipe AC High Pressure No. 61·05·001
Expansion Pipe OX High Pressure No. 61·05·002
Expansion Pipe AC Low Pressure with prewelded Union No. 61·05-003
Expansion Pipe OX Low Pressure with prewelded Union No. 61·05·004
Quick Coupling for AC Hose No. 61-05-005
Quick Coupling for OX Hose No. 61·05·006
Prewelded Union 12/20 mm fo'r Gas Central Outletfor Gas Central Outlet Acetylene No. 61·05·008
Union 12/20 mm for Gas Central Outlet Oxygen No. 61·05·009
Clamp. No. 20 for Steel Pipe 20'mm No: 61·05-012
Bushing for Steel Pipe 19.5 ·23.0 mm No. 61·05·013
Blind Plug 12 mm for Manifold No. 61·05·401
Germanischer Lloyd
F'
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lH~hspeter Raschle Christian Kaemmer
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1': Page 190 Page 2 of3
I
Approval Certificate
Certificate No. 46726·12HH
Manifold for 2 N2 Cylinders with Non-Return Valves No. 61·05·402

Manifold for 4 N2 Cylinders with Non-Return Valves No. 61·05·403
OTHERS:
Outlet Station 700 Complete W/FR-50 and Cabinet No. 61-06-001
UCT-500 Combination Torch Master for Gas Welding/Cutting No. 17-05-007
Twin Hose 2*9 mm Red/Blue f. Gas Welding AC/OX No. 17-04-005
Twin Hose 2*6,3 mm Red/Blue f. Gas Welding AC/OX No. 17-04-003
Cylinder Assembly A-40 No. 61-01-021
CONTINUATION of page 11 9ocuments:

Certificate of conformity Gas Control Equipment Flash back arrestor FR50; Test report Acetylen hose F609192A; Test report
Oxygen hose F6091928 B; Ddclaration of conformity Ningbo Longxing Welding for UCT-500 Combination Torch Master;
CertificateBAM/ZBF/009/12 fbr Safety Devices, Wilhelmsen; Certificate BAM/ZBAl003104 rev. 04 Safety devices and quick
action couplingsl Witt Gaset~1chnik; Certificate of Conformity No: 153105165-4 steam less gas cylinders of TOV Rheinland.
Test report L.34.541 Apragaz High pressure regulator OX Type 510/520; Test report L.34.542 Apragaz HighPre. ssure regulator
AC Type 510/520; Certificate f conformity Flashback arrestor Witt Gasetechnik;
REMARK: All a. m.parts have to be in accordance with the recognized standard, of approved type and marked accordingly.
I
~~rmahiSCher, Ll1yd
Hamburg,. 2012-'11·15
.~ . V 1l~.
'~lu fi.-A:;likvuz'~
Hanspeter R~sc~le Christian Kaemmer
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PRODUCT

GAS WELDING DISTRIBUTION SYSTEM

VESSEL NAME/HULL NO.: EP09

PROJECT NO.: Q-15427

4 • INSTALATION PROCEDURES 99 – 124

• MATERIAL SPECIFICATION 127 – 128

6 • CERTIFICATES 189 – 210

GENERAL INFORMATION 61-00-004-1-E

PBA 19.05.14 00 WLE Page 1 of 4

The system arrangement is built up by means of standard components, all individually

The system consists of the following main components:

GENERAL INFORMATION 61-00-004-1-E

PBA 19.05.14 00 WLE Page 2 of 4

GENERAL INFORMATION 61-00-004-1-E

PBA 19.05.14 00 WLE Page 3 of 4

GENERAL INFORMATION 61-00-004-1-E

PBA 19.05.14 00 WLE Page 4 of 4

GENERAL INFORMATION 61-00-990-1-E

PBA 19.05.14 00 WLE Page 1 of 3

UNITOR AC AND OX GAS DISTRIBUTION SYSTEM is designed and developed

 Less physical damages to cylinders because of less dangerous internal transport.

 Easy removal of cylinders in case of fire.

 Location of cylinders known to everyone on board.

 Fewer interruptions during large-scale operations due to change cylinders.

GENERAL INFORMATION 61-00-990-1-E

PBA 19.05.14 00 WLE Page 2 of 3

 Space is released for other purposes.

 Expenses concerning internal transport reduced.

GENERAL INFORMATION 61-00-990-1-E

PBA 19.05.14 00 WLE Page 3 of 3

GENERAL INFORMATION 61-01-001-1-E

PBA 19.05.14 00 WLE Page 1 of 1

An acetylene cylinder with a volume of 40 litres normally contains 16 litres of acetone.

Wrenches or other tools must never be used

GENERAL INFORMATION 61-01-002-1-E

PBA 19.05.14 00 WLE Page 1 of 1

Wrenches or other tools must never be used.

GENERAL INFORMATION 61-01-990-1-E

PBA 20.05.14 00 WLE Page 1 of 1

HANDLING, USE AND MAINTENANCE

GENERAL INFORMATION 61-01-990-1-E

PBA 20.05.14 00 WLE Page 2 of 1

 Never try to repair or modify any part of a cylinder.

 Never empty a gas cylinder complete. Return it with a positive pressure of 1

 The cylinders and their appurtenances shall be marked only by UNITOR or

GENERAL INFORMATION 61-99-991-1-E

PBA 19.05.14 00 WLE Page 1 of 2

Acetylene is produced industrially by the reaction of water with carbide in acetylene

Relative molecule mass: 26.04

temperature: 192.3 K (-80.85°C)

pressure: 1.267 bar (0.308 ato)

heat of melting: 96.46 kJ/kg

GENERAL INFORMATION 61-99-991-1-E

PBA 19.05.14 00 WLE Page 2 of 2

1.013 bar: 189.12 K (-84.0°C)

heat of evaporation: 686 kJ/kg

density: 419.4 kg/m³

temperature: 303.1 K (35.94°C)

pressure: 62.52 bar (62.75 ato)

density: 419.4 kg/m³

Highest combustion value: 503.70 kJ/kg

Spontaneous combustion temp.: 608 K (335°C)

Combustion speed in O2 : 13.5 m/sec.

Explosion limits: in air: 1.5-82 vol.%