Gas Cutting

&
Welding
 ACETYLENE CYLINDERS

 Maroon in colour.

 Acetylene gas (C2H2) is dissolved in acetone

(liquid) and stored at 250 psi, in a specially
designed cylinder.

 Acetylene cylinders has a volume of 8.5 m3.

Typical Sectional view of
Valve Arrangement
Valve protection cap
Valve Protection Cap

Valve
Valve
OXYGEN CYLINDERS
 Oxygen is a colourless,
tasteless, and odourless
gas and is slightly
heavier than air.
 Oxygen cylinder is black
in colour.
 Oxygen stored at 2200
psi
 Oxygen cylinders has a
volume of 6.9 m3
 CYLINDER STORAGE

 Well ventilated room

 No open flame in the store
 10 m distance from oxygen and acetylene
cylinders
 No materials that are prone spontaneous
combustion
 Should not be stored in direct sunlight.
CYLINDER STORAGE

Inflammable Gas
 CYLINDER STORAGE
Empty Full

Min. 10’

Min.10’

Empty Cylinders Full Cylinders Oxygen Fuel Gas

 Cylinders containing oxygen shall be stored separate from fuel gas

cylinders.
 Maintain minimum 10 feet distance between Oxy & fuel gas
Accessories
Regulators
 UNLOADING FROM TRUCK

Never drop
Use wooden Ramp and coir matters (50cm
thick)
Keep the top of the cylinder up
 Roll the cylinder keeping it upright
 Lifting cylinders by crane

Use of cradle
4-leg bridle sling
D-shackle and lifting lug
 Use of Cylinder trolley

Shifting cylinders at site

Avoid Rolling & Manual carrying
Use trolley
 RIGHT OPERATION

 Keep the cylinder upright and away from hot

jobs.
 Ensure regulator is free from dirt or grease before
fixing.
 Blue or black hoses for oxygen and red for DA.
 Check for leakage by soap water test
 Purge the oxygen line first and then the DA line
one after the other and close the valves.
 CUTTING NOZZLES
Max. Materials Cutting oxygen
Size of
thickness, pressure in
nozzle
(MS in mm) kg/cm2
12 1/32” 1.4
25 3/64” 3.0
50 1/16’ 4.0
75 1/16’ 4.0
100 1/16” 5.0
150 5/64” 5.5
200 3/32” 7.5
250 7/64” 8.0
300 1/8” 8.0
 HAZARDS

 FLASH BACK.

 BACK FIRE.

 GENERAL FIRE.

 EXPLOSION.
FLASH BACK
 Retrogression of the fire upto the cylinder

BACK FIRE
 Retrogression of the fire in the cutogen
 REASONS
 When the blow pipe becomes hot.
 Nozzle blocked.
 Nozzle close to the job.
 Job close to the ground.
 Pressure difference between flame
pressure and the hose pressure.
 IF A BACK FIRE OCCURS

 Shut off the blowpipe valves, oxygen first and

then the fuel gas;
 Shutoff oxygen and fuel gas cylinder valves
 Cool the blowpipe with water, if necessary;
 Check for damages or faults, particularly the
nozzle.
 IF A FLASH BACK OCCURS

 Cylinder valves of both fuel gas and oxygen

shall be closed immediately.
(If it is safe to do so.)

 Replace damaged Hoses, Blow pipe, Flash

back arrestors & regulators before reuse.
 FLASH BACK PREVENTION
 Purge hose pipes before lighting.
 Only Spark igniters shall be used to ignite
 Flashback arresters shall be provided at both ends of
the hoses to prevent backflow of gas towards cylinders.
 Correct gas pressure and for the nozzle size shall be
used.
 FIRE ON CYLINDER
 Close the valve
 Try to extinguish the fire.
 Detach the regulator
 Immerse the cylinder in water or apply water
copiously at the bottom half of the cylinder.
 Open the valve and keep it the cool water till it
becomes empty
 Do not stand in the direction of fusible safety valve
fixed at the bottom of the cylinder.
 EXPLOSION

Reasons:
Fire on cylinder (pouring water on hot cylinder)
Cylinder exposed to external heat
Rough handling
 PPE

Helmets with face shields

Black glass - din value 4 to 5
Leather gloves
Leather apron
Safety shoes
SAFETY IN WELDING
Basic Elements of Welding Equipment
 SAFETY IN WELDING
 Earth the body of the welding machine
 Provide lugs for welding cables terminals
 Cable joints make with terminals, kept tight
 Ensure joint free cables for at least three meters from electrode holder
 Do not lay welding cables with other electrical cables
 Use proper cable for return lead also
HAZARDS

 Fire
 Shock
 Health hazards
 HEALTH HAZARDS
 Exposure during welding may produce the
following effects:
 Inflammation of the lungs (chemical phenmonitis)
 Pulmonary edema (swelling and accumulation of fluids)
 Chronic bronchitis.
 Asphyxiation
 Welder’s Eye
 OCCUPATIONAL EXPOSURE STANDARDS
RELATING TO WELDING FUME CONSTITUENT
OES
CHEMICALS LONG TERM SHORT TERM
Aluminum oxide 10 mg/m3
Cadmium 0.05 mg/m3 0.05 mg/m3
Chromium III 0.5 mg/m3
VI 0.05 mg/m3
Copper 0.2 mg/m3
Fluoride 2.5 mg/m3
Iron 5 mg/m3
Lead 0.15 mg/m3
Manganese 5 mg/m3
Nickel (insoluble) 0.5 mg/m3
( Soluble) 0.1 mg/m3
Ozone 0.1 PPM 0.3 PPM
Welding fume 5 mg/m3
 FACTORS TO BE CONSIDERED IN
ASSESSMENTS

Welding position
Welding location
Duration of exposure
 Preventive Measures

 Elimination or substitution
 Modification of the process or engineering
 Local exhaust ventilation
 General dilution ventilation
 Personal protective equipment
Personal Protective Equipment
 Face shield with attached helmet
 Eye
 Goggles, Face Shield
 DIN Value of Black glass 12 to 14 .
 Hand
 Leather Hand gloves (Flame Resistant)
 Body
 Leather Apron & Leg Guard.
 Foot
 Safety Shoe.
 HAZARDS AT SITE

 Working overhead.
 Working in confined spaces.
 Welding or cutting tanks or vessels.
 Tripping hazards.
Thank U