Transcript Oxyfuel Process Principles

Oxyfuel Gas
Welding & Cutting
Principles of the
Processes
1
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Principles of the OFW Process
Bead without Filler Metal
Bead with Filler Metal
2
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Principles of the OFC Process
3
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Which Fuel Gas?
• Acetylene
• Methylacetylene-propadiene
• MAPP
• Propylene
• Propane
• Natural Gas
• Methan
4
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Fuel Gas Characteristics
Fuel Gas Technical Data
Neutral Flame Temperature
Acetylene
MAPP
5589oF
5301oF
5250oF
4579oF
4820oF
4.0:1
4.5:1
5.0:1
2.0:1
Oxygen Fuel Combination Ratio 2.5:1
BTU's Per Cubic Foot
Propylene Propane Natural Gas
1470 BTUs 2460 BTUs 2400 BTUs 2243 BTUs 1000 BTUs
Burning Velocity in Oxygen 22.7 Ft/Sec 15.4 FT/Sec 15.0 Ft/Sec 12.2 Ft/Sec 15.2 Ft/Sec
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Fuel Gas Characteristics - continued
Fuel Gas Technical Data
Flammability Limits in Oxygen
Flammability Limits in Air
Specific Gravity (air = 1@60oF)
Acetylene
MAPP
3-93%
2.5-60%
2.5-80%
0.91
Propylene Propane Natural Gas
2.5-60%
3.4-10.8% 2.0-11.1%
1.48
1.48
2.4-57%
5-59%
2.3-9.5%
5.3-14%
1.52
0.62
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Fuel Gas Characteristics - continued
Fuel Gas Technical Data
Acetylene
MAPP
Lbs./Gal. Liquid
--
4.80
4.80
4.35
4.28
Cu. Ft./ Lb. Gas
14.60
8.85
9.00
8.66
23.60
--
43.50
43.50
43.00
37.00
Cu. Ft./ Gal. Liquid
Propylene Propane Natural Gas
7
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Oxyfuel Gas
Welding & Cutting
Equipment
8
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Cylinders
High
Pressure
Hazard
Safety
Disc
Flammable
Monolithic
Porous
Filler
Material
Fusible
Plugs
Hollow
1/7th Rule
Vigorously
Supports
Combustion
9
Shock
Sensitive
Oxygen Cylinder
Acetylene Cylinder
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Oxygen Cylinder Valves
CGA 540
Handwheel
Packing Nut
Upper Valve
Seat
To Oxygen
Regulator
Lower Valve
Seat
Disc Ruptures
If Pressure
Goes Too High
10
From Oxygen Cylinder
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Acetylene Cylinder Valves
CGA 510
CGA 300
Handwheel
Packing Nut
Upper Valve
Seat
To Acetylene
Regulator
To Acetylene
Regulator
Lower Valve
Seat
From
Acetylene Cylinder
From
Acetylene Cylinder
11
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Acetylene Cylinder Valves - Linde (Presti-Lite)
To Acetylene
Regulator
CGA 510
Tank Wrench
Tee Wrench
Valve Stem
Packing Nut
Upper Valve
Seat
Lower Valve
Seat
12
From Acetylene
Cylinder
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Alternate Fuel Cylinder Valves
CGA 510
Handwheel
Upper Valve
Seat
Packing Nut
To Fuel
Regulator
Valve Relieves
Excess
Pressure Then
Re-seats Itself
13
Lower Valve
Seat
From Fuel
Regulator
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OFW & OFC Equipment Components
•
•
•
•
•
•
•
•
•
•
Oxygen Regulator
Fuel Gas Regulator
Gas Hoses
Torch Handle
Mixer
Welding Tips
Cutting Attachment
Cutting Tips
Filler Metal Optional
Gas Igniter
14
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Regulators
Oxygen Regulator
Fuel Gas Regulator
15
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OFW Equipment
Combination Welding Torch with Mixer and Welding Tip
16
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OFC Equipment
Combination Cutting Torch with Cutting Attachment
Straight Cutting Torch
17
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Torch & Cutting Valves
18
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Mixer Design
Fuel Gas
Oxy/Fuel Mix
Oxygen
Fuel Gas
Equal (Positive) Pressure Mixer
High Turbulence
Oxy/Fuel Mix
Fuel Gas
Oxygen
Fuel Gas
19
Injector (Low Pressure) Mixer
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Mixer Design - Continued
Equal (Positive) Pressure Mixer
Torch Head
Oxygen
Fuel Gas
Tip
Mixer
Mixer Nut
Torch Head
Oxygen
Fuel Gas
20
Injector (Low Pressure) Mixer
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OFC Head Mix Design
Equal (Positive) Pressure Mixer
21
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OFC Head Mix Design
Injector (Low Pressure) Mixer
22
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Oxyfuel Gas
Welding & Cutting
Regulators
23
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Which Regulator?
Single Stage Regulator
• Use When Slight Rise in Delivery Pressure from
Full to Empty Cylinder Condition Can Be Tolerated
Two Stage Regulator
• Use When a Constant Delivery Pressure from Full
to Empty Cylinder Condition is Required
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Single Stage Regulator
Adjusting Screw
Bonnet
Flexible
Diaphragm
Primary Spring
Gas To Torch
Gas From
Cylinder
Regulator Body
25
Secondary
Spring
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Cutaway
Bonnet
Gas From
Cylinder
Adjusting
Screw
Cylinder
Pressure Gauge
Primary
Spring
Secondary
Spring
Capsule
Flexible
Diaphragm
Working
Pressure Gauge
Gas To
Torch
Regulator Body
26
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Flow Chart
27
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Two Stage Regulator
Primary Spring
Second Stage
Regulator Body
Adjustable
Second Stage
Gas From Cylinder
Adjusting
Screw
Bonnet
Gas To Torch
Flexible
Diaphragm
Secondary Spring
Pre-Set First Stage
Primary Spring
First Stage
28
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Cutaway
Regulator Body
Gas From Cylinder
Secondary Spring
Cylinder
Pressure Gage
Bonnet
Adjusting
Screw
Capsule
Primary
Spring
Primary Spring
Capsule
Bonnet
Flexible
Diaphragm
Gas To Torch
Working
Pressure Gage
29
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Flow Chart
30
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Oxyfuel Gas Welding
Torch Handles, Mixers,
Tubes & Tips
31
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OFW Torch Handles
Tip
Mixer
Handle
Oxygen
Mixed Gases
Acetylene
Oxygen Valve
Acetylene Valve
32
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OFW Welding Tip Information
WELDING TIP SELECTION CHART
Thickness
of Metal
In Inches
Tip
Size
Number
1/64"
1/32"
3/64"
1/16"
3/32"
1/8"
3/16"
1/4"
5/16"
3/8"
1/2"
3/4"
1"
0
1
2
3
4
5
6
7
8
9
10
13
15
Diameter of
Oxygen
Welding Rod Pressure
In Inches
(P.S.I.G.)
------1/16"
1/16"
3/32"
3/32"
1/8"
1/8"
5/32"
5/32"
3/16"
3/16"
1/4"
1
1
2
3
4
5
6
7
8
9
10
13
15
Acetylene
Oxygen
Acetylene
Pressure Consumption Consumption
(P.S.I.G.)
(SCFH)
(SCFH)
1
1
2
3
4
5
6
7
8
9
10
13
15
2.2
3.3
4.4
5.5
6.6
8.8
11.0
14.3
17.6
22.0
26.4
33.0
38.5
2
3
4
5
6
8
10
13
16
20
24
30
35
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OFB Brazing Tip Information
BRAZING TIP SELECTION CHART
Thickness
of Metal
In Inches
Tip
Size
Number
1/64"
1/32"
3/64"
1/16"
3/32"
1/8"
3/16"
1/4"
5/16"
3/8"
1/2"
0
1
2
3
4
5
6
7
8
9
10
Diameter of Oxygen Acetylene
Oxygen
Acetylene
Brazing Rod Pressure Pressure Consumption Consumption
In Inches
(P.S.I.G.) (P.S.I.G.)
(SCFH)
(SCFH)
------1/16"
1/16"
3/32"
3/32"
1/8"
1/8"
5/32"
5/32"
3/16"
1
1
2
3
4
5
6
7
8
9
10
1
1
2
3
4
5
6
7
8
9
10
2.2
3.3
4.4
5.5
6.6
8.8
11.0
14.3
17.6
22.0
26.4
2
3
4
5
6
8
10
13
16
20
24
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Air-Fuel Soldering Tips
16GA Gas Air Adapter with Soldering Tip (Together)
16GA Gas Air Adapter with Soldering Tip (Separated)
½” – 20 Threads
35
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Air-Fuel Soldering Tip Information
SOLDERING TIP SELECTION CHART
Thickness
of Metal
In Inches
Tip
Size
Number
1/64"
1/32"
3/64"
1/16"
3/32"
1/8"
1
1
2
2
3
3
Diameter of Acetylene Acetylene
Soldering Wire Pressure Consumption
In Inches
(P.S.I.G.)
(SCFH)
1/16"
1/16"
1/16"
1/16"
3/32"
3/32"
2
2
4
4
6
6
1.5
1.5
2
3
4
5
36
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Oxyfuel Gas Cutting
Cutting Attachments,
Cutting Torches, & Tips
37
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OFC Hand Cutting Torches
Combination Torch with Cutting Attachment
Mixer
Cutting Tip
Cutting Lever
Cutting Valve
Oxygen
Union Nut
Oxygen Valve
Acetylene
Acetylene
Valve
38
Copyright  2004 Lincoln Global Inc.
OFC Cutting Tip Information
Thickness
of Metal
in Inches
Light gauge
to 3/16
3/16 - 3/8
3/8 - 5/8
5/8-1
1-2
2-3
3-6
CUTTING TIP SELECTION CHART
Tip
Cutting Oxygen Acetylene Oxygen
Acetylene
Size
Orifice Pressure Pressure Consumption Consumption
Number Drill Size (P.S.I.G.) (P.S.I.G.) (SCFH)
(SCFH)
000
00
0
1
2
3
4
#68
#64
#60
#56
#52
#48
#42
15-20
20-25
35-40
35-40
40-45
45-50
50-75
5-15
5-15
5-15
5-15
5-15
5-15
10-15
35-40
45-50
75-85
97-107
180-195
270-290
450-600
10-15
10-15
15-20
15-20
20-30
20-35
25-40
39
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OFC Torch Specialty Tips
Gouging
6290-G Gouging Tip
40
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OFC Torch Specialty Tips
Rivet Cutting
6290-R Rivet Cutting Tip
Tie Down Cutting
41
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OFC Torch Specialty Tips
Rivet Washing
6290-RW Rivet Washing Tip
42
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OFC Torch Specialty Tips
6290-2D Thin Sheet Cutting Tip
Thin Sheet Cutting
43
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Oxyfuel Gas Heating
Heating Assemblies,
Tubes & Tips
44
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Heating Tubes & Tips Information
HEATING ASSEMBLIES, TUBES and TIPS Selection Chart
H-63
Tip
Size
Number
2290-H
Tip
Size
Number
2290-HPM
Tip
Size
Number
1
1
1
10
25
4
12
160
320
40
80
2
2
2
15
45
7
22
220
520
55
130
3
3
3
25
70
8
25
340
920
85
230
4
4
4
50
110
10
30
640
1300
160
325
5
5
5
60
135
14
40
720
1600
180
400
Oxygen
Pressure
(P.S.I.G.)
Acetylene
Oxygen
Acetylene
Pressure Consumption Consumption
(P.S.I.G.)
(SCFH)
(SCFH)
45
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Oxyfuel Gas
Welding & Cutting
Peripheral Equipment
46
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Check Valves
Check Valves for Regulators
Check Valve for the Torch
47
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Oxygen Check Valve
Open Oxygen Check Valve
Closed Oxygen Check Valve
Normal
Gas Flow
48
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Acetylene Check Valve
Open Acetylene Check Valve
Closed Acetylene Check Valve
Normal
Gas Flow
49
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Dirty Check Valves
Dirty Acetylene Check Valve
Dirty Oxygen Check Valve
Normal
Gas Flow
50
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Flashback Arrestors
Flashback Arresters for Regulators
Flashback Arresters for Torches
51
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Normal Flow
Flashback Arrestor
Oxygen
Flashback Arrestor
Acetylene
Normal
Gas Flow
Normal
Gas Flow
Check Valve
Flame
Barrier
Thermal
Cut Off
52
Copyright  2004 Lincoln Global Inc.
Reverse Flow
Flashback Arrestor
Oxygen Reverse Flow
Flashback Arrestor
Acetylene Reverse Flow
Normal
Gas Flow
Normal
Gas Flow
Built In
Check Valve
Stops
Reverse Flow
of Gas(es)
Reverse
Gas Flow
53
Copyright  2004 Lincoln Global Inc.
Flashback
Flashback Arrestor
Oxygen Flashback
Flashback Arrestor
Acetylene Flashback
Normal
Gas Flow
Normal
Gas Flow
Flashback Flame
Quenched at the
Flame Barrier
FLASHBAC
OCCURING
54
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Quick Connectors
Quick Connectors for Regulators
Quick Connectors for Torches
55
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Hoses
Red (Acetylene) Hose Nuts
Have Left-Handed Threads
Green (Oxygen) Hose Nuts
Have Right-Handed Threads
“T” Grade Hose Required for all Fuels Except Acetylene
56
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Hose Nuts
Oxygen (Green) Hose Nuts
Have Right-Handed Threads
Acetylene (Red) Hose Nuts
Have Left-Handed Threads
57
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OFW Pressure Drop in Hoses
PRESSURE DROPS IN NOMINAL HOSE SIZES FOR OFW
Possible Pressure Drop is given in Pounds per Square Inch (PSI)
Hose
Diameters
Up to 25
Feet
25 - 50
Feet
50 - 75
Feet
75 - 100
Feet
3/16 Inch
1/4 inch
5/16 inch
3/8 inch
0.5
----
1.0
0.3
---
1.4
0.5
0.2
--
1.8
0.8
0.4
--
58
Copyright  2004 Lincoln Global Inc.
OFC Pressure Drop in Hoses
PRESSURE DROPS IN NOMINAL HOSE SIZES FOR OFC
Possible Pressure Drop is given in Pounds per Square Inch (PSI)
Hose
Diameters
Up to 25
Feet
25 - 50
Feet
50 - 75
Feet
75 - 100
Feet
3/16 Inch
1/4 inch
5/16 inch
3/8 inch
2.6
----
4.2
----
6.8
2.2
---
10.6
3.4
---
59
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Tank Wrenches
Tee Wrench
Tank Wrench
60
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Flint Lighter
61
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Tip Cleaner
Two Piece
One Piece
62
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