L&T-MHI BOILERS PVT.

LTD
CTCW-LMB TRG CENTRE

GAS CUTTING
PROCESS

PRESENTED BY :
K.S.VARIA 1
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 Main Points to be Cover
SAFETY IN GAS CUTTING.
USE OF GASES.
GAS CUTTING EQUIPMENT &
ACCESSORIES.
Oxygen Cylinder, Acetylene Cylinder, Oxygen
Regulator,
Acetylene Regulator, Cutting Torch, Cutting
Nozzel(tip),
Flash Back Arrestors, Tip Cleaner, Hose pipe,
Gas Cylinder
Trolley, Conectors.
TYPE OF FLAME.
GAS CUTTING PRINCIPLE.
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 Safety in Gas Cutting Process
FLASH BACK ARRESTORS
CAPABLE OF

ARRESTING

CYLINDER

EXPLOSIONS.

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 How They Work

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 Proper PPE for Gas Cutting
Safety Glasses
& Face Shield
Safety Helmet

Nose Mask

Leather Welding Hand Long Sleeve

Gloves

Lag Gard
Safety Shoes

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 Lens Shades Selection

LENS SHADES SELECTION FOR OXYGEN FUEL GAS

APPLICATIONS
Minimum
Material Size Recommended
Operation Protective
(inches) Shade Number*
Shade number
<1 3 3-4
Oxygen Fuel Gas
1 to 6 4 4-5
Cutting
>6 5 5-6

As a rule of thumb, start with a shade that is too dark to see the cutting
zone.
Then go to a lighter shade, which gives sufficient view of the cutting
zone without going below the minimum.
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 Equipment Inspection
Look For Any Physical Damage
Look For Signs of Abuse or Improper
Use
Look For Contamination Oil, Gress,
etc.
Clean, Replace Or Repair Before Use

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 Cutting Gas

Cutting Gas
Oxygen
Fuel Gas
Acetylene
LPG Liquified Petroleum Gas
Propen

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 Oxygen Cylinder

High Pressure Cylinder 2200 PSI ,

154.67 Kg/cm2
Oxygen
Hollow, Seamless Steel (Cylinder Painted
Black)
Construction

Do Not Abuse Cylinder

Report Any Damage to Supplier
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 Acetylene Cylinder

Fusible
Plug
Low Pressure 250 PSI, 17.57 Kg/cm2 @
70o F

Thin Walls, Welded And Easily Damaged

Monolithic
Porous Filler
Material Do Not Abuse Can Explode Because of
Abuse

Never Use A Damaged Cylinder

Fusible
Report Damages To Supplier
Plug
Do Not Attempt To Repair Leaks
Move Leakers Outside If Permitted
Acetylene
(Cylinder Painted
Maroon)
Acetylene Cylinder

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 Regulators
Oxygen Acetylene
Regulators Regulators

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 What is the difference between the
Single-stage and Two-stage Regulator?

Single-stage pressure regulators reduce the

cylinder pressure to the delivery or outlet
pressure in one step.
Two-stage pressure regulators reduce the
cylinder pressure to a working level in two
steps.
The best recommended action is to
determine how you intend to use the
pressure regulator. Generally a
single-stage regulator is good for short
duration applications; a two-stage regulator
is good for long duration applications, such
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 Single-Stage Regulator

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 Two-Stage Regulator

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 Oxy-Fuel Gas Cutting Torch

Become universal tool

Used widely for straight-line,
shape cutting
Used to fabricate metal
structures from heavy rolled
steel

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 Gas Cutting Torch Comparision

ANM Torch
Price of each torch :
MESSER make = Rs 2800/-
Price of each nozzle = Rs 300/-

All new torches purchased on shop

floor as a replacement to scraped
cutogen torch are of MESSER make
NM type only

CUTOGEN-5 Torch

Price of each torch with nozzle:-

ESAB make = Rs 4000/-

Advani make = Rs 3500/-

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 Gas Cutting Torch Comparision

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 Gas Cutting Torch
CUTOGEN Torch

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 Gas Cutting Torch
ANM Torch

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 Gas Cutting Operating Parameters

OPERATING PARAMETERS
CUTTING OXYGENE ACCETYLENE
MATERIAL THICKNESS SIZE OF PRESSURE PRESSURE
NOZZLE KG/SQ.C
MM INCH KG/SQ.CM PSI PSI M
6 1/4 1/32 - A 8 1.4 20 3 0.2
12 1/2 3/64 -A12 2 30 3 0.2
25 1 1/16 -A16 2.5 35 3 0.2
50 2 1/16 -A16 3.2 45 3 0.2
75 3 1/16 -A16 3.5 50 4 0.26
100 4 1/16 -A16 4.2 60 4 0.26
150 6 5/64 - A20 4.5 65 5 0.33
200 8 3/32 -A24 4.9 70 6 0.4
250 10 7/64 - A24 5.3 75 6 0.4
300 12 1/08 - A32 5.3 75 6 0.4

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 Cutting Tips

Straight Gouging Tip

4

1 Rivet-Burning Tip 5
Close Quarters
Cutting Attachment
Bent Gouging Tip 6
2
Long Cutting
Tip Sheet Metal Cutting Tip 7
3
Rivet-Cutting Tip
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 Cutting Tips
Around this
center hole are
a number
of preheating
flame holes.
The cutting tip has
a central hole
through
which the high
pressure oxygen
flows

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 Standard Cutting Tips
Cutting tips are designated as
standard or high speed.
The standard tip has a straight
bore cutting oxygen port and is
typically used with oxygen
pressures in the 30 to 60 p.s.i.
range.

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 High Speed Cutting Tips

The high speed tips have a

diverging
cutting oxygen port that flares
out
toward the opening.
This flaring out allows much higher
oxygen
pressure (60100 p.s.i.), while
maintaining
a uniform oxygen jet at supersonic
velocities.
These high speed tips are typically
used only
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 Gas Cutting Hose Pipes

INCH ID (MM ) OD ( mm WP BP ( mm
) ( BAR ) )

6 13 15/20 45/60

5/16 8 15 15/20 45/60

3/8 10 17 15/20 45/60
13 22 15/20 45/60

5/8 15 25 15/20 45/60

19 30 15/20 45/60

1 25 36 15/20 45/60
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 Gas Cutting Hose Pipes
Application
Used in almost every engineering workshops, steel mills,
power stations, construction sites, ship yards etc.
Constructions
Lining Smooth linings of natural/synthetic/blend rubber
compound resistant to fuel gas, oxygen and other non
combustible gases.
Reinforcement
Natural/synthetic fiber applied by a suitable technique.
Cover
Smooth/fluted/cloth marks finish of suitable rubber
compound resistant to heat and weather.
Color
Red for fuel gases, Blue for Oxygen and other
noncombustible gases.
Pressures
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 Tip Cleaner & Lighter

One Two Piece

Piece

Lighter
Lighter
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 Size of Conector & Accessories
Cutting head
Nut 250 Nm Right Hand Cutting
(L.H) Hose Nut 1/4" Bsp ,
3/8" Bsp

Cutting head Left Hand Cutting

Nut 250 Nm Hose Nut 1/4" Bsp ,
(R.H) 3/8" Bsp

Cutting Hose
Coupler 1/4"-1/4"
Regulator Inlet M , 3/8"-1/4" M , 3/8"-
Stem 1/2" x 3/8" M
27mm
O Clips/Hose
Clamp 3/8 ,
3/8" Nut Hose Tail 1/2"

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 Gas Cylinder Trolley

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 Types Of Cutting Flame

Carburizing Flame
50000F - 27600C

Neutral Flame
59000F - 32600C

Oxidizing Flame
63000F - 34820C

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 Gas cutting principle
Feasible Only On Plain Carbon Steels & Low Alloy
Steels
Process is by Conversion of iron to iron oxide
Steel Locally Heated to Kindling Temperature
(870C) by Oxy Fuel Preheating Flame.
A jet of oxygen is then impinged on this preheated
hot iron.
Iron instantaneously converted in to black iron oxide.
Exothermic Reaction
2Fe + O2 = FeO + Heat (270 kJ),
3Fe + 2O2 = Fe3O4 + Heat (1100kJ)
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 Gas cutting principle

Kinetic energy of Oxygen jet drives all non metallic

iron oxide .
Heat Generated in exothermic reaction is self
sustaining for preheating the metal ahead to cut
When flame with a jet of oxygen at the centre
moves close to the material, the process is
continues by separating the material along the path
of oxygen jet
Purity of oxygen required for cutting - 99.5%

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 Oxy-Fuel Cutting
Definition: Burning is the rapid
oxidation of a material
Does Metal Burn?
Virtually all materials will burn if they are
first heated to their ignition temperature.
Steel ignition temp is when it is cherry
red, 1300-1400 F
Oxygen burns preheated metal and blows it away
from the work piece.

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 Cutting Speed
Too Slow- Molten metal will collect on
bottom of work piece and need to be
ground off
(this is called Dross)

Too Fast- Metal will not be cut all the

way through

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 Oxy Fuel Flame Cutting
Requires that the part to be cut be
raised to a temperature of 1,500-
1,600F
Stream of pure oxygen directed onto
hot metal causing it to burn rapidly
Burning steel gives off iron oxide as a
product of combustion
Iron oxide solid at room temperature
Melting point below melting point of
steel so iron oxide runs off as molten
slag, exposing more iron to jet
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 Procedures for Metal Cutting
Place the cutting tip perpendicular to the metal surface.
Align the preheat flame so that half the flame is on the
metal.
Place the tips of the preheated inner cones as close as
possible to the metal without touching it.
Preheat the starting point until the metal is cherry
red, and then press the oxygen cutting lever.
To start the cutting, tilt the cutting tip slightly in the
direction of the cut.
Move the tip at a constant speed along the cutting
line.
If you stop the cutting in the middle of
the procedure, immediately release the
oxygen cutting lever. To restart the
procedure, preheat the starting point at
the edge and continue as normal.

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 Oxy Fuel Flame Cutting

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 Demonstration of Gas Cutting

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 Cut Quality

Quality Cut

Extremely Fast

Irregular Pressure

Extremely Slow

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 ANY
QUESTION

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