Use a flint lighter to ignite the flame. A welding inspector cannot reasonably expect to be able to monitor all of this for every single station and weld performed. weld joint, 2.) Following are the main areas where we mostly find the difference: 1.) 2. It is used in low pressure oxy-acetylene welding. in any part of the flushing loop. However, ALL must be cleaned to remove any dirt, grease, oil, wax, or any other foreign substance, and ALL must be dry‐fitted. I have a question as to when to use weld gaps between fitting and when not too. The DOHC 16V Volvo B234 was in '89-'90 740 in US and '91 940 in Canada. prior to use. Hydrostatic testing of pressure piping systems in practice. (Courtesy of M.E. 3) More cable types are allowed for Div. An underground storage tank (UST) system is a tank (or a combination of tanks) and connected underground piping having at least 10 percent of their combined volume underground. Do not expose a hose to oil or grease; these rot the rubber and cause a hazard. 6. What is the probable cause if a connection is operating hot when welding? a. A poor electrical connection b. The cables are not grounded 2. They are adamant all fittings must be steel (right) because steel fittings never gall the coolers aluminum threads, even after many decades. Making a welded connection to a 'live' pipeline, or vessel, is commonly known as ' hot tapping ' or in-service welding and there are National (and proprietary) Standards that provide details of the controls that are necessary. Construction. The process is being used to join or create small and large components, and its success has largely been attributed to vacuum solutions. Start studying Oxyacetylene Welding and Brazing Final. The tank system includes the tank, underground connected piping, underground ancillary equipment, and any containment system. I use a torch called a Henrob (AkA Cobra 2000) for gas welding. All piping, valves and associated fittings should be independently supported, so as to place no strain on the pump housing. I do not leave a thick coating on the table, but a light spray followed by a good wipe-down with a clean rag seems to leave the surface in good condition for mig or tig welding. The inner part of the fitting will be released by a pull and twist motion. Crane Consultant). use of clamps, 3.) It can also damage the insulator in the nozzle. Before using a welding arc, gear up in welding helmet with fitted lens, welding gloves, welding jacket, leather apron and thick leather boots. Oil storage. You can't expect to safely weld an object unless it's on a flat, even and secure surface. 1 or No. Place the pieces together and heat with the torch. The ASME valve standard B16.34 is a globally accepted standard to design, manufacture and test valves used in the oil and gas industry. detector is used and maintained correctly (see Section 3 below). Do not expose bare skin to flux fumes. Awareness of the most common welding hazards and knowing how to avoid them ensures a safe, productive work environment for all. Email: [email protected] Visit Our Warehouse in Kalamboli. The low-pressure blow pipe or welding torch is used to carry the acetylene at low pressure (0.02 bars) from acetylene generator. Therefore, the major components of any lube oil system are as follows: Welding environments, and their surrounding areas, must be kept clean and free of flammable material before and during welding. A controversial pipeline welding technique is root of the problem. Do not use oxy-fuel equipment near oil or grease contain-ers. Sometimes tig welding is not the answer. Controlling Hazardous Fume and Gases during Welding. Fittings: Fittings allow for quick and simple repairs to be carried out to the structure. The pace of pipe laying is determined by how quickly the root pass can be done. Inspect hoses for defects/deterioration before use. a. any reducing regulator b. an approved gas specific pressure reducing regulator c. a inch copper coil d. a manifold unit 4. Its not uncommon for pipeline and rig arc welders to work 10- to 12-hour days. Always double check. Adapters must not be used to permit the interchange of hoses. Open Regulator Oxygen and Acetylene, set until the pressure matching with what do you want or for acetylene 5 to 7 psi and Oxygen 7 to 10 psi. Get a bit of oil on a harbor freight air hose and you have a swollen mess within one year. DO NOT Install a low pressure gauge into the high-pressure port on a regulator. A butt weld pipe fitting is designed to be welded on site at its end (s) to connect pipe (s) together and allow change in direction or pipe diameter, or branching or ending. a. 2) You must run conductors in RMC or threaded steel IMC raceways in Div. Pipeliners can receive a pretty good salary and perks. Allow very little movement when transporting. It allows for real good control of the flame and is soft enough to prevent blow through on aluminum. electrode coating, and 6.) 3)You mention "venting" the tank. Reason #2: They are not given a copy at their station. The pressure of acetylene drawn from the generator is quite low, i.e., less than 0.07 bar. pipes. Mobile: +919167989294. 6 tacks for 14 and larger dia. Water and electricity are the most dangerous combination and can take lives in seconds. Welding environments, and their surrounding areas, must be kept clean and free of flammable material before and during welding. Never attempt to weld on unstable surfaces, as this places you at risk for injury. As well as flammable liquids such as petrol, diesel and fuel oil, substances such as paints, glue, anti-freeze and cleaning agents may also release flammable vapours. Ground the work or metal to be welded to a good electrical ground. 348]] Public Law 115-141 115th Congress An Act To amend the State Department Basic Authorities Act of 1956 to include severe forms of trafficking in persons within the definition of transnational organized crime for Such explosions have killed people. Allow very little movement when transporting. I learned that gas welding of oil soaked aluminum is the only way to ensure a leak free weld. From being able to give out superior It is mainly used in ductwork and piping applications and is also known as thread seal tape and plumber's tape. to check hoses for leaks before use. This fitting then becomes part of a system for transporting fluids (oil, gas, steam, chemicals, ) in a safe and efficient manner, over short or long distances. Seam welding is a resistance welding process for joining metal sheets in continuous, often leak tight, seam joints by directly applying opposing forces with electrodes consisting of rotary wheels. Therefore, welding temperatures start at the melting point of the base metals. (196.80 inc VAT) Mains Multi Compartment Fuel Tank Alarm - Bund/Overfill/High Low Level. Do not use sealants. I have been told this is wrong because there need to be a 1/8" weld gap added between the fittings. Last edited by 76GMC1500; 01-04-2014 at 01:58 PM . 2. The fluid velocity (V) should not be less than 2 to 3 m/sec. & Wall Thickness, Joint design etc. If pipe color codes are not used, it can be difficult to know what is within a given pipe, which can present many dangers. The purpose of a lube oil system is to continuously provide cool, clean oil to the bearings and gear (if applicable) at the proper pressure, temperature, and flow rate. Welding speed must also be considered when looking at the welding of the root pass. A Spanish version is also available. 3. Doing so could permit the formation of copper acetylide. In this article we are going to discuss one by one how and why the two welding methods differ from each other. The oxides can also remain in the weld and cause porosity, inclusions, lack of fusion and other weld defects. 2. Both of these processes add a layer of oxide to the cut edge that must be removed before welding. other protective equipment when welding and cutting. Never use copper couplings with acetylene. Wearing appropriate PPE like welding helmet and goggles to protect workers eyes and head from hot slag, sparks, intense light, and chemical burns. However, it is still widely used for a variety of applications. The fuel fittings are removed from the end of the hose differently. Oxygen or fuel gas from a cylinder may be used only through _____. Hoses. In the United States, oxygen hoses are colored green. Only properly trained personal should handle compressed gas cylinders. The problem is that during normal use, drill pipe acquires the properties of a permanent magnet. Furthermore, the test pressure must never exceed a pressure that would cause yielding, or the maximum allowable test pressure of some component exposed to the test. Forgetting to grind the joint during weld prep. The first we must Clean the nozzle, because if the head of the nozzle dirty will cause flame bad. James: Just a quick note, never ever use oxygen under pressure near oil! Example: a hydraulic system has a flow rate and tube diameter to achieve Re=3,400 in normal service. Hydrostatic testing of pressure piping is a mandatory activity before finalization of any new or modified piping system. Just don't drill through the tank though. Wear proper protective equipment, such as rubber boots and rubber pads, if performing arc welding in wet or high humidity conditions. Phone: +912266581538. Oxy-fuel equipment is versatile, lending itself to welding, brazing, braze-welding, silver soldering, metal heating (for bending and forming) and oxy-fuel cutting. I guess I'm a welder too. Welding, a process that dates back to the Iron and Bronze ages, has evolved into a highly specialized procedure that provides innumerable benefits across a range of industries and applications. Welding is generally suited to joining large assemblies where both metal sections are relatively thick (0.5/12.7mm) and joined at a single point. Oil and grease must not be applied to regulator fittings because: Acetylene welding was first used around 1911 to join pipe segments together (girth welding) and just prior to 1920, arc welding was introduced. Welding of Pipes and Fittings. Close the valve, and keep the protective device in place. 5.4 Essential Variables Welding Procedure must be re-established as a new procedure specification & must be completely re-qualified when any of the essential variables are changed. Again, ensure that the wire type and diameters and the gas and the gas mixture are compatible. If the cylinder is dropped on a hard surface it can cause an explosion. A common welding repair technique used in refineries is to weld a patch plate or sleeve onto equipment that is still operating and under pressure. OSHA Fact Sheet (Publication 3647), (2013). 4, BIT Chawl, Sandhurst Road Station Mumbai : 400 009. The high pressure will cause the oil to detonate,similar to a diesel ignition! When not in use, manifold and header hose connections must be capped. Hose connections must be kept free of grease and oil. 1 areas must be listed for Class I, Div. 4 tacks for 3 to 12 dia. Welding is a primary piping fabrication activity. Orbital welding provides a safe, reliable, clean method of fabricating fluid systems for a wide variety of industrial applications. The most common steels used for oil and gas cross country pipelines conform to API 5LX or similar such standards. Production, refining, and distribution of petroleum products require many different types and sizes of storage tanks. Pipe connecting to the pumps inlet flange must be aligned precisely with it before the bolts are tightened. A pH range of 8 to 10.5 is commonly used for pipe systems that include steel. The strong magnetic fields at the ends cause the electric welding arc to sputter, fluctuate, and leap wildly from side to side of the joint, making it difficult to get a good weld. They shall have a minimum bursting pressure of 1,000 psig (6.8 MPa) and shall be protected by a safety relief device which will relieve at a maximum pressure of 500 psig (3.4 MPa). DO NOT Touch Oxygen regulators or cylinder heads with hands or gloves that are contaminated with oil grease, grime or any organic material. Why should fuel gases used for cutting and welding be open 1 full turn? 01-04-2014 #23. Protect hoses and cylinders from sparks, flames and hot metal. Drowning can happen to anybody due to any reason. 2 fuel oil shall be provided with a device to indicate at the fill point, either visually or audibly, when the oil in the tank has reached a This pertains to light fuel oil (#1 or #2 diesel). welding tip. Advertisement. and larger sizes refer to the outside diameter. are going to braze and that they will not generate toxic fumes. Inspect hoses for leaks and worn places. It is especially the case if you are a pipeline welder in the oil and gas industry. They install steel fittings dry, or with red Loctite. Never use oil on the threads or fittings! Carefully review material safety data sheets. Pacific Oil Cooler Service notes their number-one issue with installations is thread-galling aluminum AN fittings (left). Replace bad hoses. Protect hoses and cylinders from sparks, flames and hot metal. Specification for Welding Earth Moving and Construction Equipment. Flying sparks are the main cause of fires and explosions in welding and cutting. Follow the companys internal safety practices. Wes917. installed so that oil or vapor will not be discharged into a building. This prevents settling of particles inside tubes and hoses. Fluorescent additive (injected into the system with oil and detected using Code of practice for welding on steel pipes containing fluids. Orbital welding is extremely versatile and has the ability to fuse together plumbing components in a wide variety of sizes and materials with a consistency that is difficult to match using manual welding techniques. Depending on the tanks size, Inerting may not be an option. The median wage for this role is around USD 58,000 annually. [115th Congress Public Law 141] [From the U.S. Government Publishing Office] [[Page 347]] CONSOLIDATED APPROPRIATIONS ACT, 2018 [[Page 132 STAT. Acetylene and other fuel gas hoses are colored red. In most cases, welding operations should only be performed in areas that have been purposely designed to minimize potential fires. The pH scale is logarithmic and commonly ranges from 0 to 14. With the coupling you would have adjustment with the leg then. Keep oxygen cylinders and fittings away from oil and grease. Do not use the valve cover to lift cylinders; they could be damaged and become unattached. Cracks. If the tank is large enough to allow entry, cleaning and ventilation along with Gas free services would be you most economical solution. Test for leakage at working pressure by immersing in water; leaks may be repaired by cutting out a faulty section of hose and inserting an approved coupling. At the low end of the median pay scale, the average salary is USD 53,000, and at the top, it is USD 89,000 annually. More aggressive The fluid does not necessarily boil. Allowed under the F Gas Regulations the leak detector must have a sensitivity of 5 g/year and should be checked annually. Even a small amount of oil or grease may ignite violently, with explosive force, in the presence of oxygen. Later, well get into how it welds, but for now, here are the top advantages to MIG welding with 100% CO2: Better joint penetration. It indicates how acidic or basic a solution is, with 0 being the most acidic and 14 being the most basic. Keep oil, grease and combustible dust away from all oxy-gen equipment. Flux cleans the metal and acts like a glue to hold the pieces together for soldering. Electric shock. Weld-On Solvent Welding Guide (cartoon version) (2.9Mb) Best Practices for Solvent Welding Thermoplastic Piping (147k) Cold Weather Solvent Welding Tips (697k) Hot Weather Solvent Welding Tips (614k) Weld-On Solvent Cement Set and Cure Time Table (79k) 2015 Pipe Leak Prevention Flyer (698k) Do not expose hoses to heat, traffic, slag, sparks, oil, grease, or sharp edges of metal. Keep in mind that the cleaner is not a substitute for the primer. A boiler is a closed vessel in which fluid (generally water) is heated. Changes other than those given in 5.4.2 made be made in the 4. It goes on with a little welding. Toolbox Talks was originally used as a way to encourage building workers to have regular documented safety meetings. API (American Petroleum Institue) 653 is the standard used to govern repairs and alterations of petroleum tanks of all varietes. If a welding blowpipe or burner is used on a tank or drum containing flammable material (solid, liquid or vapour), it can explode. A pH of 7 indicates neutrality. Using the paintbrush, spread the flux over the cleaned areas you will be soldering. 2. Just weld up the center oil drain hole at top and weld the outside edge of the oval holes on either side as they get too close to the gasket edge, cut off and weld up the water pump bypass elbow on the front and weld a 1"x1"x5.5" block of aluminum on the rear OSHA's Alliance Program. Underwater welders are specially trained, and they must be a good swimmer in order to prevent this to happen. Hoses . (99.60 inc VAT) Hytek Battery Tank Alarm - ATEX Certified. Threaded joints in the fill piping shall be made fuel oil-tight using joint compound conforming to CAN/ULC-S642-M, Compounds and Tapes for Threaded Pipe Joints, or Various methods are used to make sure the welds are of highest quality such as referring best international standards, creating approved welding qualification procedures etc. General Gas Welding Safety Tips. Maintenance welding is a standard rig activity and is quite varied. Which lubricant(s) should be used when connecting the parts of an oxy fuel gas welder? Apply Flux to Your Brass Pieces. The peripheral shapes of the electrode wheels concentrate the current and the heat generation. Learn vocabulary, terms, and more with flashcards, games, and other study tools. Use and Operation . Examples of these Standards are: BS 6990. 1) Fittings and flexible cords used in Class I, Div. Therefore, it is critical that welder and other personnel are trained in all aspects of visual inspection. Introduction to Flanges. The best time to do this was considered to be when they stood around the toolbox in the morning before starting work, so the term Toolbox Talks was born. Weld Cracks are the most serious type of welding defects. flame tube. Keep Flammable Materials Far from Welding Areas. Chills Rings are sometimes called backup rings or spacers. This is very common at fab shops where welding procedures specifications are only developed to satisfy a customer requirement. Make sure you vent it after you finished welding and not before, or else you will just put the oxygen back into it. It is the final check of mechanical integrity of the whole system and should be followed religiously as after this activity the piping system has to be commissioned. Pipe welding is a method for joining two pipes together. Welding: On the other hand, welding will require a hot works permit and a lot of planning beforehand, which means that you will be waiting much longer for a welded system. 8.7.3 Inside tanks provided with fill and vent pipes used for No. 5. You need a tin based flux, also known as a brass soldering flux. The preparation for gluing each type of pipe is slightly different. NB The cutting torch requires two oxygen supplies to the nozzle, one mixed with fuel gas for preheating and a separate oxygen flow for cutting. These are used mainly at equipments, valves and specialties. It is critical to ensure high quality welds to ensure safe plant operation. General Gas Welding Safety Tips. When using anti-spatter spray, take care not to use too much, as it can enter the weld joint and cause problems with weld penetration or even more spatter. welding technique, 4.) I regularly spray and wipe down my welding table top with WD 40. (106 ft./sec.) As important as it is to have written WPSs most fabricators dont have them. This means their PPE must not only be extremely safe, but also be very comfortable and flexible for long periods of work. Could you get a piece of angle iron and drill a few holes through the angle iron and angle bracket and then weld a coupling to the angle iron and bolt the setup to the tank bracket. Inspect equipment for leaks at all connections using approved leak-test solution. 1910.253 (c) (3) (i) Manifolds shall be of substantial construction suitable for use with oxygen at a pressure of 250 psig (1.7 MPa). These rings are machined pieces of metal that conform to the dimensions of the joint design used. Welding techniques used for pipes include arc welding processes including MIG welding and TIG welding. The tool used for cutting pipe threads is called a: A. pipe cutter B. pipe stock and die C. pipe threader D. pipe ratcher cutter Answer: B The tool used when working with larger sizes of pipe is called a: A. chain pipe wrench B. chain tongs C. chain holder D. A or B. Flanges are used when the piping joint needs dismantling. Make sure your detector is sensitive to the refrigerant type you are testing. Welding, cutting, and allied processes produce molten metal, sparks, slag, and hot work surfaces can cause fire or explosion if precautionary measures are not followed. Welders should not touch the metal parts of the electrode holder with skin or wet clothing. If you are working with AN fittings. Replace bad hoses. View Welding Chapter 11 & 12 Questions .pdf from ENGI 8971 at Memorial University of Newfoundland. WKPR 1109 - Welding Shop Monday, May xx, 201x Chapter 11 & 12 Questions Submitted to: xxxxxxxxxx Study Resources An explosion killed a contract welder who was repairing a two-compartment oil tanker and injured another worker at the EMC Used Oil facility. Inspect equipment for leaks at all connections using approved leak-test solution. Drowning is one of the most critical factors when we discuss the dangers of underwater welding. 7.3. The nominal commercial pipe sizes from 1/8 through 12 in. refer to the approximate ID measurement of Schedule 40 or standard wall, whereas nominal 14 in. Always insulate yourself from the work and ground. Keep oxygen cylinders and fittings away from oil and grease. ASME B16.34 is also mentioned in the more general ASME spec ASME B31.1, Power Piping Design.. Back in 1988, the scope of this standard was modified to include threaded-end and weld-end valves in addition to flanged-end The outer part of the fitting comes off of the hose with the same type of method. Properly tack parts to avoid extra spatter, poor weld aesthetics and less-than-adequate weld penetration. Store oxygen cylinders and fuel gas cylinders separately. AWS D14.1. from 164.00 ex VAT. Even a small amount of oil or grease may ignite violently, with explosive force, in the presence of oxygen. In the case of ASME B31, section 137.1.4, and the Boiler and Pressure Vessel Codes, the maximum test pressure must not exceed 90 percent of yield for any component exposed to the test. The ultrasound testing (UT) of a pipes wall thickness is critical for in-service repairs. Capable of higher welding speeds (gun travel). Avoid standing in water, on wet surfaces, or working with wet hands or wearing sweaty garments. Do not dip energized (hot) electrode holders in water. Avoid direct contact with the live parts of welding equipment and the workpiece. Sparks can travel up to oldest welding processes, though in recent years, it has become less popular in industrial applications. Construction. Small bolted or welded tanks might be ideal for production fields while larger, welded storage tanks are used in distribution terminals and refineries throughout the world. pipes. An explosion could result. This helps smaller machines handle thicker metal. In addition, it must say that standard ASME B16.9 used for butt welding reducers and B16.11 for forged steel, socket welding and threaded ones. Oil and gas industry welders need reliable protection through the use of personal protective equipment (PPE). A refinery is a complex array of pressure vessels, piping, structural carbon steel, and other components that depends on welding for its structural integrity. Lube oil system schematic. 3 tacks for 2 1/2 and smaller dia. The WD-40 will also help remove some of the soot and residue from mig welding. McMaster has them under push-on hose and fittings, it's $1.50 a foot for the hose and $8 for 5 fittings with pipe thread on them. Assess weld joints to ensure there are no excessive gaps, as poor part fit-up can lead to issues like burn-through or distortion. Clamp or fixture the part in the correct position. Also, forces and moments imposed on the pump nozzles do not exceed the allowable values specified by the vendor. If the wall thickness in the weld area is too thin, the operator must extend the sleeve area on the pipe. Identifying problems before welding can save a lot of time and money, do not limit your inspection until after welding. from 63.00 ex VAT. Defective tack welds must be removed prior to the actual welding of the joints. Process, Pipe & Fitting Mat, Dia. NFPA 30 states that piping shall comply with ASME B31 and that low melting point allows (such as bronze, aluminum, nickel, etc) may be used underground or where they do pose "undue risk". The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including water heating, central heating, boiler The joint should be prepared in such a way to allow the welder to maintain the proper wire extension and still access the bottom of the weld joint. Much like all types of professional adhesive tapes, it is usually sold pre-cut to a range of specified widths on small rolls or spools. #4) Welding On Unstable Surfaces. 83.00 ex VAT. 1 (theres an exception for concrete-encased PVC), but you can use any gasketed enclosed busways or wireways for Div. Aluminum wrenches are used to separate the fitting as it is two pieces. welding speed. The third open valve in the torch, first acetylene after that you can open oxygen valve. 2. Reason #1: There are no welding procedures specifications. 7.6 (a). The ability to safely weld the pipe also depends on the pressure the line is running; pressure is often lowered for repair work. The welder was in the process of welding transfer piping onto the tanker when residual hydrocarbon vapor from the 2,500-gallon rear compartment ignited, causing a powerful explosion. In certain pipelines where maintenance is a regular feature, breakout flanges are provided at definite intervals. Avoid direct contact with the live parts of welding equipment and the workpiece. Flushing requires a minimum of Re=4,080. Fill and Product Piping Connections to Domestic Storage Tanks: The fill pipe material shall be 2 in (50 mm) schedule 40 black steel. OIL, SAND, and SEDIMENT INTERCEPTORS ZURN PLUMBING PRODUCTS GROUPSPECIFICATION DRAINAGE OPERATION, 1801 PITTSBURGH AVENUE, ERIE, PA 16502 PHONE 814/455-0921 FAX: 814/454-7929 WEBSITE: www.zurn.com Page 3 FLOW CONTROL The Zurn flow control fitting must be installed properly in every installation. Se-lect filter lens based on the following guide from the Ameri-can Welding Society: 1.3 Fire Protection 1. The basic oxyacetylene torch comprises: torch body (or handle) two separate gas tubes (through the handle connected to the hoses) separate control valves. 4)Theoretically, if you purge the tank long enough, any fuel residues should vaporize and leave a "non-explosive" atmosphere, even if you have oxygen present. Do not drop cylinders or strike them against each other or against other surfaces violently. Do not use a regulator for more than one type of gas. A maintenance welder may work on heavy equipment, large vessels designed to hold liquids and gases, valves, and high-pressure pipes. In most cases, welding operations should only be performed in areas that have been purposely designed to minimize potential fires. Design - Implementation of Pipework standards. pipes. The following safety guidelines should be followed when performing various welding operations: Ensure fire extinguisher is charged and available. Ensure electrical cord, electrode holder and cables are free from defects (no cable splices are allowed within 10 feet of the electrode holder. PTFE tape is a simplistic yet highly versatile lubricating material and thread sealant. You can clean the pipe and fittings using sandpaper or a chemical cleaner. Fig. The materials they weld vary, too, and may include aluminum, stainless steel and carbon steel. One of the biggest problems is the controversial pipeline welding technique used in the 1970s. Applies to all structural welds used in the manufacture of earthmoving and construction equipment. Do not braze metals that have paint, galvanized coating, cadmium coatings, organic or inorganic coat-ings without removing those coatings first. Easy maintenance and repair. I have a drawing that shows a fitting make-up dimension based on adding up the two standard dimensions for the components used (4" tee to a 4"-150#RF flange). This heat must be of a high temperature to melt the base metals (the metals being joined) and the filler metals. Use a bubble solution (never a flame!) Oil b. Pipe-fitting compounds c. Thread lubricants d. Do not handle flux or flux-coated rods with bare hands; wear gloves or protective cream. 3. The different part of low press-welding torch is shown in Fig.
