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23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
http://www.marineinsight.com/misc/marinesafety/20practicaltipsforsafegasweldingandcuttingoperationsonships/ 1/24
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20 Practical Tips for Safe Gas Welding and CuttingOperations On Ships
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23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
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JUNE 23, 2014 BY ANISH
On a cargo vessel, fire occurred in the mast house where oxygen and acetylene cylinders were stored.The crew had arranged two gas torches in tandem for carrying out hot work on the windlass drum. Boththe torches were connected in parallel from the same pair of gas cylinders by temporarily fitting“standard” tjoints at the regulator valves. At sometime during the hot work, it was decided to use onegas torch to carryout brazing repair work on the other torch while it was connected to the pressurizedgas hoses.
Flashback from the torch being heated travelled through the hoses up to the mast house, rupturing thehoses at the regulator valve connections and causing a fire inside. Fortunately, the backfire arrestors onthe regulators prevented a major explosion of the cylinders.
Such hazardous accidents can take place on any kind of ship if proper precautions are not taken whilehandling gas welding/cutting on board ships.
Compressed gas cylinders are used in ship’s engine room and deck for a variety of repair andmanufacturing operations. The two most used types of gas cylinders for this purpose are oxygen andacetylene.
When performing gas welding or cutting operation, following practical tips must be considered for safetyand efficiency of operations and to avoid accidents while carrying out deck operations :
23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
http://www.marineinsight.com/misc/marinesafety/20practicaltipsforsafegasweldingandcuttingoperationsonships/ 3/24
1. Secure in Vertical Position: Compressed gas cylinders must be handled with utmost care andalways be secured in vertical position even if they are full or empty. Full and empty cylinders to besegregated and marked clearly.
2. Store in Right Spaces: Never store oxygen and acetylene cylinder together in one space wheneverpossible. Keep them separately in well ventilated spaces. Ensure when not in use, their caps shouldalways be on them.
3. Keep Grease and Oil Away: Control valves and fittings should be kept free of oil and grease. Neveroperate cylinder valves and parts with oily and greasy hands.
4. Ensure Flame Arresters Are Properly Fitted: Ensure nonreturn valves and flame arresters arefitted in the acetylene and oxygen cylinder lines. One flame arresters is normally fitted in the lowpressure side of the regulator near cylinder and other near the torch.
23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
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5. Keep Pressure of Oxygen Higher: When performing gas welding, ensure the pressure of oxygen isalways higher than the acetylene to avoid acetylene going back to the oxygen line.
6. Handle Acetylene With Care: Acetylene should not be used for welding at a pressure exceeding 1
23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
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bar of atmosphere gauge as it is liable to explode, even in the absence of air, when under excessivepressure.
7. Rectify Cause of Backfire: In case of back fire, the first priority should be to close the oxygen valveand then immediately close the acetylene valve. No operation is to be performed until the cause ofbackfire is rectified.
8. Handle Flashback carefully: In case of flashback or explosion of the gas pipes, first action must beto isolate the cylinder valves for both the cylinders. Further action to be taken as per ship’s fire drillprocedures.
9. Ensure Proper Connections: The connections between the hose and blowpipe, and between hosesshould be securely fixed with fittings to comply with Regulatory Standard.
10. Keep a Steady Watch: A regular watch to be kept on the temperature of acetylene cylinder. If thetemperature is elevating, it is to be considered same as flashback or explosion situation for taking action.
11. Prevent Interchange of Hoses: Manifold hose connections including inlet and outlet connectionsshould be such that the hose cannot be interchanged between fuel gases and oxygen manifolds andheaders.
12 Replace Old and Faulty Hoses: Any hose in which flashback has occurred must be replaced withnew one.
13. Handle Hoses Properly: While performing the job, the hoses should be laid properly and kept out of
23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
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any moving machinery, sharp corners, high temperature areas etc. Ensure they are not dangled, knittedor tipped over.
14. Use Only Approved leak detection fluid: Only approved leak detection fluid to be used fordetection of leak from hose or regulator arrangement. If it is not available, nondetergent soap (Ivory)can be used.
15. Never Use Sealing Tape: Never use sealing tape of metal joining material to prevent leak betweenmetal to metal gas tight joints. With an oxygen cylinder this could result in initiation of a metal oxygenfire.
16. Never Over Tight Connections: Never try to over tight any nut of regulator connection or cylindervalve spindle to stop the leak. This can lead to damage.
17. Take Proper Steps for Maintenance: Only special tools should be used to clean any clogging inthe blow pipe. Before performing any maintenance, complete system to be isolated. Never attemptrepairs on pressurized oxyacetylene equipment nor carry out any unauthorized modification on hot workequipment.
18. Use Safe Ignitors Only: Blowpipe should only be ignited with friction ignitor or other stable flamegenerator. Avoid using lighter as sudden flame, else blow pipe can hit the lighter body and explode
19. Never Use Oxygen: Oxygen should never be used for ventilation, cooling purpose or for blowingdust off the surface or clothes.
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20. Discard Hoses That Had Flashback: Any length of hose in which a flashback has occurred shouldbe discarded immediately.
Last but not the least, make sure before carrying out any kind of hot work, the hot work checklist and riskassessment forms have been duly filled. Also, do not forget to follow all safety procedures while carryingout such jobs in enclosed spaces.
High pressurized gas cylinders carrying highly flammable material are a major threat to the ship and itscrew. Special care and attention must therefore be taken while handling such equipment, taking intoconsideration all safety procedures and manufacturers’ notes.
Do you know any other important point that must be added to this list? Let’s know in the commentsbelow.
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COMMENTS
Don Lund saysJuly 18, 2014 at 9:00 pm
I read your article on gas welding and cutting and was favorably impressed with your obviousconcern for safety. The pressures that you set the respective guages to are dictated by the sizeof the tips that you are using on the torch, and the tip size is dictated by the thickness of thematerial that you are cutting or welding. The respective pressures of the oxygen and acetyleneguages are set according to the respective welding position, type of material you arewelding/cutting, diameter of hoses, length of hoses, as well as the particular job conditionspeculiar to the job at hand. Victor is a torch manufacturer that you can look up on the internet
23.08.2015. 20 Practical Tips for Safe Gas Welding and Cutting Operations On Ships
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and they are happy to provide specific information for anyone who might need help.One other point I would like to point out is that when you turn on the Acetylene, only turn thevalve one quarter of a turn, that way if you have to turn it off in a hurry, you only have to makeone turn of your wrist. Also, always shut the acetylene off first as it is the source of the openflame. You should always turn the oxygen valve fully open as it is the high pressure gas andsometimes the valve packing when worn will leak. This will not occur if the valve is turned fullyopen as it seats tightly when fully extended. I hope that this information will be of some help tomy fellow weldor/burners in the field.Stay safe,Don Lund – Certified Welder for 35 years, now retired.
Charles Jackson saysApril 1, 2015 at 11:42 am
Thank you so much for sharing these tips. I really appreciate the efforts you made to share thishere. I don’t have much knowledge and experience in welding techniques. I am a beginner butvery passionate about exploring them in detail. I have completed a short term course onwelding from Weldtech Training Inc in Ontario. I am looking forward to join the next phase ofmy career. But I didn’t get good advices from anyone. Some of my friends advised me to join insmall companies as a welding trainee. But I am looking for some good certifications. After that Iwill consider about getting a job.
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