Welding and Cutting 焊接和切割.ppt

HotWork Welding Cutting动火作业 焊接和切割 Hotworkoperationscanpresentseriousfirehazards leadingtosignificantpropertydamage injuryand orlossoflife Thisclassisdesignedtomakeyoumoreawareofthehazardsassociatedwithweldingandcuttingoperations itisnotintendedtoteachyouhowtoweld 动火作业存在很大的火灾风险 会造成严重的人员和财产损失 本培训会使你更加深入地了解焊接和切割作业相关的风险 但是本次培训并不涉及对你进行有关焊接操作指导 Overview概要 WeldingandCuttingProcesses焊接和切割工艺FireandExplosionHazardsandControls火灾和爆炸危害及控制HealthHazardsandControls健康危害及控制ElectricalHazardsandControls电气危害及控制PhysicalHazardsandControls物理危害及控制 ProhibitedSituations禁止状况 OSHAprohibitsweldingorcuttinginthefollowingsituations 在下列情况下禁止焊接或切割Inareasnotauthorizedbymanagement 没有经过批准的区域Insprinkleredbuildingswhilesuchprotectionisimpaired 正在维修喷淋装置的建筑物内Inthepresenceofexplosiveatmospheres 存在爆炸危险的空气环境Inareasnearthestorageoflargequantitiesofexposed readilyignitablematerials 在靠近存放大量爆炸性 可燃性材料的区域 WeldingProcesses焊接工艺 Inwelding 2ormorepiecesofmetalarejoinedtogethertoformasinglepiecewhenmoltenmetalisgeneratedthroughanintenseheatsource suchas 焊接是两块或多块金属通过高温熔融的金属而连接为一体的过程 例如 Oxygen FuelGas氧气 可燃气体ElectricalArc电弧ShieldedMetalArcWelding屏蔽金属弧焊GasMetalArcWelding气体金属弧焊GasTungstenArcWelding钨电极惰性气体保护焊 Oxygen FuelGasWelding氧气 可燃气焊 Mostpopularfuelsusedwithoxygeninclude 常用的可燃气体包括Acetylene乙炔Methylacetylene MAPPgas Hydrogen氢气Gaswelding oroxy fuelweldingasitiscommonlyreferredto isslowerandeasiertocontrol comparedtoarcwelding Thismethodunitesmetalsbyheating theheatsourcebeingaflameproducedbythecombustionofafuelgas whichcanreachtemperaturesof6 000 F Thisprocesssometimesincludestheuseofpressureandafillermetal 气体焊接相对于电弧焊接要慢和易于控制 通过加热使金属连接 可燃性气体的燃烧产生的温度可以达到华氏6000度 这个过程有时还要用到压力和焊料 RefertotheMaterialSafetyDataSheetforspecificsafetyinformation 查阅MSDS获取安全信息 ArcWelding电弧焊接 Inarcwelding theintenseheatneedtomeltmetalisproducedbyanelectricarc Thearcisformedbetweentheactualworkandanelectrode stickorwire thatismanuallyormechanicallyguidedalongthejoint 在电弧焊接中 熔融金属的热量来源于电弧 电弧在工作面和电极之间产生 并通过人工或机械沿接缝处操作 Theelectrodecaneitherbearodwiththepurposeofsimplycarryingthecurrentbetweenthetipandthework oritmaybeaspeciallypreparedrodorwirethatnotonlyconductthecurrent butalsomeltsandsuppliesfillermetaltothejoint 电极可以只用于用以传导电流 也可以不仅传导电流同时能够熔融和向连接处提供焊料 焊接设备 直流或交流电源 电导线 焊枪 工作线 电弧 焊条 工件 电弧焊工作原理图 Thispictureindicatesabasicarc weldingcircuit AnACorDCpowersourceisconnectedbyaworkcabletotheworkpieceandbyan hot cabletoanelectrodeholderofsometype whichmakesanelectricalcontactwiththeweldingelectrode Anarciscreatedacrossthegapwhentheenergizedcircuitandtheelectrodetiptouchestheworkpieceandiswithdrawn yetstillinclosecontact 图示为基本的电弧焊过程 交流或直流电源通过工作线和工件连接和通过带电导线和焊枪连接 当线路连通 电极 焊条 末端和工件接触时产生电弧 Thearcproducesatemperatureofabout6 500 Fatthetip Thisheatmeltsboththebasemetalandtheelectrode producingapoolofmoltenmetal Metalsathightemperaturescanreactchemicallywithelementsintheair oxygenandnitrogen Oxidesandnitridesformwhichdestroythestrengthandtoughnessoftheweld Aprotectiveshieldofgas vapor orslagisusedtocoverthearcandmoltenpooltopreventorminimizecontactofthemoltenmetalwithair 电弧末端的温度大约是6500华氏度 热量将金属工件和焊条熔融 金属在高温下会和空气反应 氧气和氮气 氧化物和氮化物会影响焊缝的强度 采用保护气 蒸汽或焊渣遮盖电弧和焊点以尽可能的减少和空气的接触 ShieldedMetalArcWelding焊条电弧焊 knownas stick welding手持焊条焊接usesafluxcoveredelectrodetoformagasshieldaroundthemoltenweldpool采用熔融焊条所产生的气体来遮盖焊接熔池slagmustbechippedawayafterward熔渣必须随后铲掉 Electrodes焊条 GasTungstenArcWelding钨极惰性气体保护焊 knownas TIG or precision welding缩写为 TIG 或 精密 焊arcisformedbetweenanon consumabletungstenelectrodeandthemetalbeingwelded在焊件和钨电极之间产生电弧 georgel GasMetalArcWelding气体保护电弧焊 knownas MIG welding缩写为 MIG acontinuous feedwirefromaspoolisused采用线轴上连续进给焊丝gasesusedtoshieldtheweldpoolinclude 用于保护熔池的气体Argon氩气carbondioxide二氧化碳Helium氦气 CuttingProcesses切割过程 Incutting apieceofmetalisseparatedwhenmoltenmetalisgeneratedthroughintenseheat 在切割过程中 金属被高温所熔化而分离 Oxygen FuelGas氧气 燃气Metal powder iron isaddedtotheoxygenstreamwhichburstsintoflameandstartscutting金属粉末 铁 添加进氧气流中 产生火焰进行切割ElectricalArc arc gouging ahigher moreintenseheatofanelectricarcmeltsawaymetal电弧 电弧气刨 更高更剧烈的电弧热熔化金属 HazardsandControls危害及控制 FiresandExplosions火灾和爆炸HealthEffects健康影响ElectricalHazards电气危害PhysicalHazards物理危害 FireorExplosionHazards火灾或爆炸危险 Fires火灾flammable combustiblematerials易燃 可燃材料previouscontentsofcontainer容器内残留的物质Explosions爆炸pipelines管道chemicalstorageareas化学品储存区hollowspaces空腔classifiedareas分类区域 Control HotWorkPermit控制 动火作业许可证 HotWorkPermitProgramisdesignedtoreducethelikelihoodoffireinareaswherehotworkisperformed Thepermitwillidentifyresponsiblepersonnel suchasthesupervisor thepersonperformingthehotwork andafirewatch aswellasserveasachecklistforensuringthatallprecautionsnecessaryaretakentopreventfirehazards 动火作业许可程序用于减少动火作业区域引发火灾的可能性 许可证应明确责任人 例如主管 作业人和火情监控 还有一个检查表来确保已经采取必要的措施来预防火灾 Straysparksandhotslagcansmolderforhoursbeforeigniting 喷溅的火星和焊渣能够在着火前闷燃数小时 Containers容器 Hotworkshallnotbeperformedonusedcontainersuntiltheyhavebeencleanedthoroughlyofanypotentiallyflammablematerialorvapor 只有当容器内残存的可燃性物质或蒸汽被完全清除才能实施动火作业Anypipelinesorconnectionstothedrumorvesselshallbedisconnectedorblanked 与容器连接的管道应隔离或清空Allhollowspaces cavities orcontainersshallbeventedtopermittheescapeofairorgases 所有的空洞或容器应给予通风 ConfinedSpaces狭窄空间 Adequateventilationisrequired 足够的通风是必要的Compressedgascylindersmustremainoutside 压缩气体钢瓶必须放在外面Weldingmachinesmustremainoutside 焊接设备必须放在外面Closetorchvalveswhennotinuseforsubstantialperiodsoftime ex lunch 不使用时 关闭焊枪阀门 例如午餐 Heavyportableequipmentmountedonwheelsshallbesecurelyblockedtopreventaccidentalmovement 带有轮子的设备应进行固定以防意外移动 Whenentranceisthroughasmallopening meansforquickremovalinemergencysituationsisrequired ex attendantandlifeline 如果入口很狭小 需要考虑当意外状况发生时快速撤离的方式 例如监护人员和救护索Removeelectrodesfromholdersandlocateholderscarefullytopreventaccidentalcontactwhennotweldingforaperiodoftime ex lunch 当休息时应将焊条从焊枪上取下并将焊枪妥善放置Afterweldingiscompleted theweldershallmarkthehotmetalorprovidesomemeansofwarningotherworkers 焊接作业完成后 焊工应对灼热的金属做出标识应警告他人 HealthHazards健康危害 1 Chemicalpneumonitisisaninflammationofthelungs 化学性肺炎2 Pulmonaryedemaisswellingandaccumulationoffluidsinthelungs 肺水肿3 Emphysemaisalossofelasticityofthelungs 肺气肿4 Chronicbronchitisisalong term respiratoryinfection 慢性支气管炎5 Asphyxiationisalackofoxygeninthebloodstream 哮喘6 Therearemanyothermetal andgas specifichealthhazardsalsoassociatedwithweldingprocesses suchasleadpoisoningandmetalfumefever 其他的包括焊接过程中相关的金属和气体引发的疾病 例如铅中毒和金属烟尘热 Oncethemetalsareheated theyproducefumeswhichcanbeinhaled thesameistrueforgasesusedintheheatingprocess Exposuremayresultin 金属在加热时产生的烟气会被吸入 会导致 HealthHazards健康危害 By productsofweldingprocesses焊接过程会产生Ozone臭氧oxidesofnitrogen氮氧化物Phosgene碳酰氯 光气 Phosphine磷化氢carbonmonoxide一氧化碳carbondioxide二氧化碳Smoke烟尘 HealthHazards健康危害 Somemetalsareknownorsuspectedcarcinogens 某些金属是已知的或怀疑的致癌物质Somemetalstargetspecificorgansofthebody suchastheliverorkidneys 某些金属对身体的特定器官造成危害 例如肝脏或肾脏Othersresultinblooddisorders nervedamage orevendisability 某些会影响造血功能 损伤神经甚至残疾Mostmetalscancreateflu likesymptomsifexcessivefumesareinhaled commonlycalled metalfumefever 如果吸入过量的烟尘 大部分的金属会使人产生类似感冒的症状 通常称为 金属烟尘发热 HealthHazards健康危害 Aluminosis aluminumdust 铝尘肺Anthracosis carbondust 煤肺病Siderosis ironoxidedust 铁尘肺Stannosis tinoxidedust 锡尘肺 Particulatematter dust canbebreathedintothelungsandisreferredtoas benignpneumoconiosis 颗粒物质会被呼吸进入肺部而引起 尘肺病 Themajorityofthesediseasesdonotproduceanysignificantcomplications 大多数的疾病不会产生明显的并发症 NaturalVentilation自然通风 Tokeepfumes vapors andothertoxicby productsofweldingatsafelevels youmustensurethattheweldingareaisadequatelyventilated 为将焊接过程中产生的烟尘 蒸汽等有毒物质的浓度达到安全限度 必须对焊接区域进行有效的通风Naturalventilationinvolveskeepingthewelder sbreathingzoneawayfromthesmokeplumesothatairsamplingindicatesthatlevelsarewithinallowablelimits 自然通风应使得焊工的呼吸区域远离烟尘 有害物浓度在限度之内Thesizeandconfigurationoftheareawheretheweldingisoccurringisalsoconsidered 还应考虑焊接区域的大小和布局 MechanicalVentilation机械通风 Localexhaust suchasthatshowninthepicture局部排风 如图所示preferredmethod首选方式Localforcedair局部强制通风 ex afanthatmovestheairatrightanglestothewelder例如安置一个风扇在焊工的右侧 Generalareaairmovement suchasroofexhaustfans wallexhaustfans 常规方式 例如屋顶和墙面的排气扇 Airfiltering空气过滤 localexhaust局部排风 MechanicalVentilation机械通风 Mechanicalventilationshallbeprovidedwhenweldingorcutting 以下状况应采用机械通风isdoneoncertainmetals在某个特定的金属上inspaceslessthan10 000cubicfeetperwelder空间大小小于10000立方英尺 每名焊工inroomswithaceilingheightlessthan16 房间的天花板高度低于16英尺inconfinedspaces在限制空间内inspaceswherepartitions balconies orotherstructuralbarrierssignificantlyobstructcrossventilation作业空间内存在隔断 夹层或其他结构上的障碍明显阻碍空气的流动 Control Respirators控制 呼吸器 Air purifying空气过滤式filtersexistingair通过滤盒过滤 Air Supplied供给空气式suppliesbreathingairtothewearer向佩戴者提供空气requiresasupplyofbreathableair需要输送可呼吸的空气 Ifnaturalormechanicalventilationcannotreduceexposureofharmfuldustsandfumestoanacceptablelevel arespiratormustbeworn 如果自然或机械通风都不能将有害粉尘和烟尘的暴露水平降低到可以接受的水平 则必须佩戴呼吸器 ElectricalHazards电气危害 PowersupplycanbeeitherACorDCforarcweldingorcuttingofanykind 电源可以是直流或交流Currentcanvaryfrom10 15ampsforsmall diameterelectrodesusedonthinsheetsformanualarcwelding toamaximumof500 600ampsforsomeapplications 人工电弧焊接的电流范围是10 15安培 最大可以达到500 600安培 Voltagevariesfrom15 40volts dependingonthesizeofelectrodeused 电压范围是15 40伏特 依据所采用的焊条型号Electricshockfromwelding cuttingequipmentcancausesevereburnsorevenkill 焊接 切割设备引发的电机是造成严重的伤害 甚至死亡 ElectricalHazards电气危害 Cableswithspliceswithin10 oftheholdershallnotbeused 不要使用距离焊枪10英尺内有破损的导线Donotuseworn damaged undersized orpoorlysplicedcables 不要使用陈旧 破损 不合规格的导线Connectionsshouldbetight clean anddry 连接处应牢固 Inspectcablesbeforeeachuseforcuts nicks cracks etc 每次使用前检查导线 ElectricalHazards电气危害 Usefullyinsulatedelectrodeholders 使用绝缘良好的焊枪Donotdiptheholderinwatertocoolit 不要将焊枪进入水中冷却Donotlaytheholderonconductivesurfaces 不要将焊枪放置在导电体上Donottouchholdersconnectedtotwoweldingmachinesatthesametime 不要将焊枪同时连接在两个焊机上 Donottouchotherpeoplewiththeholderorelectrode 不要用焊枪或焊条碰触到人员 Control Grounding控制 接地 Weldingmachinesaregenerallygroundedthroughtheirelectricalconnectionswitha3rdgroundingwire Mobileengine drivengeneratorweldingunitsaregroundedbyconnectingacabletoagroundstudonthemachinetoametalstakedrivenintotheground Alwaysfollowthemanufacturer sinstructionsandrecommendationsforproperlygroundingtheparticularweldingmachineyouhave 焊机通常是通过三相导线接地 移动式的焊机通过从设备引出的一根导线连接到接地桩 遵守制造商的要求进行接地 Auxiliaryreceptaclesmayormaynotbeground fault circuit interrupterprotected GFCIsdonotworkonDCpower GFCIadaptersmaybeused Anytools equipment andextensioncordspluggedintothesereceptaclesshouldbegrounded 3 pronged ordouble insulated 插座通过接地电路故障断路器保护 直流电源不起作用 应使用适配器 所有工具和设备以及延长线路的插座应接地 3相插头 或双重绝缘 Grounding接地 Theworkpieceisgroundedbyacablefromtheweldingmachine Ifthecableisconnectedtotheweldingtable theweldingtableshouldalsogrounded Don tgroundtoabuildingstructurethatisagreatdistancefromtheweld andneverusepipelinescarryinggasesorflammableliquidsorconduitscarryingelectricalconductorsasgrounds 工件通过从焊机引出的一根导线接地 如果这根导线和焊接线连接 那么焊接导线也应接地 不要和距离焊接点距离很远的建筑结构接地 决不要利用含有气体和易燃液体或连接电缆的管道作为接地点 Insulation绝缘 Weardry insulatedgloves i e leather 佩戴干的绝缘手套 例如皮质 Wearprotectiveclothing i e cotton wool orflame retardantsleeves etc 穿戴防护服 例如棉 羊毛或阻燃手套 Wearrubber soledshoesorstandonadryinsulatedmat 穿着橡胶底的鞋子或站在干的绝缘垫上 Usefullyinsulatedelectrodeholders 使用绝缘完好的焊枪Donotuseworn damaged undersized orpoorlysplicedcables 不要使用破损和开裂的导线Inspectequipmentbeforeeachuse andrepairorreplacedamagedpartsimmediately 每次使用前检查设备 如有损坏立即更换 Electricarcsandgasflamesproduceultravioletandinfraredradiationthatcanbeharmfultotheeyesandskinuponcontinuedorrepeatedexposure 电弧和气体火焰会产生紫外和红外射线 持续的暴露会对眼睛和皮肤造成伤害 Ultravioletrays sunburn theeyes whichispainfulanddisabling butusuallytemporary 紫外射线会导致眼部疼痛和短暂的失明 Infraredradiationmaycausepermanenteyeinjuryifyoulookdirectlyintoapowerfularcwithouteyeprotection orareincloseproximitytotheheat 如果没有使用眼部防护用品或过于靠近 红外射线可能会导致永久性的眼部伤害 PhysicalHazards物理危害 PhysicalHazards物理危害 Repetitivemotionsandpoorlydesignedworkstationsmayresultinworkerfatigue ormaybethestartofpotentiallylargerinjuries especiallyinthewrists 重复性的动作和设计不合理的工作位置会容易疲劳 而且具有更大伤害的潜在性 特别是在肘部 Excessivenoisefromgrinderscancausepermanenthearinglossovertime 长时间的暴露在砂轮机的噪声中会导致永久性的听力损失Flyingdebrisfromsparking chipping grinding andmoltenmetalsplashcancauseeyeinjuries etc 飞溅的碎片 火星和熔化的金属颗粒会造成眼部伤害 Screens屏风 Curtains screens andshieldscanbeerectedaroundtheweldingareatoprotectotherpeopleintheareafromharmfulradiationandflyingdebris 在焊接区域周边设置挂帘 屏风和屏障来保护其他人员避免有害辐射和飞溅碎片的伤害 Curtains screens andshieldsalsoprotectflammableorcombustiblematerialsfromhotsparksandslagwhichcouldignitethem还可以用于防护火星和焊渣喷溅到易燃物上而引起火灾 Control FireBlankets防火毯 Fireblanketsusedtobemadefromasbestos butarenowmadefromfiberglassyarn chemicallytreatedfiberglass silica oracombinationoffiberglass graphite andceramic 防火毯过去由石棉制成 现在采用玻璃纤维 石墨 陶瓷经过化学处理后制成 Theyaregenerallyusedtoprotectotherequipmentormaterialsfromsparksandslag 用于覆盖在设备和原料上以防护焊接 切割所产生的喷溅的火星和焊渣 PersonalProtectiveEquipment个人防护用品 Welding cuttinggogglesprovideprotectionfromlightimpact flyingdebris andultravioletraysandglare 焊接专用护目镜可以防护紫外射线 飞溅的碎片和强光 Theytypicallycomewitha 5shadefilteredlens 通常配有5 滤光透镜Weldinghelmetswiththeappropriateshadeoffilteredlens usually 7 14 arerequiredforallotherweldingapplications 在焊接作业中应佩戴配有合适滤光透镜的专用焊接头盔 Tintedsafetyglassesarenotdesignedtoprovideadequatefiltrationforultravioletrays 普通的变色安全眼镜不能够对紫外射线进行有效的过滤 AppropriateDress适当的服装 Coverasmuchofyourbodywithnatural fiberclothing cottonorwool aspossible 尽可能穿着天然纤维的衣服 棉质或羊毛 longsleeves长袖longpants长裤腿highnecklineshirts高领衬衫close toedshoes全部盖住脚面的鞋子gauntlet stylegloves开口手套 Equipment设备 CompressedGasCylinders压缩气体钢瓶Torches焊枪CheckValves止回阀FlashbackArrestors回火阻燃器 Neverusedamagedordefectiveequipment 决不要使用损坏的有缺陷的设备 CompressedGasCylinders压缩气体钢瓶 Compressedgascylindersshall 压缩气体钢瓶应 belegiblymarkedastocontents清楚标示内容物bekeptawayfromsourcesofheat远离热源havetheircapsinplace exceptwheninuse不使用时盖上瓶帽beproperlystoredandhandled正确储存和使用 TestingforLeaks检漏 Closetorchvalve 关闭焊枪阀门Openadjustingscrew 打开调节旋钮Applyleak testsolutiontoconnections Lookforbubbles 观察气泡 Hosesmaybedippedinwatertoidentifyleaks 气管浸入水中 Torches喷枪 Torchesarefairlysafewhenusedandmaintainedproperly Thehandleisessentiallyasetofgastubes oneforthefuelgasandonefortheoxygen withcontrolvalves 喷枪在正确使用和维护的情况下是非常安全的 在把手位置安装有气管 一个是燃起 另一个是氧气 并有控制阀 Thegasesaremixedintheweldingapparatus oratthecuttingtip toproduceaflame 气体在焊接装置或切割端头混合并产生火焰 Most Victor weldingtorchhandlesareequippedwithinternalcheckvalvestoreducethepossibilityofexplosionorfireasaresultofthegasesbeingmixedinsidethehosesorregulators 大部分的焊接喷枪把手安装有内部单向阀来降低由于气体在气管或调解阀内混合后引发火灾或爆炸的可能性 Welding焊接 Cutting切割 Careshouldbetakenwhenlightingthetorch 点燃喷枪时应小心Opentheoxygenvalveonthetorchhandleandadjusttheoxygenregulatortothedesireddeliveryrange Closethetorchhandleoxygenvalve 打开喷枪把手上的氧气阀并调节至需要流量 关闭喷枪把手氧气阀 Openthefuelvalveonthetorchhandleandadjustthefuelregulatortotherequireddeliveryrange Closethetorchfuelvalve 打开喷枪把手上的燃气阀并调节至需要流量 关闭喷枪把手燃气阀 Neveruseabutanelightertolightatorch orhaveoneinyourshirtpocket explosive 决不要使用打火机去引燃喷枪或者将打火机放在上衣口袋内 会引发爆炸 Wearingweldinggoggles openthetorchfuelvalveabout1 8turnanduseaspark friction lightertoignitethegas 佩戴焊接专用眼镜 拧开喷枪燃气阀大约1 8圈 使用点火器引燃火焰 Continueopeningthefuelvalveuntiltheflamestopssmoking 继续缓慢拧开燃气阀直至火焰停止冒烟Openthetorchoxygenvalveuntilabrightneutralflameisestablished 拧开喷枪氧气阀直至出现明亮的无色火焰 Ifyougetabackfireorflashback immediatelyturntheoxygenvalveoffan