The document provides details about the student's practical training at Tanzania Zambia Railway Authority (TAZARA) Mbeya workshop. It discusses:
1) TAZARA's historical background and organizational vision/mission.
2) Services provided at TAZARA Mbeya workshop, including maintenance of diesel electric locomotives.
3) Welding processes used at the Production Planning and Control department, focusing on arc welding techniques and equipment.
Acknowledgment
Before all I would like to thankful almighty God for giving me guidance and health on the whole year of my semester’s time up to this moment of preparing this report. I would like to take this time to express my deeply and strongly sincerely on gratitude of this report Tanzania Telecommunication Company Limited (TTCL) by giving me the chance to do Industrial Training within their company and experts Mr. Fulgence Mayeye, Mr. Nicholaus Mality and Mr. George Mtendamema for their guidance, support and advice because without their contributions this report could not be completed. Also I would like to take this opportunity to appreciate the work done by Mr. N. Gati the supervisor from The university of Dodoma (CIVE) for good assessment during the Practical Training at Tanzania Telecommunication Company Limited (TTCL) and Mr. Khamis Fereji the project coordinators.
Lastly my special acknowledgements should go to my fellow students of the college of informatics and virtual education for their full time support starting from requirements gathering up to this moment of preparing this report.Introduction
This report is about the knowledge that acquired during industrial training for a student in the University which conducted at the Tanzania Telecommunication Company Limited (TTCL) which program was conducted for six weeks from 15th August, 2016 to 23th September, 2016. It is driven by a need to centralize all related subjects during training period so as to control well all activities and operations of the system.
The applications of Computer Networking are currently accepted and applicable by different people and in several organizations because it’s expected to be implemented practically in automatic way. Through this Industrial Training I have been able to perform several activities and communicate with college staffs through practicing in order to get feedbacks on time.
The tasks and activities that organization experts leave to us was merely involve Network configuration by using Cisco packet tracer and using real computers and real router, configuration and installation of printers in the TTCL offices and their branches, Computer maintenances and Troubleshooting and participating in developing of TTCL Field Student Registration System.
These practices were helped us a lot to gain more knowledge and skills and building confidence among us because it involves actions not only theories.
But this report explains much about the Printers as we know Printers produce paper copies of electronic files. Hard copies of computer documents remain important today.
And explain more about configuration and installation details also explain much about the problems might face the printer and their techniques to troubleshooting and fix those problems
This report is based on the internship experience I had during my time of internship. The relevant details of the internship program are available in the cover page. This report contains three main chapters namely, Introduction to the Training Establishment, Training Experience and Conclusion. In the following paragraphs, what each chapter contains is explained briefly.
The first chapter is titled, “Introduction to training establishment” and it contains information about the organization that I had my training at.
The second chapter includes information related to the training experience I had, during my time of stay at the training establishment.
The final chapter is the conclusion of the report, where it contains a summary of the training experience mentioned in chapter 2 and how all these training experiences affected my life and career and it distinguishes the university life from the training life, by clearly mentioning what I gained as an intern in that company.
This report contains concise details of in-plant training received at Colombo Dockyard PLC to fulfill the industrial training requirements of B.Sc. Eng. degree program at University of Moratuwa.
Acknowledgment
Before all I would like to thankful almighty God for giving me guidance and health on the whole year of my semester’s time up to this moment of preparing this report. I would like to take this time to express my deeply and strongly sincerely on gratitude of this report Tanzania Telecommunication Company Limited (TTCL) by giving me the chance to do Industrial Training within their company and experts Mr. Fulgence Mayeye, Mr. Nicholaus Mality and Mr. George Mtendamema for their guidance, support and advice because without their contributions this report could not be completed. Also I would like to take this opportunity to appreciate the work done by Mr. N. Gati the supervisor from The university of Dodoma (CIVE) for good assessment during the Practical Training at Tanzania Telecommunication Company Limited (TTCL) and Mr. Khamis Fereji the project coordinators.
Lastly my special acknowledgements should go to my fellow students of the college of informatics and virtual education for their full time support starting from requirements gathering up to this moment of preparing this report.Introduction
This report is about the knowledge that acquired during industrial training for a student in the University which conducted at the Tanzania Telecommunication Company Limited (TTCL) which program was conducted for six weeks from 15th August, 2016 to 23th September, 2016. It is driven by a need to centralize all related subjects during training period so as to control well all activities and operations of the system.
The applications of Computer Networking are currently accepted and applicable by different people and in several organizations because it’s expected to be implemented practically in automatic way. Through this Industrial Training I have been able to perform several activities and communicate with college staffs through practicing in order to get feedbacks on time.
The tasks and activities that organization experts leave to us was merely involve Network configuration by using Cisco packet tracer and using real computers and real router, configuration and installation of printers in the TTCL offices and their branches, Computer maintenances and Troubleshooting and participating in developing of TTCL Field Student Registration System.
These practices were helped us a lot to gain more knowledge and skills and building confidence among us because it involves actions not only theories.
But this report explains much about the Printers as we know Printers produce paper copies of electronic files. Hard copies of computer documents remain important today.
And explain more about configuration and installation details also explain much about the problems might face the printer and their techniques to troubleshooting and fix those problems
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The first chapter is titled, “Introduction to training establishment” and it contains information about the organization that I had my training at.
The second chapter includes information related to the training experience I had, during my time of stay at the training establishment.
The final chapter is the conclusion of the report, where it contains a summary of the training experience mentioned in chapter 2 and how all these training experiences affected my life and career and it distinguishes the university life from the training life, by clearly mentioning what I gained as an intern in that company.
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Welding and allied processes field report
1. i
UNIVERSITY OF DAR ES SALAAM
COLLEGE OF ENGINEERING AND TECHNOLOGY
FACULTY OF CHEMICAL AND PROCESS ENGINEERING
DEPARTMENT OF CHEMICAL AND MINING ENGINEERING
PRACTICAL REPORT
PT 1
2013/2014
WELDING AND ALLIED PROCESSES
DEGREE PROGRAMME: BACHELOR OF SCIENCE IN CHEMICAL AND
PROCESS ENGINEERING
NAME OF STUDENT: MARO, ROLLAND D.
STUDENT’S REGISTRATION NUMBER: 2013-04-01965
NAME OF PT COMPANY: TANZANIA ZAMBIA RAILWAY AUTHORITY.
NAME OF INDUSTRIAL TRAINING OFFICER: Mr. MUSHI
NAME OF ACADEMIC TUTOR/SUPERVISOR: ABRAHAM TEMU
PT DURATION: EIGHT WEEKS
2. i
AKNOWLEDGEMENT
I owe a great deal to the glorious almighty GOD who gave me health, strength and
capability to complete this program.
Many people have been extremely generous with their time and expertise while I have
been in my field work at Tanzania – Zambia Railway authority (TAZARA) Mbeya.
Particularly I should like to thanks the following people from TAZARA Mbeya for
their contribution all the time on during field work Work Shop manager ,Mr.
Joshua(Engineer at QUA department) , Mr. Banda(technician), Mr.
magemo(Laboratory artisan), Mr. Oswald Seme.
In very special way I extend my sincere and heartfelt gratitude to Mrs. Alice all
member of chemical and mining department at University of Dar es Salaam (UDSM). I
accept their full responsibility, patient, guidance, encouragement and useful antiques.
Lastly I would like to thanks all people who enhance their effort to work with me yet
their names do not appear in this report.
3. ii
GENERALABSTRACT
The objective of this field work training was to acquire training and experience in a
real life situation practicing the knowledge we acquired from course studies inside the
university.
The Tanzania – Zambia railway authority (TAZARA) deals with provision of
transportation through rail to people, goods and Manufacture parts and provide
maintenance and repairs services at any foundry, workshop or other factory owned or
operated by the Authority.
In Tanzania – Zambia Railway Authority (TAZARA) we make use of Diesel Electric
Locomotives with DC traction motors as major means of transportation. In TAZARA
workshop in Mbeya we dealt with maintenances and repair of parts and locomotives at
large using different sections of the workshop for example quality assurance
department dealt with maintenance of armatures and motors , production control
department dealt with welding, machinery and forging and maintenance department
which dealt with repairing of small repairs and major repairs that may be caused by
accident.
In PPC department (production planning and control) department we dealt with repair
by welding of different machine parts of locomotives. Welding was used for different
purposes for example reproducing/ filling worn out parts of different machine parts,
cutting and straightening metal parts, and joining different metal parts.
Also the heat given out by the welding torch was used for expanding rings and gears so
that they may fit into shafts or may easily be removed.
4. iii
Table of Contents
AKNOWLEDGEMENT.............................................................................................................. i
GENERAL ABSTRACT ............................................................................................................ ii
PART A........................................................................................................................................1
WEEKLY REPORT.....................................................................................................................1
PART B........................................................................................................................................2
MAIN REPORT...........................................................................................................................2
1.0 TANZANIA – ZAMBIA RAILWAY AUTHORITY ..........................................................2
(TAZARA)...................................................................................................................................2
1.1 HISTORICAL BACKGROUND OF TAZARA................................................................2
1.2 INSTITUTIONAL VISION AND MISSION....................................................................3
1.2.1 VISION .......................................................................................................................3
1.2.2 MISSION ....................................................................................................................3
2.0 TAZARA MBEYA WORKSHOP.........................................................................................4
2.1 ORGANISATION STRUCTURE IN MBEYA WORKSHOP. ....................................4
2.2 SERVICES PROVIDED BY TAZARA MBEYA WORKSHOP. ................................4
3.0 PRODUCTION PLANNING AND CONTROL DEPARTMENT (PPC)............................6
3.1 WELDING AND ALLIED PROCESSES. ........................................................................6
3.2.1 ARC WELDING.........................................................................................................6
3.1.2 GAS WELDING .......................................................................................................11
3.2.0 WELDING AND CUTTING TORCHES.....................................................................16
3.2.1 DESCRIPTION OF W ELDING AND CUTTING TORCHES..............................16
3.2.2 FUNCTION OF A WELDING AND CUTTING TORCHES..................................16
3.2.3.2 REPAIR AND PLACEMENT OF WELDING TORCHES ..............................19
CONCLUSION..........................................................................................................................20
RECOMMENDATION .............................................................................................................20
REFERENCE.............................................................................................................................21
6. 2
PART B
MAIN REPORT
1.0 TANZANIA – ZAMBIA RAILWAY AUTHORITY
(TAZARA)
Tanzania-Zambia Railway Authority also known as TAZARA, is a two national
railway, jointly owned by the Government of the United Republic of Tanzania and the
Government of the Republic of Zambia on the basisi of equal share holding. The
1,860km-rail runs from Tanzania and East Africa’s major seaport of Dar es Salaam
into the parts of Zambia’s Central Province and ending at New Kapiri - Mposhi, where
it is further linked by road and rail to Zambia’s capital city, Lusaka (about 200km),
Zambia’s mining nerve centre, the Copper belt province (about 100km) and the
Democratic Republic of Congo (DRC).
1.1 HISTORICAL BACKGROUND OF TAZARA.
TAZARA raised from the need to develop vast areas of northern Rhodesia (Zambia )
and Tanganyika(Tanzania ) which was greatly motivated by the need to develop
agriculture in these regions. In northern Rhodesia these plans started to gain
momentum in the year 1963 while in Tanzania the plans were discussed for many
years.
The Tanzania-Zambia Railway Authority was established in March 1968 and the
survey and design work started in October 1968 and finished in May 1970. The
surveys that were done by the Chinese produced favourable recommendations, which
completely disregarded all conclusions of earlier surveys. By now it had been decided
that the line would start from Dar es Salaam and end at Kapiri Mposhi.
The leaders of Tanzania (the late Mwalimu Julius Nyerere) and Zambia (Dr. Kenneth
Kaunda) who were aware of Zambia’s dependence on the southern route and its
implications visualized that the North East Rail Link was the only other way for
Zambia to maintain economic and political independence. In a significant way,
7. 3
therefore, Ian Smith’s UDI spurred the proponents and even quickened the pace at
which the TAZARA project was implemented.
Construction of the line started in October 1970. The then Presidents Dr. Kenneth
Kaunda of Zambia and late Mwalimu Julius Nyerere of Tanzania officially inaugurated
the commencement at Dar es Salaam in Tanzania and Kapiri Mposhi in Zambia,
respectively. After two years construction reached a most complicated geographical
profile 158-kilometre Mlimba/Makambako section, The track crossed the Tanzanian
border at Tunduma into Zambia at Nakonde in August 1973. The track crossed the
Tanzanian border at Tunduma into Zambia at Nakonde in August 1973.
1.2 INSTITUTIONAL VISION AND MISSION
1.2.1 VISION
The vision of TAZARA is to provide a safe, reliable and quality means of
transportation to the traders, agriculturalists and all citizens of the two countries.
1.2.2 MISSION
The mission of TAZARA organization since the establishment of its foundation is to
be the most preferred means of transport to the countries involved.
8. 4
2.0 TAZARA MBEYA WORKSHOP
2.1 ORGANISATION STRUCTURE IN MBEYA WORKSHOP.
The production organization structure is as follows:
2.2 SERVICES PROVIDED BY TAZARA MBEYA WORKSHOP.
In Mbeya workshop we dealt with maintenance of General Electric/Krupp (Diesel
Electric) Locomotives and all scopes of repair, including the rehabilitation of
locomotives from serious train accidents also we dealt with some engineering services
like Steel casting, General purpose and light metal casting, Forging services, all basic
machining processes, including planning, grinding, turning, shaping and more,
laboratory services, equipment maintenance, repair and overhaul.
2.2.1 DIESEL ELECTRIC LOCOMOTIVES
9. 5
All the repairs and services done under Mbeya Tazara workshop was for diesel electric
locomotives. A summarized description of these locomotives is done in the following
diagram
Workshop Manager
The workshop manager manages all activities and finances inside the
workshop and coordinates with the higher administration for feedback and
requests of funds, tools and machine parts for repairs.
Locomotive maintenance department (LMR)
Dealt with casual light and overhaul mechanical and electrical repairs like oil
change , checking and changing of motor and combo(combination of traction
motor and wheel set)
Production planning and control (PPC)
PPC is incharge of planning the repairs of locomotives which are totally
damaged from accidents they build a locomotive from scratch, also it is
incharge of all welding activities in the workshop; this activity is the area of
concentration in this general field report.
Quality assurance department (QUA) dealt with assurance of quality of every
repaired and manufactured tools tools and machinery so that they can be safely
used again for example testing of motor, repaired locomotives, also laboratory
artisan under this section is incharge of checking fuel and oil samples for
safety.
10. 6
3.0 PRODUCTION PLANNING AND CONTROL
DEPARTMENT (PPC)
3.1 WELDING AND ALLIED PROCESSES.
In TAZARA workshop under production control department the main activity
engaged are welding processes to join material. A large bulk of materials that are
welded are metals of different or the same alloy. The allied processes besides welding
done are straightening of machine parts, expansionof rings and gears.
During the welding practical, 2 type of basic welding were called Arc and Gas
welding. At the practical, we learn different kind of tools that use in Arc and Gas
Welding. This kind of tools that use in each basic of welding is one of the most
different of Arc and Gas welding. At the same time, safety is no 1 to prevent an
accident while working at workshop.
3.2.1 ARC WELDING
The purpose of this practical is :
To learn the basic techniques of arc welding.
To learn a real life experience of metal arc.
3.1.1.1 PROCESS DESCRIPTION
In Arc welding a welding power supplies used to create an electric arc between an
electrode and the base material to melt the metals at the welding point. The welding
power supply used was either direct (DC) or alternating (AC) current, and consumable
or non-consumable electrodes, but consumable electrodes ware preferred. The welding
region is protected by some type of shielding gas, vapor, or slag that resulted from the
filler material. The method used is physical welding.
3.1.1.2 EQUIPMENTS
The description of equipments used in arc welding is as follows:
11. 7
WELDING MACHINE
Generaly there are two types of welding machines that are used during the welding
process.
I. Alternating current AC welding machine.
This type of machine was very useful in workshop as it was usually used compared to
DC machine. It worked with small voltage for example 37.5 amps. It was essential
for welding work in all conditions without considering whether the voltage is small or
large. Its distinctive advantages are:
It is cheap and the cost of running was low since it consumed less energy per
unit weight of deposited metal.
Maintanance of this machine was easy and it does not result in a lot of noise
during welding operations.
It produced a stable arc that was important when precision was considered.
It occupied less space.
Produced less noise.
It was suitable for most of the work pieces since most of them are thick
Although this type of machine was mobile, it can only used limited amount of
electrode ie. It was used for ferrous materials. Apart from that, it does not have
movable components and cannot be used on aluminum electrode. It uses only one level
of electricity.
II. Direct current DC welding machine
Direct current machine was built in capacities up to 1000A, having an open circuit
voltage 40 to 95 V. This machine is very expensive and it uses three level of
electricity and it requires a generator to provide the current. The advantages of using
the machine was:
there is no confinement on the type of electrode being used
12. 8
It was a good method to do welding operations when there was no electricity or
voltage level has dropped.
Arc produced by this DC machine was more stable.
It was used for welding non- ferrous metals and alloys.
It has less open ciruit voltage of 45 – 95V thus makes it safer.
This type of machine was used only few times. The disadvantages of this machine was
difficulty to maintain and it also produces a lot of noise while functioning. This DC
machines use air as cooling agent and thus it was always kept in a dry place to avoid
transformer and generator damage.
Cables
Generally, there are two cables that carry the electricity from welding machine to work
metal and back to welding machine and earth cable. These cables are made from small
copper wire coated with strong rubber so that we can hold it without feeling the intense
heat. Besides that, every cable has it own size. For instance, size No. 2 means that the
cable will be able to withstand welding electricity up to 200 amps. Therefore the
choice of these cables depend on the current used during the welding process. These
cables are connected to the welding machine through its copper end.
Electrode holder
The electrode holder had the following functions. Firstly, it was used to provide the
electricity from welding machine to metal work, also used to hold the electrode during
the welding operations. One of its constituent parts was the spring where it hold the
electrode firmly and withdrawn the electrode easily after finish welding, also it was
light weighted and has enough size conductor to carry electrons.
Earth electrode
The earth holder was always connected to the earth cable and clamped to the work
metal or to the work table. It has a spring so that is can be easily clipped and unclipped.
Without this equipment, welding operation definitely cannot be done.
13. 9
Shield
It is made from inflammable material. In the middle of the shield there is a bright
rectangular glass coated with dark colored glass. It is used to protect from flying hot
pieces of metal and harmful rays during welding work. The type of shield used is the
hand held type.
Chipping hammer
It is made from an old spring metal. Shape like a chisel at one end and has a sharpened
end at the other one. Its holder is made from welded soft metal. It is used commonly to
remove the slag excess stringer from the surface of the work metal.
Wire brush
It was used to clean the surface of the weld after the slag is chipped away and to
remove dirt from the surface of metal work before welding can be done.
Glove.
It is made from high quality leather. Used to protect your hand from fire-bolt and hot
metal welding.
Leather jacket
Leather jacket is used to protect the user from the intense heat produced during
welding operations. It is made of high quality leather to provide greater comfort for the
user.
Tongs
It is use to hold hot work metal after welding process.
3.1.1.3 PROCEDURES OF ARC WELDING.
Electrode cable and the earth cable was connected to the Alternating Current AC
Welding Machine.
i. The earth cable is connected, using its holder to the work piece .
14. 10
ii. The electrode is clipped with the holder. The flux is not in contact with the
holder so as to allow current to flow. Undesired spark would occur if the flux is
in contact with any metal.
iii. The welding machine is turned on and set the dial to 90 amps.
iv. Before beginning welding, gloves and shield are put on.
v. The electrode is held about 90o
above the metal to be welded. The electrode is
tilted 20o
-25o
degrees to the right or left depending on which hand do you use
from the work metal.
vi. The front end of the electrode is scratched onto the work metal to start the
burning. After the electrode has started burning, hold it at 10mm above the
work metal. If the electrode is in contact with the surface of work because the
electrode might be stucked onto the work, therefore this is avoided..
vii. The welding process is repeated for several times until you get a straight and
firm stringer bead line when welding. .
viii. When the welding line is done, the chipping hammer is used to chipp off the
slag and brush it off using a wire brush.
Welding process.
3.1.1.4 SAFETY PRECAUTIONS.
Before and during the welding process the following precautions were emphasized;
15. 11
a. All the personal protective equipment are worn.
b. Eyes protection is made sure; to protect from arc rays.
c. Face and body is protected from heat radiation and molten metal.
d. All the flammable material are moved off the working place or covered it using
fireproof material.
e. The welding machine is earthen.
f. Assurance that all line holder, earth clip and connection placed on good place.
g. Make sure that all electric connection is tight, clean and dry.
h. the cable is not to be pulled on top or near sharp things.
i. The welding machine is turned off when not in use.
j. Welding cable is to not contact hot metal, water, oil and grease.
k. All safety clothing are worn when welding.
l. All equipment such as hammer, chisel, brush and others are well maintained.
3.1.2 GAS WELDING
The common gas welding used was oxy-acetylene welding.
The purpose of this practical is :
To learn basic technics of gas welding.
To learn and exercise the safety precautions during gas welding.
To acquire real life experience of gas welding.
3.1.2.1 PROCESS DESCRIPTION
The heat in gas welding comes from the reaction as follows:
Stages of Chemical reaction and temperature distribution in a neutral oxy-acetylene
flame
• Oxy-acetylene Welding:
CaC
2
+ 2H
2
O = Ca (OH)
2
+ C
2
H
2
C
2
H
2
+2.5O
2
= 2CO
2
+H
2
O
(vapour)
+ 306.800 cal /mol
16. 12
.
When the inner core flame is passed over the metal fusion is obtained and the metal melts.
The later can simply be explained in the following block diagram.
3.1.2.2 EQUIPMENTS
1. Gas Cylinders; pressures are :oxygen-125kg/cm2 and acetylene-16 kg/cm2.
2. Regulators
The regulator was used to regulate the pressure from the tank to the working pressure
in the horse; Working pressure of oxygen 1 kg/cm2 and acetylene is 0.15 kg/cm2 .
3. Pressure Gauges
The pressure gauges are used to show the cylinder pressure and the working pressures
of the horse.
17. 13
4. Hoses
Gas horses were used to deliver the gases to the welding torch, horses has color coding
according to the gases they carry; the one that carries oxygen is green and the one that
carries acetylene gas is red.
5. Welding torch
The welding torch is the tool that was held when welding.
6. Check valve
7. Non return valve
The non- return valves prevented the back flow preventing fire to explode the
cylinders.
Types of flames used in gas welding.
Three types of flames were used in oxyacetylene welding:
18. 14
a. Neutral flame - Acetylene (C2H2) and O2 are mixed in equal amounts and burn
at the tip of the welding torch. The inner cone generates is the one that
generates a lot of heat. Used for welding steels, aluminium, copper and cast
iron.
b. Reducing flame - The excess amount of acetylene is used this produces a three
layer flame with the inner core, a white-hot second layer which is also called
acetylene feather and a blue colored outer core this flame was mostly used to
weld aluminium and high carbon content steel.
c. Oxidizing flame - The excess amount of O2 is used, the envelope becomes
darker and more pointed, while the envelope becomes shorter and fiercer
giving an oxidizing flame. This type produced highest temperature. It was
useful in welding brass and brazing operation.
3.1.2.3 PROCEDURES USED TO CONDUCT GAS WELDING.
I. Lighting the flame.
The main valve of the acetylene tank is opened at least 1/2 of its full turn which
charges the pressure regulator at the top of the tank. The pressure is regulated to
5 psi. The main oxygen pressure valve is opened and the pressure is regulated
to 10 psi. The acetylene valve is opened 1of 8th
turn and a striker is used to
ignite the flame.
II. Adjusting the flame.
The acetylene valve is opened further until the flame is about to detach from
the tip of the welding torch, the oxygen valve is slowly opened and flame turns
bluish in color the quantity of oxygen added determines the type of flame i.e.
neutral, oxidizing or reducing flame.
III. Welding
All protective gears are worn i.e. dark face shield, leather jacket, and
long sleeves.
The flame is applied to the parts to begin heating until the metal begins
to glow and forms a pool of molten metal near the edge of each parts of
the metals to welded.
19. 15
After the pool is formed the flame is used to gently stir the pool to form
a weld.
After the pool is mixed the torch is moved along the line of welding
while gently circulating the pool to help mixing the metal in a circular
swilling motion.
The process is continued until the weld is done.
DURING GAS WELDING.
• Simple equipment
• Portable
• Inexpensive
• Easy for maintenance and repair
The bed and viscosity of the weld was easily controlled since the welding filler
material is added separately of the welding heat source.
SETBACKS DURING GAS WELDING.
• Very low welding speed
• High total heat input per unit length
• Large heat affected zone
• Severe distortion
• Not recommended for welding reactive metals such as titanium and zirconium.
20. 16
3.2.0 WELDING AND CUTTING TORCHES
3.2.1 DESCRIPTION OF W ELDING AND CUTTING TORCHES.
A welding torch is been referred to as a complete unit , to which a tip and mixer are
added and gas is supplied. A Cutting attachment and tip can replace the tip (and nut) to
transform it into a Cutting Torch.
3.2.2 FUNCTION OF A WELDING AND CUTTING TORCHES.
Welding and cutting torches has the following functions:
1. Flame adjustment.
21. 17
The flame needed is selected by adjusting the proportions of oxygen to acetylene gas .The
flame is neutral, reducing or oxidizing flame.
2. Welding.
The main job for the welding torch is welding; it has the tip where flame forms, mixing
chamber and provide handling for the welder.
3. Cutting.
A specified cutting torch was used in this process ,it has an extra oxygen hose pipe for cutting.
3.2.3 SEQUENCE FOR TROUBLE SHOOTING AND REPAIR.
3.2.3.1 TROUBLE SHOOTING
When adjusting a malfunctioned or leaking torch, accessory or tool the following table was
useful
TROUBLE SHOOTING CHART
SYMPTOM POSSIBLE CAUSE REMEDY
1. Backfire,
flashback, or
erratic flame.
a. Damaged tip or
mixer.
a. Replace with
new tip or
mixer
b. Insufficient flow. b. Readjust
pressures.
Reduce
number of
fittings.
Increase hose
size.
c. Improper gas
pressures or
flows.
c. Readjust
pressures or
torch valves
d. Loose tip or
mixer.
d. Allow to cool,
then tighten,
or replace
seals.
e. Dirty or deformed
tip.
e. Allow tip to
cool, then
clean and
replace.
f. Tip too close to
work, or
f. Increase
distance.
22. 18
overheated.
g. Tip or torch head
does not seat
(cutting torch).
g Discard tip or
send torch to
service facility
for new head.
h. Failure to purge or
use check valves.
h. Purge lines.
Install check
valves.
2. Gas leakage. a. Loose torch or tip
nut
a. Tighten tip nut.
b. Dirty or damaged
seating surfaces
between torch
and tip.
b. Clean or send
torch to
service facility.
3. Oxygen or
fuel leak
through
valve stem.
a. Loose packing
nut.
a. Tighten nut
(packing type
only.
b. Worn packing or
O-ring.
b. Send torch to
service facility.
c. Improper gas
pressures or
flows.
c. Send torch to
service facility.
4. Oxygen or
fuel leak
through
valve seat.
a. Dirty or damaged
valve seat or bent
valve stem.
a. Clean or send
torch to service
facility.
b. Damaged body. b. Send torch to
service facility.
5. Cutting
oxygen valve
leaks.
a. Dirt in cutting
oxygen valve.
a. Send torch to
service facility.
b. Damaged cutting
oxygen valve
b. Send torch to
service facility.
c. Worn or damaged
valve seat.
c. Send torch to
service facility.
23. 19
d. Broken valve
spring.
d. Send torch to
service facility.
6. Oxygen leak
at cutting
oxygen valve
stem.
a. Damaged cutting
oxygen valve Oring
or packing.
a. Send torch to
a service
facility.
b.Packing loose b. Tighten
packing nut.
7. O-ring type
valve stem
binds.
a. Drag sleeve over
tightened.
a. Loosen
sleeve.
b.Damaged body. b. Send torch to
service facility.
8. Hose/Torch
connection
leak.
a. Damaged seat. a. Send torch to
service facility.
3.2.3.2 REPAIR AND PLACEMENT OF WELDING TORCHES
Firstly the gas supplies are shutoff at the source before attempting inspection, or
maintenance except for leak checks.
A defective or leaking torch or cutting attachment is not repaired but returned to the
authorized service facility, as special tools, tests and techniques may be required. Only
replacements of readily removable tips nuts, mixers, and cutting attachments are made.
For example the repairs of
Cleaning of welding tip
The flame is first switched off and the tip is allowed to cool first then the tip is cleaned.
Welding Tip and Mixer replacement
Welding tip and mixer chamber are removed by opening the head nut from the torch
head fitting ;while protecting the seat so as not to damage it. The defective part can be
changed by buying a new part from local dealers who engage in selling these kind of
equipments.
24. 20
Cutting oxygen valve leak
The packing nut is tightened over a wench ;but if the leak continues the torch is
discarded.
REORDERING OF PARTS
Reordering of small parts in smaller quantity is done using local dealers found in the
area/town, But ordering of large quantities of spare parts is done from international
dealers in China, this is where most of the parts are obtained.
CONCLUSION
During my practical training I learnt a lot of thing concerning my course of study. I
learnt also how to work with different people in an organization by cooperation. Apart
from that I enjoyed a lot both practical works assigned to me because they made me
become confident and familiar mostly to welding operations.
Welding operations were basic and common to all departments in the workshop;
therefore it’s a primary operation to any industrial practice because it resides and goes
hand in hand with other operation, for example in TAZARA welding was used in
smaller operations like filling worn out parts, straightening of metal parts to major
operations like rebuilding structures torn apart in accidents for example a structure
called cowcatcher.
RECOMMENDATION
The implementation of safety regulations for the organization is not strictly followed
which is due to lack of safety tools and equipment. This lack of safety tools and
equipment is due to lack of funds ,therefore since it is a governmental organization ;the
government should look into ways to revive the organization to be able to compete
again by providing it with funds, intellectuals and promotion.
25. 21
REFERENCE
Controls Corporation of America, 2009, Hand welding and cutting attachments(ADI 1647J),
1501 Harpers Road.Virginia beach, VA23454
American torch tip, Cutting, heating, welding and brazing instruction manual, 6212 29TH
Street
East, Bradenton, FL 34203, United states
http://www.weldguru.com/welding-electrode.html
http://www.tazarasite.com/
http://www.acastronovo.com/ClassHtms/Weld01.htm
http://www.slideshare.net/RakeshSingh125/f-gas-welding
http://en.wikipedia.org/w/index.php?title=Oxy-fuel_welding_and_cutting&redirect=no
http://www.concoa.com/docs/ADIS/ADI1647J.pdf