Lesson 1Safe pressure ranges and regulator settings summary for typical mild steel plate cutsSummarises safe oxygen and fuel pressure ranges for mild steel plates, proper regulator adjustments, and gauge readings. Stresses avoiding excess pressure, backfires, and poor cuts by using stable, balanced settings for reliable results.
Typical pressures by plate thicknessSetting and balancing regulatorsReading and interpreting gaugesAdjusting for preheat and piercingRecognizing unsafe pressure signsLesson 2Metallurgy basics of carbon/mild steel relevant to oxy-fuel cutting (thickness, oxidation, heat-affected zone)Introduces basic metallurgy of carbon and mild steel for oxy-fuel cutting. Covers oxidation, heat-affected zone effects, thickness impacts, and how steel composition and structure affect cut quality and potential distortion during fabrication.
Carbon content and steel categoriesRole of iron oxidation in cuttingHeat-affected zone and hardnessThickness, mass, and heat flowEffects on distortion and warpingRecognizing metallurgical defectsLesson 3Cutting technique for straight, square cuts (torch angle, travel speed, preheat/run-on, piercing)Details torch handling for straight, square cuts, including proper torch angle, distance, and travel speed. Explains preheat timing, run-on tabs, piercing methods, and keeping a steady kerf for accurate boiler plate preparation.
Torch angle and nozzle stand-offPreheat time and puddle formationPiercing procedures and safetyControlling travel speed and kerfUsing run-on and run-off tabsMaintaining a steady hand motionLesson 4Edge cleaning and preparation after cutting (grinding, slag removal, dimensional checks)Explains post-cut edge preparation using chipping, grinding, and filing. Covers slag and dross removal, deburring, and checks with gauges and squares to ready edges for welding, fitting, or machining in boilermaking tasks.
Removing slag and dross safelyGrinding and blending cut edgesDeburring holes and cornersChecking squareness and bevelMeasuring length and straightnessPreparing edges for weldingLesson 5Marking, layout, and measurement techniques for cutting rectangular frame parts (scribing, square, templates)Covers precise layout for rectangular frame parts using squares, scribers, and templates. Details datum selection, dimension transfer from drawings, and marking that stays visible while minimising surface damage for shop fabrication.
Reading drawings and dimensionsChoosing datums and reference edgesUsing squares, tapes, and rulesScribing and center punching linesUsing templates and jigsChecking diagonals and squarenessLesson 6Pre-use inspection and leak testing procedures (visual inspection, soap test, flashback device checks)Outlines pre-use checks for cylinders, hoses, regulators, and torches. Includes soap leak tests, flashback device verification, and valve checks to prevent gas leaks, flashbacks, and failures during oxy-fuel operations.
Visual checks of hoses and jointsInspecting regulators and gaugesSoap solution leak test methodTesting flashback arrestorsVerifying valve operationDocumenting and tagging defectsLesson 7Oxy-fuel system components and maintenance (cylinders, regulators, hoses, torch, tips, flashback arrestors)Describes oxy-fuel system parts and functions, from cylinders to flashback arrestors. Covers routine maintenance, cleaning, and replacement schedules to keep equipment safe and reliable for boilermaker daily use.
Cylinder valves and fittingsRegulators and pressure controlHose types, color codes, and careTorch body, mixers, and valvesTip types, cleaning, and wearFlashback arrestors and check valvesLesson 8Common practical troubleshooting and quality checks (undercut, taper, dross)Identifies and fixes common cut issues like undercut, taper, drag lines, and dross. Offers practical tweaks to speed, tip size, pressures, and quick quality checks for efficient production cutting in workshops.
Identifying undercut and washoutRecognizing taper and bevel errorsHeavy dross and drag line causesAdjusting speed, height, and angleCorrecting pressure and tip issuesSimple visual and gauge checksLesson 9Handling, storage, and identification of cut parts (tagging, stacking, corrosion prevention)Covers safe handling and storage of cut parts, with tagging, stacking, and rust prevention. Ensures dimensional accuracy and traceability for parts used in boiler frame assembly and further processing.
Tagging and part identificationMarking orientation and fit-up sidesSafe lifting and manual handlingStacking, dunnage, and supportsShort-term corrosion protectionShop storage records and labelingLesson 10Gas selection and tip sizing for common plate thicknesses (acetylene vs propane, recommended tip numbers)Guides selection of gas mixes and tip sizes for mild steel plates. Compares acetylene and propane, with recommended tips and flows for cost-effective, efficient cutting in Indian fabrication shops.
Comparing acetylene and propaneGas choice by thickness and dutyManufacturer tip charts and dataSelecting tip size and orificeFlow rates and preheat adjustmentEffects on cut speed and quality
