IOSH89-T-030 The Safety Operation Handbook of Arc Welding
(Standard Operation Procedure, SOP) SOP i
...i...ii...iii...v...1...1...2...4...4...11...14...14...18...20...28...30...33...33...36...40...42 SOP...45 SOP...45...47... 56 ii
2-1....5 2-2...6 2-3......6 2-4.....7 2-5...7 2-6...8 2-7......10 2-8...12 2-9...13 2-10......13 3-1.....15 3-2.....15 3-3......16 3-4...17 3-5...21 3-6...22 3-7...22 3-8...23 3-9...23 3-10...23 3-11.... 24 3-12....25 3-13...29 3-14......31 3-15......32 4-1...34 4-2...34 iii
4-3......39 4-4...40 5-1 SOP...48 iv
2-1...5 2-2...10 2-3... 12 3-1 L...26 3-2 H.....26 3-3... 27 3-4...31 4-1 78 82......35 4-2 78 82...35 5-1...49 5-2...50 5-3...51 5-4...52 5-5...53 5-6 ( )...54 5-7 ( )...54 v
110/220/440V 55~85V 1
CNS 250 (Standard Operation Procedure, SOP) SOP 2
3
(Shielded Metal Arc Welding, SMAW) 2.1.1 2-1 2-2 2-1 2-3 2-4 2-5 4
2-1 2-1 (V) (Hz) (V) (V) (A) (%) 3.5KW/7KVA 120A 110/220 50/60 55 27 120/25 20 Φ3.2-Φ2 26 4KW/8KVA 130A 110/220 50/60 60 30 130/25 20 Φ3.2-Φ2 31 5KW/10KVA 140A 110/220 50/60 60 30 130/25 20 Φ3.2-Φ2 31 6KW/12KVA 150A 110/220 50/60 60 30 150/25 20 Φ3.2-Φ2 31 6KW/12KVA 150A 220 50/60 75 30 150/30 40 Φ3.2-Φ2 50 8KW/16KVA 200A 220 50/60 80 30 200/40 40 Φ4-Φ2 61 9KW/18KVA 220A 220 50/60 80 30 220/40 40 Φ4-Φ2 63 10KW/20KVA 250A 220 50/60 80 30 250/50 40 Φ5-Φ2.6 71 13KW/25KVA 300A 220 50/60 80 30 300/60 40 Φ5-Φ2.6 88 15KW/30KVA 350A 220/440 50/60 80 30 350/70 50 Φ6-Φ3.2 94 19KW/35KVA 400A 220/440 50/60 81 30 400/70 50 Φ7-Φ3.2 133 25KW/45KVA 500A 220/440 50/60 85 35 500/70 50 Φ9-Φ3.2 159 m/m kg 5
2-2 2-3 6
2-4 2-5 7
2.1.2 2-6 60Hz (SMAW) (Gas Tungsten Arc Welding, GTAW) 2-6 8
2.1.3 2.1.4 2-7 (Arc Blow) 9
2-7 2.1.5 2-2 SOP 2-2 (AC) (AC) (DC) (1) (1) (1) (2) (2) (2) (3) (1) (1) (1) (2) (2) (2) 10
5000 2-8 80V 2-9 (600~900mm) 3~4 ( ) 2-10 2-3 11
5k 80V 16mA 1mA 2-3 R AB 198k 6.5k 3.75k R AC 220k 7.6k 5.5k R AD 0.03 5 300k A B C D 2-8 12
2-9 2-10 13
1. 2. 3. 1. 2. 10~14 3-1 (1) (2) 14
(3) (4) (5) 3-1 3-2 15
3. 3-2 4~5 4. 3-3 (1) (2) (3) (4) 5. 3-4 3-3 16
3-4 (1) (2) (3) (4) 6. 7. 8. 17
(1) (2) (3) (4) 1. 2. (1) 10cm 10cm 120kg 5cm 50kg (2) (3) (4) 3. 9~16mm (1) (2) 18
(3) (4) 4. (1) (2) (3) (4) 5. (1) (2) 6. ABCD A B C D ABC (1) (2) (3) 7. 19
(1) (2) 60 (3) (4) (5) 8. (1) (2) (3) 55~85V 25V 250 CNS 4782 20
332 3.3.1 3-1 1 3-5 21
(a) (b) (c) 3-6 3-7 3-8 3-6 (Current Transformer, CT) 3-9 3-10 MC 3-6 MC b a 3-7 22
MC b 3-8 3-9 3-10 23
3-11 3-11 thyristor 3-12 24
3-12 3.3.2 1. 2. 3. 4. 5. CNS-4782 3-1 3-2 3-3 3 5 300A 500A 25
3-1 L (A) V S V SP-3A-L 130 300 50 25 1.0 0.3 2 65 85 SP-5A-L 220 500 70 70 95 SP-3B-L 130 300 50 60 85 SP-5B-L 220 500 70 70 95 SP-3C-L 110 300 50 60 85 SP-5C-L 180 500 70 70 95 SP-2E-L 200 50 60 85 SP-3E-L 300 50 60 85 SP-5E-L 500 70 60 85 3-2 H (A) V S V SP-3A-H 130 300 50 25 1.0 0.3 2-500 65 85 SP-5A-H 220 500 70 70 95 SP-3B-H 130 300 50 60 85 SP-5B-H 220 500 70 70 95 SP-3C-H 110 300 50 60 85 SP-5C-H 180 500 70 70 95 SP-2E-H 200 50 60 85 SP-3E-H 300 50 60 85 SP-5E-H 500 70 60 85 26
(1)SP (2)SP (3)A (4)B (5)C (6)E (7)L L (8)H H 3-3 FSP3AH FSP5AH 1.1SEC 1.1SEC 70% 70% 220V 220V 50/60Hz 50/60Hz 360 360 6090V 6090V 15V 15V 3.3.3 1. 2. 3. 27
4. 5. 6. 220V440V 7. 8. 9. 10. 11. 243 28
3-13 150V 100 151V 300V 50 301V 10 3-4 A C B IA IC IB IC IA IB IB IC 3-13 29
3-4 (ma) () 30 50 75 100 150 200 300 500 1000 500 500 333 259 166 125 83 50 25 500 500 500 500 333 250 166 100 50 3-13 3 ABC A I A B I B C Ic 1. 2. 3. 3-4 30
3-13 4. 5. 243. 59 3-14 I 1 I 2 0 I 1 I 2 30mA 0.1 0.1 2 I 1 I 2 I 1 I 2 3-14 31
3-15 1. 2. 3. 4. 5. 6. 3-15 32
80V 50V 40V k 789 33
72% 4-1 4-2 50V 30mA I=116/ t 15 30mA 1mA 5mA 4-1 4-2 34
4-1 4-2 78 82 8 28 2-3 4-1 78 82 (%) 8 42.11 4 21.05 3 15.79 2 10.53 2 10.53 19 100.00 4-2 78 82 (%) 5 45.45 3 27.27 1 9.09 1 9.09 1 9.09 11 100.00 35
1. 2. 36
3. 4. 5. 37
6. 7. 10 10 ABCD 4-1 4-2 1. 38
2. 4-3 3. 4-3 39
4-4 4-4 40
1. (1) (2) (3) (4) (5) (6) (7) 2. (1) (2) (3) (4) (5) (6) (7) (8) (9) 3. (1) (2) (3) (4) (5) 41
(6) 1. 2. 3. 0.75 0.75 4. 1 (1) (2) (3) A B 220V 80V 30V 250A 60A 180 260 42
(4) A. B. C. D. E. F. 2 (1) (2) (3) A H H 7.75 20 25 5.6 (4) A. B. H C. D. E. 43
3 (1) (2) (3) ABC AB A H 200/400V 55kVA28kW 86V 46V (4) A. B. H 11 C. D. E. F. 44
SOP SOP SOP 1. 2. 3. 4. 5. 6. 10 7. 8. 9. 10. 45
11. 1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 46
OK NO NO NO OK A OK A OK NO NO NO NO NO OK OK OK OK NO NO OK NO OK 5-1 SOP 47
3. 4. SOP 5-1 SOP SOP 5-1 (1) (2) (3) (4) 5-2 5-3 5-4 5-5 48
5-1 9-2 9-3 9-4 9-5 49
5-2 1. 2. 1. 2. 3. 4. 5. 6. 1. ( ) 2. 3. 4. 5. 6. 7. 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 1. 2. 3. 50
5-3 1. 2. 3. 4. 5. 1. 2. 3. 4. 1. 2. 1. 2. 3. 4. 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 7. 1. 2. 3. 1. 2. 3. 4. 51
1. 2. 3. 4. 1. 2. 5-4 1. 2. 3. 4.? 5. 6. 7. 8. 9. 10. 11.? 12. 13. 5-5 52
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.? 15. 16. 5-6 ( ) 53
5-7 ( ) 5-6 5-7 54
1. 5-2 2. 3. 4. 5. 6. 7. 5-1 8. 55
[1] O`Brien, R. L., 1991; Welding Handbook, American Welding Society, Miami. [2] Jeffus, L. and Johnson, H. V.,1988; Welding-Principles and Applications, Delmar Publishers, New York. [3] Smith, D, 1984; Welding Skill and Technology, Mc Grall-Hill, Inc., New York. [4] Gallerman M., 1994; Welding Fundamentals, Delmar Publishers, New York. [5] Althouse, A. D., Turnquist, C. H., and Bowditch, W. A., 1976; Modern Welding, The Goodheart-Willcox, Inc., South Holland, Illinois. [6] 1985 [7] 1995 [8] 1992 [9] 1990 [10] 1987 [11] Yu, L. and Beck, R. T., 1988; "Evaluation of Electrical Hazards in AC Low Voltage Systems," PCIC, Proc. of the IEEE Petroleum and Chemical Industry Conference,: 213-218. [12] Yu, L., Chow M., and Bowen, J., 1998; Safety and Ground Fault Protection in Electrical Systems, IEEE Industry Applications Magazine, March/April: 32-36. [13] Doughty, R. L., Epperly, R. A., and Jons R. A., 1991; Maintaining Safe Electrical Work Practices in a Competitive Environment, PCIC, Proc. of the IEEE Petroleum and Chemical Industry Conference,: 1257-1283. [14] 1992 [15] 1993 OHM [16] 1986 OHM [17] 1989 JIS C 9311 [18] 1984 CNS 4782 [19] 1991 172-175 [20] 1992 139-145 56
[21] Cullison, A. and Newton-Montiel B., 1990; "Change are Coming for Welding Power Sources, Welding Journal, May: 37-42. [22] Kemppi, Inc., 1990; Inverters Give Welder More Options, Welding Journal, December: 59-62. [23] Rankin, T., 1990; New Power Source Design Breaks with Tradition, Welding Journal, May: 30-34. [24] 1994Pspice Design Center3 [25] 1997 [26] 1987 [27] 1995 57
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