©ÐàØÙÖÙÎÓê ÚÙÖÞâÐØÓê £ « ÛËÒÛË MAF production process …ekoilas.lt/wp-content/uploads/2017/07/Prezentation-MAF-2013.pdf · kh^ . [he__ 70% f_^b Avoid alloys

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Belneftekhim Concern OJSC Naftan, the plant Polymir

METHYLACETYLENE-ALLENE FRRACTION (MAF GAS)

И я да я History of development

-

, « », .

« » -

« », . .

№ 431943.

1997 :

( - .

MAF production process has been developed based on research work carried out at the laboratory of gas separation VNIIOS, Moscow and has been tested in operation at the pilot plant at the ethylene production workshop of PO Polymir and at the pilot-industrial unit of the pilot plant VNIIOS, Moscow.

The process developed by VNIIOS has received the certificate of authorship № 431943

1997 : The unit for MAF gas

(methylacetylene-allene fraction) production has been constructed.

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– .

Ф ы в ых е в: - ( ) 3 - ≡ ; - ( ) 2 = = 2.

-

2003 .) – 40,065.

MAF is a mixture of hydrocarbon gases liquefied under pressure.

Formulae of main components: -methylacetylene (propyne) 3 - ≡ ; -allene (propadiene) 2 = = 2. Relative molecular weight of methylacetylene and allene (as per the international atomic weights of 2003) – 40.065.

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, ,

, .

. К , . .

– ,

.

.

, ,



Manufacturing Process

The manufacturing process for production of MAF gas has been chosen basing on its nature as a mixture of liquefied gases with narrow distribution of boiling temperatures and relatively low volatility. MAF is extracted from non-hydrated propane fraction of cracked gas by means of extractive rectification. The quantitative composition of MAF gas is variable, as it depends on the composition of the feedstock received for cracking, that is, straight-run naphtha or NGL, which composition also varies. Minimal and maximal possible quantities of main components are specified in the Product Specification. Propane and propylene present in MAF gas are important as stabilizers necessary for safe storage, transportation and usage of methylacetylene-allene fraction.

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BY 300042199.043-2009



MAF gas quality parameters BY 300042199.043-2009

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Parameter

/Norm for the grade

. , %, , /

Volume fraction of methylacetylene and allene, %, including methylacetylene, not less

70-75 38

65-75 Not rated

. 4, %,

Volume fraction of C4 hydrocarbons, %, not more

6

. , %, /

Volume fraction of acetonitrile, %, not more

0,5

. , %, /

Mass fraction of water, %, not more

0,004

Not rated

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BY 300042199.043-2009



MAF gas quality parameters BY 300042199.043-2009

:

– , – .

.

Depending on the application, MAF can be produced of two grades, grade A and grade B. Grade A is used for gas-flame treatment of metals, Grade B is used in gas-flame treatment for cutting the metal. Both MAF grades can be used in organic synthesis and for other purposes.

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Typical chromatogram of MAF

Met

hyl

acet

ylen

e (p

rop

yne)

B

uta

die

ne-

1.3

izo

-bu

ten

e

Bu

ten

e-1

Pro

pad

ien

e (a

llen

e)

Bu

tan

e

Pro

pyl

ene

C

yclo

pro

pan

e

P

rop

ane

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: •

; • .

- -

(50 1586-84

Field of application: • analogue of acetylene in all processes of gas flame treatment of metals; • in pharmaceutics and pharmacology Packing and transportation – Tank trucks designed for liquefied gases or cylinders (50 liters) for liquefied gases as per GOST 1586-84

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: •

• .

- -

(50 1586-84

Field of application: • analogue of acetylene in all processes of gas flame treatment of metals; • in pharmaceutics and pharmacology Packing and transportation – Tank trucks designed for liquefied gases or cylinders (50 liters) for liquefied gases as per GOST 1586-84

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:

• 50 4 ;

• 0,005 (0,05 / 2) 50 3 ;

• 80

3,5 10 (100 / 2); •

40 5 10 (100 / 2);

• - , 14 150 4 .



MAF gas can be used instead of acetylene in gas welding of: - steam and hot water pipelines made of carbon and low-alloyed steels with nominal diameter up to 50 mm and wall thickness not more than 4 mm - above ground gas pipelines with pressure up to 0.005 MPa (0.05 kgf/cm2) inclusive with nominal diameter not more than 50 mm and wall thickness up to 3 mm inclusive - process pipelines made of carbon and low-alloyed not hardenable steels with the nominal diameter up to 80 mm and wall thickness not more than 3.5 mm at pressure up to 10 MPa (100 kgf/cm2) -process pipelines made of low-alloyed hardenable steels with the nominal diameter up to 40 mm and wall thickness not more than 5 mm at up to 10 MPa (100 kgf/cm2) -pipelines not supervised by GOSPROMNADZOR provided the welding seams are strong enough and the requirements of technical normative and legal acts for pipes with the outside diameters from 14 to 150 mm and wall thickness up to 4 mm are observed.

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Technical specifications

Пок тел / Parameter Ф/ MAF ет ле /

Acetylene П оп / Propane

е оп о т , у т тел о т к уд у/

Safety, impact sensitivity

Ст ле /

stable

е т ле /

unstable

Ст ле /

stable

П едел е о т о ду е, %/

Explosivity limit in air, % 2,3-11,9 2,2 - 83 2,3 - 9,5

Скло о т к о т о у уд у/

Probability of flash back

е т./

negligible

З т./

significant

е т./

negligible

П едел я те пе ту пл е , ⁰С, е

к ло од/ о ду /

Limit flame temperature, ⁰С, in oxygen/air mixture

2927/2165 3087/2325 2526/1925

я теплот о я о о е п о .

у ло я , Кк л/ 3/

Lower heat value of gas mixture combusted under normal

conditions, kcal/m3

21000 12600 21795

Те е к к.п.д. от о тел о т л / ед , /

Coefficient of thermal efficiency in relation to steel/copper

0,54/0,63 0,56/0,65 0,46/0,57

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Technical specifications

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/ Parameter / MAF /

Acetylene / Propane

0° 101,3 (760 . .), / 3

Gas density at 0° and 101.3 kPa (760 mm. Hg), kg/m3 1,7 1,17 2,01

Reaction with base metals

И ,

. 65%

Avoid alloys

containing more than

65% of copper

И ,

. 70%

Avoid alloys

containing more

than 70% of

copper

.

Limitations are

negligible

, / 3

Liquefied gas density , kg/m3 570 - 513

, °

Boiling temperature, ° -20÷ -42 -85 -162÷ -5

( ) Relative density (in relation to air)

1,3 0,89 1,54

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– .

, ,

.

(2927 ° 3087 °

12

.

Technical specifications Propane and natural gas are characterized with heat emission less in the first zone of the flame and to the higher degree in its second zone. MAF gas has high heat irradiation both in the second and the first zone of the flame in comparison with the other gases. MAF flame efficient zone temperature is close to the temperature of acetylene flame (2927 ° against 3087 ° ) and the quantity of heat emitted to the heated metal at the distance of 12 mm and farther from the hottest spot in the flame is still high.

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4

.

- К – 135 /

:

, , .

, , .

.

Safety When Working with MAF Gas

MAF gas has Hazard Class 4 acc. to it impact onto a human (low-hazard substances). Maximum admissible concentration of MAF vapors in the air of working zone calculated by acetylene is 135 mg/m3. General character of action: in high concentrations it is hazardous when inhaling, getting onto skin and into eyes. MAF vapors cause redness and itching of skin, lacrimation, smarting in eyes. When getting onto human skin liquid MAF can cause frostbites.

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К

. : ,

, . К .

:

,

, , , –

.

.


When maximum admissible concentration is exceeded, MAF vapors result in narcotic action with obvious irritating action onto mucous membranes. Symptoms of poisoning: dizzy head, choking, headache. Cumulative effect is negligible. Fist aid measures in case of MAF intoxication: remove the victim from hazardous area to the fresh air, release the tight parts of the clothes, provide warmth, rest and in case of necessity make artificial breathing. In case of necessity seek medical assistance.

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,

.

,

.

,

- ,

.


Operations with MAF gas shall be performed observing the safety rules established for work with liquefied flammable gases. The containment of production processes shall be provided, and all sources of initiation of explosion or combustion shall be excluded. Operations with MAF gas shall be performed in production rooms equipped with general suction and exhaust ventilation. MAF is heavier than air, that is why, to avoid its accumulation in the above floor area of the room the ventilation shall have downdraft suction hood.

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Э ,

.

, 65 % ,

.

, .

, , ,


Electrical equipment, wiring and artificial lighting shall be explosion-proof. In case of MAF contact with copper and its alloys containing more than 65% of copper explosive copper acetylides can be generated. In case of MAF combustion the primary fire extinguishing means which shall be used are carbon acid and powder fire extinguishers and fire blanket. Operators working with MAF shall have special clothing, shoes, respiratory protection means, protection for eyes and skin.

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: ; 1,5 – 2 ; –

; -

, ,

:

(>65%)

MAF

Advantages: Easy and convenient usage; 1.5 – 2 times cheaper than acetylene ; Environmentally friendly, no wastes

when welding ; Soft flame is an advantage when

working with thin metal, nonferrous metals, when shape-cutting the articles.

Disadvantages: In case of MAF gas contact with

copper or its alloys (>65%) explosive copper acetylides may be generated.

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:

, ⁰ , / – 3087/2325

: –

;

ACETYLENE

Advantages: High limit temperature of the flame,

⁰ , in oxygen-air mixture – 3087/2325

Disadvantages: Disposal of wastes (slaked lime ) is

necessary; Tendency to flash back

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50- 22

21 , 5 82

50-litre cylinder of 22 kg weight may contain 21 kg of pumped in MAF gas while 5 kg of acetylene are pumped into the cylinder of 82 kg weight.

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MAF ACETYLENE

kg kg

ACETYLENE ACETYLENE ACETYLENE

kg kg kg

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50 15860 1,6 ,

, .

40

45 ° . 12 3 - .

« ».

MAF gas cylinders

For MAF gas welded cylinders shall be used with capacity of 50 liters as per GOST 15860 intended for pressure of 1.6 MPa designed for storing and transporting of liquefied hydrocarbon gases (propane, butane and their mixtures). Cylinders shall be operated at wall temperature from minus 40 to plus 45°C. Liquid can produce approximately 12m3 of MAF gas. Cylinders shall be colored red and have an inscription 'MAF‘ in white color.

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К , , -

: - ; - ; -

- ; - , ; - , ; -

; - , ; - , ; - , ; - (V), ; - К -

10 . К

.

50 - .

Each cylinder shall have a plate at the place convenient for seeing made of corrosion resistant metal with the following data: •Trademark or manufacturer name; •Designation of the vessel; •Number of the cylinder as per the numeration system of the manufacturer plant; •Cylinder weight with gas (WG), kg; •Empty cylinder weight (WE), kg; •Month and year of manufacturing (testing) and the year of the next certification; •Design pressure, MPa; •Operating pressure (P), MPa; •Test pressure, (T), MPa; •Volume (V), liters; •Manufacturer company quality control stamp of round shape, 10 mm in diameter. Fixation of the plate shall be reliable and permanent. The cylinders with 50 liter volume may have the information applied on the collar.

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,

.

.

. ,

. К , :

« . !».

10 .

After the job is finished the cylinders with MAF gas shall be placed in a separate specially allocated room (storage) or in the open air under the shelter, only in vertical position in the nests of special supports. The cylinders with liquefied gas shall be kept in the specially equipped ramp areas or metal cabinets with natural ventilation. The cabinets shall be locked and have ventilation openings to avoid accumulation of gases. They shall be colored the same color that the cylinders for the relevant gases, Moreover, the cabinets shall have the warning statements 'Flammable gas. Fire hazard'. When at work, the distance from the cylinders to the burner shall be not less than 10 meters.

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.

, ,

Я

,

(2,3-11,9% .

The cylinders with MAF gas shall be installed vertically and fixed against falling. MAF gas is heavier than air and may accumulate in the lower part of the room, that is why when working it is PROHIBITED to place the cylinder with MAF gas in those rooms where it is impossible to exclude the explosive concentration formation of MAF gas in mixture with air (2.3-11.9% vol.) by means of natural or forced ventilation.

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UN 1965

Ф

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« » 7 Technical Characteristics of GZU DONMET 247 Burner (MAF Gas)

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Parameter

ч

Tip Numbers

2 АФ

2MAF

3 АФ

3MAF

4 АФ

4MAF

,

Thickness of welded metal when working with MAF gas, mm 0,5 – 1 1 – 2 2 – 4

,

Pressure, MPa

- /oxygen

- /MAF

0,2 – 0,25

0,0025 – 0,12

, /

Consumption when working with

MAF gas, l/hr

- /oxygen

- /MAF

290 – 370

80 – 92

470 – 490

110 – 113

640 – 730

160 – 190

№3 – 400

Length of the burner with the tip No.3, not more than – 400 mm

№3, – 0,42

Weight of the burner with the tip No.3, not more than – 0.42 kg

– 6 9

Inner diameter of attached sleeves – 6 or 9 mm

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,

,

0,05 (0,5

К « » 950. К

:

.

Check Flame Arrestor Valves

To protect the apparatuses and rubber-fabric sleeves against rupture and ignition in case of flashback and to avoid counter-flow of flammable gas or oxygen and overflowing of gases at residual pressure in cylinders lower than 0.05 MPa (0.5 bar), it is absolutely necessary to use a check flame arrestor valve of KO DONMET 950 type. Flame arrestor valve is installed as follows; two valves shall be installed at the burner and two valves shall be installed at the oxygen cylinder and MAF-gas cylinder, correspondingly

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« » 9 Technical Characteristics of the Check Valve KO DONMET 950 Type

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Operating

medium

,

Maximum

operating

pressure, MPa

Δ %

Relative

pressure drop,

Δ %

,

3/

Nominal

through-out

capacity, m3/hr

Attachment

thread

,

Maximum

diameter

and length,

mm

,

Weight,

kg

К

(« » 950-К К)

Oxygen

(DONMET

950-KOK)

1,0 15 60

12 1,25

2171

0,09

14 1,5 0,09

16 1,5 0,1

G1/4 0,09

G3/8 0,1

(« » 950-К )

MAF

(DONMET

950-KOG)

0,3 15 5

12 1,25LH 0,098

14 1,5 LH 0,098

16 1,5 LH 0,107

G3/8 LH 0,107

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« »

« -

». -

, , ,

.

, ,

, ,

, .

Flame arrestor devices with the integrated check valve produced by DONMET plant have been named as 'Flame Arrestor Valve'. Flame arrestor valve is different from the check valve as it has an integrated flame-extinguishing piece. The flashback flame front passes through the flame extinguishing element and extinguishes, while the shock wave locks the spool immediately shutting down the feeding of gas to the burner thus functioning simultaneously as a check valve.

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, ,

.

-

5

К -25, К -

50, К -2-78

.

Reducers The reducers are used for reduction and control of pressure of the gas coming from the cylinder and for maintaining automatically the constant set operating pressure value of gas when feeding the gas flame equipment. It is recommended to install the one-stage cylinder propane reducer of BPO-5DM type. Oxygen cylinders shall have the reducers of BKO-25, BKO-50, DKP-2-78 type installed. For safe operation of oxygen reducers they shall be protected from contamination with oil and grease.

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- Technical Characteristics of the Reducer Type BPO-5DM

* . Inner diameter of attached sleeves

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Parameters

З ч

Value

, 3/

Maximum through-put capacity, m3/hr 5,0

, ( / 2)

Maximum gas pressure at the inlet, MPa (kgf/cm2) 2,5 (25)

, ( / 2)

Maximum operating gas pressure, MPa (kgf/cm2) 0,3 (3)

Attachment to the cylinder

21,8 14 1"

Thread SP21,8 14 threads per 1"

(9)*/Attachment to the reducer 16 1,5LH

(6)*/Attachment to the reducer 12 1,2LH

, , /Overall dimensions, mm, not more than 130 110 90

, , /Weight, kg, not more 0,5

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: 0,6 (6 / 2).

: 1,5 (15 / 2). 6, 9, 12 16 :

– ; – .

, ,

, .

Sleeves (hoses) MAF gas is fed through sleeves made of rubber on the threaded carcass, the 1st type, for supply of pressure not more than 0.6 MPa (6 kgf/cm2). To supply the oxygen the sleeves made of rubber on the threaded carcass, the 3rd type are used, for supply of pressure not more than 1.5 MPa (15 kgf/cm2). The sleeves are produced with the inner diameter 6, 9, 12 and 16 mm with strength margin (not less than): for the first type – four times for the third type – three times The outside layer of the sleeves used for supply of MAF gas is colored red, for oxygen it is colored blue.

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: • ,

50 4 «

»; • 0,005 (0,05 / 2)

50 3 3.05.02 «

»; •

80 3,5 10 (100 / 2),

• 40 5 10

(100 / 2) « ».



Welding procedure

Gas welding procedure with usage of MAF gas is valid for: •steam and hot water pipelines made of carbon, low carbon and low-alloyed steels with nominal diameter up to 50 mm and wall thickness not more than 4 mm as per The Rules of Design and Safe Operation of Steam and Hot Water Pipelines •above ground gas pipelines with pressure up to 0.005 MPa (0.05 kgf/cm2) inclusive with nominal diameter not more than 50 mm and wall thickness up to 3 mm inclusive as per The Rules of Industrial Safety in the Field of Gas Supply of the Republic of Belarus and SNiP 3.05.02. •process pipelines made of carbon and low-alloyed not hardenable steels with the nominal diameter up to 80 mm and wall thickness not more than 3.5 mm at pressure up to 10 MPa (100 kgf/cm2) •process pipelines made of low-alloyed hardenable steels with the nominal diameter up to 40 mm and wall thickness not more than 5 mm at up to 10 MPa (100 kgf/cm2) as per The Rules of Design and Safe Operation of Process Pipelines

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,

, .

, -

– « » :

К = -----------------≥ ,

-

.

, .

, « » .



The temperature of MAF gas flame in mixture is to some degree less than the temperature of acetylene-oxygen flame, that is why in order to receive similar weld penetration of metal the heating capacity of MAF gas in mixture with oxygen can be increased. To increase the flame temperature and to compensate for somehow slower initial warming-up of welded materials if compared to acetylene flame, the welding with MAF-oxygen flame at the beginning (initial warming-up stage) may be performed with increased quantity of oxygen in mixture (oxidizing, noisД flame):

Oxygen Ratio = -----------------≥ .5

MAF-gas

The main stage of welding shall be performed with neutral flame. The mixture is regulated by appearance of the flame, the cone of the flame shall have precise shape. The correctness of flame composition regulation is determined by absence of sparks from the welding bath and by absence of its boiling.

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Temperature Distribution Schedule

Ма а ая а а а 9 °С а я , а а

а а а я , -2,0 L, L – а а я а, – я , – а ая

а, – а , – а а а .

- , (29300

, 5-6 .

Maximum flame temperature (2930 °C) is observed at the point located from the tip face at a distance of 1.5 –

2.0 L, where L is the length of the flame cone, 1 – the cone, 2 – reducing zone, 3 – f lare, 4 – welded metal.

Temperature distribution studies for MAF-oxygen flame determine the maximum flame temperature (2930°C) at the point distanced 5-6 mm from the top of the flame cone.

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1

3

L

2

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-

, ,

.

.

. , .

To receive a good quality seam during gas-welding with MAF it is necessary to choose correct filler material, burner capacity, tip number and regulate the welding flame. Welding with MAF gas is not different in general from welding with acetylene. Burner capacity and tip number are chosen by thickness of welded material. Usually the tips have indication of welded material for which this tip is intended.

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Preparation of edges and steel welding procedures

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,

Thickness

of welded

metal, mm

,

Initial

gap at

the butt

area, mm

, .

Edge

bevels,

degrees

,

Distance

between

tack welds,

mm

, .

Diameter

of welding

wire, mm

Burner tip

number

, /

Gas consumption, l/hr

, /

Weldin

g

velocit

y, m/hr

MAF

К

Oxygen

0,5-1 1-1,5

Without

bevel

10-40 1-1,5 1-2 30-90 70-210 7-10

1-2 1,5-2

The same 20-80 1,5-2 2-3 60-180 140-415 5-7

2-3 2-3

The same 40-120 2-3 3-4 120-270 280-620 4-5

3-4 3-4 60-90 60-240 3-4 4-5 180-540 415-1240 1,6-4

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. S>3 .

К , 15-20

, .

It is important when preparing the edges for welding to minimize their blunting and to maximize the gap between the welded parts. At S >3 mm the bevels at the edges are made. The edges to be welded and adjacent metal surfaces of 15-20 mm width, as well as welding wire, shall be carefully grinded.

Consumption Norms of Materials for 1 Meter of Seam for Welding of Low-Carbon Steel with MAF Gas

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Т ,

Welded material thickness, mm

,

Deposited weld metal weight, kg

ч ,

Wire filler weight, kg

АФ, 3

MAF volume, m3

, 3

Oxygen volume, m3

Butt joints without edge preparation

1 0,028 0,029 0,013 0,030

1,5 0,040 0,051 0,023 0,053

2 0,070 0,074 0,034 0,078

2,5 0,084 0,088 0,044 0,101

3 0,094 0,103 0,051 0,174

V-

Butt joints with V-shape edge preparation

3 0,123 0,140 0,063 0,145

4 0,178 0,187 0,104 0,240

5 0,224 0,235 0,139 0,320

6 0,265 0,278 0,197 0,450

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-08 2 2246 400074854.009-

2001. К ,

, ,

,

,

.

Filler Material Choice

The main filler material for gas welding of pipes with MAF gas is the wire of SV-08G2S type as per GOST 2246 or as per TU RB 400074854.009-2001. Silica and manganese content in this wire which is higher than in the common welding wire adds to deoxidation of welding bath what allows using flame of gas mixture with increased oxygen content with the higher temperature.

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,

Chemical Composition of Welding Wire used for MAF

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Wire grade

%

Elements in composition, %

( )

Carbon

(not

more)

Manga

nese

К

Silica

Chrome

Nickel

Sulphur

Phosphor

Aluminum

Not more than

-08 2

SV-08G2S 0,11 1,8-2,1 0,7-0,95 0,20 0,25 0,03 0,03 0,05

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Я SUMMARY

• • 2927º

3087 º , 2526 º

• 20 º

• ,

•

82

(1 21 = 4

• - ,

, . .

Advantages •Cheaper than acetylene •Welding flame temperature is 2927º , that is, a little lower than of acetylene (3087 º and higher than of propane (2526 º flame •It is possible to work at minus temperature, lower than minus 20 º •Not necessary to dispose of the wastes, as in the case when gaseous acetylene is produced from carbide •Decrease of transportation costs in comparison with the transportation of acetylene cylinders of 82 kg weight to the location (1 cylinder with MAF containing 21 kg of gas = 4 cylinders with acetylene) •Due to higher temperature, the efficiency of labor is better than in comparison with propane, the welding seam has better quality because of the smaller area of temperature impact

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Я SUMMARY

• 2927 º

3087 º • •

2,3 : 1,

-08 2 2246 400074854.009.

• ё , 65% ,

.

• ё

65% •К ,

65% .

Disadvantages •Welding flame temperature (2927 º is lower than with acetylene (3087 º •More expensive than propane •Consumption of oxygen to consumption of combustible gas ratio is 2.3:1, that is why when welding responsible butts with MAF the wire of SV-08G2S grade as per GOST 2246 or as per TU RB 400074854.009 will be required •In case of MAF contact with copper and its alloys containing more than 65% of copper explosive acetylides may form

•Gas-flame equipment cannot be made of pure copper and its alloys with the copper content of more than 65% •As a rule, the brasses used for gas equipment and cylinder valves contain less than 65% of copper

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ATTENTION

The cone even of neutral flame when using MAF gas is 1.5 – 2 times longer that when using acetylene. When starting using MAF instead of acetylene the welder shall remember that to receive a good quality seam during gas welding with MAF it is necessary to choose properly the fillers, regulate the capacity of the torch and the welding flame, choose the proper size of the tip. In general, the welding with MAF gas is not different from welding with ethylene.

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TECHNICAL SPECIFICATIONS FOR MAF GAS

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CERTIFICATES FOR ATTESTATION OF MAF GAS AS WELDING MATERIAL AND OF ITS

CORRESPONDENCE

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SAFETY DATA SHEET OF MAF GAS

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The Guidance for Gas Welding Process with MAF Gas (methylacetylene- allene fraction) developed by GUVPO Belarusian-Russian University, Mogilev.

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ATTENTION!

Documents

©ÐàØÙÖÙÎÓê ÚÙÖÞâÐØÓê £ « ÛËÒÛË MAF production process …ekoilas.lt/wp-content/uploads/2017/07/Prezentation-MAF-2013.pdf · kh^ . [he__ 70% f_^b Avoid alloys