Cut Metal Using Oxyacetylene 63B34G05 / Version MOSC 01 Oct 2004

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported

ADMINISTRATIVE DATA
Course Number Version Course Title

091-63B30-MOSC

MOSC

Wheel Vehicle Mechanic BNCOC

Task Number

Task Title

INDIVIDUAL 091-63B-3416 (*) Operate Oxyacetylene Equipment

Task Title

Reinforced Task(s) Academic Hours

Task Number

The academic hours required to teach this lesson are as follows:

ADT Hours/Methods

Test Test Review Total Hours: Test Lesson Number

45 mins / Conference / Discussion 5 mins / Demonstration 4 hrs 25 mins / Practical Exercise (Performance) 0 hrs 0 hrs 5 hrs 25 mins
Hours Lesson No.

Testing
(to include test review)

2 hrs
Lesson Title

63B34G06 version MOSC

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions References

Lesson Number

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. FD5. This product/publication has been reviewed by the product developers in coordination with the CASCOM-TD foreign disclosure authority. This product is releasable to students from all requesting foreign countries without restrictions.
Number Title Date Additional Information

TC 9-237

Operator's Circular Welding Theory and Application

07 May 1993

Student Study Assignments Instructor Requirements

One instructor per group during Conference. One instructor per group, during PE1

Additional Support Personnel Requirements Equipment Required for Instruction

Name

Stu Ratio

Qty

Man Hours

None
Id Name Stu Ratio Instr Ratio

Spt

Qty

Exp

3433-01-183-2675 TORCH SET, CUTTING AND WELDING 4720-01-043-4099 DUPLEX HOSE, RUBBER 4820-00-551-1094 VALVE, REGULATING, FLUID PRESSURE 4820-00-641-3519 VALVE, REGULATING, FLUID PRESSURE 5180-00-754-0661 TOOL KIT, WELDER'S 8120-00-268-3360 CYLINDER, COMPRESSED GAS, ACETYLENE 8120-00-357-7992 CYLINDER, COMPRESSED GAS, OXYGEN, T 8415-00-268-7859 GLOVES, WELDERS' 8415-00-268-8263 JACKET, WELDER'S 9515-01-035-7732 ARMOR PLATE *P16312 Light PRO Projector *ZX7024 Industry Standard Laptop Computer * Before Id indicates a TADSS

1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:12 1:12

No No No No No No No No No No No No

0 0 0 0 0 0 0 0 0 0 0 0

No Yes Yes Yes No No No No Yes Yes No No

Materials Required

Instructor Materials: 63B34G05, Suppl 1c, Practical Exercise Checklist 63B34G05, Suppl 1b Practical Exercise Instructor Guide Power Point presentation Student Materials: 63B34G05, Suppl 1a Practical Exercise Direction to the Student TC 9-237 Torch Outfit Cutting and welding set Hard hat and gloves Apron Welding safety goggles

Classroom, Training Area, and Range Requirements

General Instruction Building Vehicle Maintenance Instructional Building

Ammunition Requirements Instructional Guidance

Id

Name

Exp

Stu Ratio

Instr Ratio

Spt Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material.

Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material. The instructor must also ensure that all training and safety equipment is within operation standard before starting class.

Proponent Lesson Plan Approvals

Name

Rank

Position

Date

Deilus, John

GS-12

Military Analyst

12 Aug 2004

SECTION II.

INTRODUCTION

Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:12 Time of Instruction: 5 mins Media: Large Group Instruction
Motivator

The use of oxyacetylene cutting equipment in recovery operations has saved many lives and valuable equipment. The time will come when you will have to perform oxyacetylene cutting to save a life or retrieve a piece of equipment. During this lesson, you will cut armor plates or regular steel with an oxyacetylene torch. You must develop the coordination required to perform cutting on low carbon steel used for various repairs and fabrications This skill will be used on a daily basis when you repair or fabricate parts used on vehicles and equipment and possibly during recovery operations.
NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action: Conditions:

Terminal Learning Objective

Perform selected Oxy-fuel cutting operations. In a classroom/field environment, given the necessary tools, equipment, and reference material. Perform Oxy-fuel cutting operations IAW with reference, and correctly and safely complete the practical exercise, correctly answer all check on learning questions, and score 70 percent or higher on job knowledge test 63B34G06.

Standards:

Safety Requirements

CAUTION: Remind the student of the following safety precautions: Inform the students that anyone can stop training immediately if they see an unsafe act occurring or about to occur. Always be safety minded and accident free. Horseplay or fighting is not permitted in the school area. To prevent dehydration, ensure students drink fluids. All jewelry and ID tags must be removed. Flammable items are not permitted in the school area. Know where the fire extinguishers, fire lanes, and fire exits are located. Toolbox lids will be closed, locked, and secured to the booth with the chain provided. Wear all protective clothing and equipment; leathers, gloves, goggles, and ear

plugs. When welding, ensure that clear goggles are to the rear of the neck, to prevent melting them. PMCS will be done on a daily basis. Bend a hook on the end of the welding rod to prevent eye injury. Use correct oxyacetylene working pressures. Light the torch using an igniter only. Never leave a lit torch unattended. Exhaust vents will be approximately 6" from the work piece. After completing a weld, quench the metal using pliers and gloves. When approaching the quench tank, hold the metal below waist level and sound off with HOT METAL. After the metal has been quenched, hand the metal to an instructor using bare hands. Shut off all gases prior to lunch and before the close of the day. During shut down, shut off the acetylene first and then the oxygen. If an injury or medical emergency occurs, notify an instructor at once. Comply with all TMs and TBs, WARNINGS, CAUTIONS, NOTES, applicable ARs, TRADOC safety policies and procedures, and shop safety practices.

Risk Assessment Level Environmental Considerations

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction.
NOTE: It is the responsibility of all soldiers and DA civilians to protect the environment from damage.

Use proper procedures for containment, leakage, recovery, disposal, and storage of any hazardous material. Comply with all federal, state, and local regulations. Ensure that there is a current Material Safety Data Sheet (MSDS) for the consumable materials used during this lesson. Ensure soldiers read and comply with the MSDS before using the material.
Evaluation

This lesson will be tested in examination 63B34G06. The test will consist of multiple choice questions. The student must score a minimum of 70 percent to receive a passing score. We are now ready to begin our instruction on cutting metal using oxyacetylene equipment.

Instructional Lead-In

SECTION III.

PRESENTATION

NOTE: A.

Inform the students of the Enabling Learning Objective requirements. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS: STANDARDS:

Identify safety precautions and personal protection equipment. In a Classroom, given instruction and TC 9-237. IAW applicable references.

1.

Learning Step / Activity 1. Identify Safety Precautions Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:18 15 mins Large Group Instruction

NOTE:

Show Slides 2 and 3 Safety, have students turn to chapter 2, par 2-1, pg. 2-1, in TC 9-237. a. Safety (1) Remove all flammable material from vicinity of welding. (2) Do not permit unauthorized persons to use welding or cutting equipment. (3) Do not weld or cut on wooden floors (4) Keep a suitable fire extinguisher nearby at all times. (5) Before welding or cutting, warn those in close proximity who are not protected to wear proper clothing or goggles. (6) Remove any assembled parts from the component being welding that may become warded or damaged by the welding process. (7) Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or around the welding equipment. (8) Mark all hot metal after welding operations are completed. (9) Must wear safety goggles to protect their eyes from weld spatter.

NOTE:

Show Slide 4, Personal Protective Equipment (PPE), Refer students to Chap. 2-2, Page 21 in TC 9-237. b. Personal Protective Equipment (PPE) (1) Helmets and Shields (a) Lenses are designed to prevent flash burns and eye damage by absorption of the infrared and ultraviolet rays produced by the arc.

(b) Proper filter shades to be used depends on the welding process, type of base metal, and the welding current. (2) Safety Goggles (a) During all electric welding processes, operators must wear safety goggles to protect against weld spatter, slag particles when chipping, and hot sparks when grinding. (b) Those working around welders should also wear tinted safety glasses with side shields. NOTE: Show Slides 5 and 6, Protective Clothing c. Protective clothing (1) Personnel exposed to the hazards created by welding, cutting, or blazing operations shall be protected by personal protective equipment in accordance with OSHA standards, subpart I, Personal Protective equipment, Para. 1910.132. (2) Leather apron (a) Should have know openings (b) Protects against spatter of molten metal, radiated heat, and sparks (3) Sleeves should be kept buttoned to aid in preventing sparks lodging in cuffs. (4) Leg apron used primarily during heavy work. (5) Coat- Should have no openings or gaps (6) Cape and bib (7) Gloves - Protects against spatter of molten metal, radiated heat, and sparks. B. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS: STANDARDS:

Identify Oxyacetylene Equipment In a classroom environment, with references and equipment. IAW applicable references.

1.

Learning Step / Activity 1. Instructor will lead a discussion on regulator components. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:12 15 mins Large Group Instruction

NOTE:

Show Slide, 7 Have students discuss fundamentals IAW applicable references. If any uncertainties arise, refer group to TC 9-237, Pg 9 thru 5-8 a. Regulator (1) Regulators reduce pressure and control flow of gases from the cylinders. (2) The regulators for oxygen, acetylene and liquid petroleum fuel gases should be used only for the gas for which they were designed. (a) Single stage regulator: The single stage regulator reduces the cylinder pressure of a gas in one step. (b) Two stage regulator 1. Reduces pressure in two steps, the pressure is reduce from cylinder pressure to intermediate pressure on the high-pressure side. 2. On the low pressure side the pressure is reduce from intermediate pressure to working pressure.

NOTE:

Show Slide 8, Hoses. Have students discuss marking and color. arise, refer group to TC 9-237, Pg. 13, and Para. 5-11. b. Hoses

If any uncertainties

(1) Hoses are used to make connection between the regulators and the torch. (2) In North America, the oxygen hose is green and the acetylene hose is red. (3) In Europe oxygen is blue and acetylene is orange. NOTE: Show Slide 9, Torch body. Have students discuss the torch body. If any uncertainties arise, refer group to TC 9-237, Pg 5-19 thru 5-20. c. Cutting Torch (1) Similar to welding torch. (2) Tips have center hole and several preheating holes. (3) Lever controls cutting oxygen. (4) The cutting torch is furnished with interchangeable tips for cutting steel from less than 1/4" to more than 12" in thickness. NOTE: Show Slide10, Cylinders. Have students discuss the oxygen and acetylene cylinders. Refer group to TC 9-237, Pg 5-5 thru 5-9. d. Cylinder (1) Oxygen Cylinder (a) Oxygen is fill 2,000 PSI at 70 degree F. (b) Outlet nipples on valves stem have right hand threads.

(c) Has one safety fuse under the bronze valve. Safety plugs melt at 212 degree F. (d) Color is green. (e) Made of steel and has a capacity of 200 cu ft at a pressure of 2,000 PSI. (2) Acetylene cylinder (a) Acetylene is filled at 250 PSI at 70 degree F. (b) Always store in the upright position, if not, wait 45 minutes before use. (c ) Acetylene is non-toxic, an anestric, and if present in sufficiently high concentration it can produce asphyxiation. (d) DO not exceed 15 PSI, it will become unstable. (e) In order to decrease the open space in the cylinder, acetylene cylinders are filled with porous materials such as balsa wood, charcoal, corn pit, or portlan cement. (f) It has two safety fuses on the top of the tank, and the other is located at the bottom. Safety plugs melt at 212 to 220 degree F. NOTE: Conduct a check on learning and summarize the learning activity.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. C. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS:

Set up and shut down oxyacetylene equipment. In a classroom or shop environment, with references and equipment. IAW applicable references.

STANDARDS:

2.

Learning Step / Activity 2. Instructor will lead a discussion on setting up and shutting down oxyacetylene cutting equipment. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:12 5 mins Large Group Instruction

NOTE:

Show Slide 11 and 12, Equipment Set up. Read warnings. Discuss set up procedures with students, using cutting equipment and slides as necessary, on the set up the oxyacetylene equipment. If any uncertainties arise, refer group to TC 9-237, Pg 2-14 thru 2-22.

Warning: Warning:

Do not stand facing cylinder valve outlets of oxygen, acetylene, or other compressed gases when opening them. Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can cause serious injury to personnel and damage to the equipment. a. Setting up equipment. (1) Secure cylinders Place cylinders on a level floor (if not mounted on a truck) and tie them firmly to a work bench post, or other secure anchorage to prevent their being knocked or pulled over. (2) Remove the valve

Warning:

Do not stand facing cylinder valve outlets of oxygen, acetylene, or other compressed gases when opening them. (3) Crack cylinder valves to blow out any dirt or foreign matter that may have accumulated during shipment. (4) Close the valves and wipe off the connection seat. (5) Check the regulator fittings for dirt and obstructions and connect the acetylene regulator to the acetylene cylinder. (6) Check the regulator fittings for dirt and obstructions and connect the oxygen regulator to the oxygen cylinder. (7) Connect the red hose to the acetylene regulator (8) Connect the green hose to the oxygen regulator (9) Screw the connecting nut tight to ensure leak proof seating. (10) Release the regulator or screw to avoid damage to the regulator and gages (slowly open the cylinder). (11) Read the high-pressure gages to check the cylinder pressure. (12) Blow out the oxygen hose by turning the regulator screw in and release then release the regulator screw. (13) Connect the red acetylene hose to the torch needle valve which is stamped AC. (14) Connect the needle valve which is stamped OX (green hose) to the torch. Test all hoses for leaks at the regulators and torch valves using soapy water. (15)Release the regulator screws after testing and drain both hoses by opening the torch needle valves. (16) Assemble cutting tip to torch body, blow orifices out with 20 to 30 PSI of dry air. (17) Tighten by hand and adjust the tip to the proper angle. Secure with tip nut wrench.

10

(18) Adjust acetylene working pressure by opening the acetylene needle valve on the torch and turn the regulator screw to the right, then adjust the acetylene regulator to the required pressure for the tip size. (19) Close the needle valve. Adjust the oxygen working pressure in the same manner. Warning: Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can cause serious injury to personnel and damage to the equipment. (20) Light the torch and adjust the flame to what is called a neural flame. (Para 11, fig 11-2, Pg 11-8 thru 11-1. b. Shut Down Equipment (1) First shut off acetylene gas on the torch body. (2) Shut off oxygen gas on torch body. (3) Turn off oxygen and acetylene valves at cylinder. (4) Drain regulators, hoses, and torch by opening needle valves on torch (5) Remove torch body. (6) Remove hoses and coil or hang. (7) Release tension on regulators by turning regulator screws counterclockwise. NOTE: Conduct a check on learning and summarize the learning activity. body.

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. D. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS:

Cutting metal while using oxyacetylene equipment. In a shop environment, given TC 9-237, welder's tool kit, Oxy-fuel cutting attachment, Steel Rod, safety equipment, check on learning questions, practical exercise, and Student Handout . Perform Oxy-fuel cutting operations IAW references, correctly and safely complete the practical exercise, correctly answer all check on learning questions, and score 70 percent or higher on job performance test 63B33G05.

STANDARDS:

1.

Learning Step / Activity 1. Using all necessary equipment the instructor will demonstrate cutting metal using oxyacetylene equipment. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Demonstration 1:12 5 mins Large Group Instruction

11

NOTE:

Demonstrate cutting metal using the following steps. 1. 2. 3. 4. Check adjusting screw on both regulators before opening cylinders (both should be loose). Open the oxygen cylinder valve all the way and the acetylene cylinder valve from 1/4 to 1/2 turn (quick turn off is necessary). Adjust pressure on regulator to suit tip size. Open oxygen needle valve on the torch handle all the way, needle valve on cutting attachment will control the oxygen for the preheating flames (needle valve on the acetylene torch handle is closed at this point). Open acetylene needle valve approximately 1/4 to 1/2 turns and lights the torch with lighter. Adjust the oxygen needle valve until there is practically no smoke given off from the flame. Adjust the oxygen needle valve on the torch until the preheating flames are neutral. Direct the flame on the back of metal with the inner cones approximately 1/16 above the line to be cut and torch tip at 90-degree angle to the work. Hold this position with the torch until a spot has been raised to a bright red.

5. 6. 7. 8. 9.

10. To start the cut, press the oxygen high pressure lever holding the torch so that the expelled oxygen will pass the back of the metal. Then move the torch just fast enough for the cut to penetrate the metal completely. NOTE: Conduct a check on learning and summarize the learning activity.

2.

Learning Step / Activity 2. The student will cut metal using oxyacetylene cutting equipment. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Performance) 1:6 4 hrs 25 mins Large Group Instruction

NOTE: Issue students 63B34G05 Suppl 1a student guide. Assist students if necessary and observe for safety Restate any safety precautions and the training objective. Divide the class into groups. Assign assistant instructor(s) as necessary. NOTE: Conduct a check on learning and summarize the learning activity.

12

SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:12 Time of Instruction: 5 mins Media: Large Group Instruction

Check on Learning

Determine if the student has learned the material presented by: a. Soliciting student questions and explanation.

b. Asking question and getting answers from students. NOTE: Show slide 13 thru 15 Q. At what temperature does the safety plugs melt on oxygen and acetylene? A. 212 degree F. Q. Operating pressure for acetylene should not exceed how many PSI? A. 15 PSI Q. In what position are cylinders stored? A. Upright Q. What is the purpose of the torch body? A. Mixes and controls the gases Q. When shutting down equipment, what is shut down first? A. Acetylene valve on the torch body c. Proving immediate feedback in context to the material presented and correcting student misunderstanding.
Review / Summarize Lesson

Review and summarize how to perform Oxy-fuel cutting operations. Ask the students if there are any questions.

13

SECTION V. Testing Requirements

STUDENT EVALUATION NOTE: Describe how the student must demonstrate accomplishment of the TLO. Refer student to the Student Evaluation Plan. This lesson will be tested in examination 63B33G05. The test will consist of multiple choice questions. The student must score a minimum of 70 percent to receive a passing score.

Feedback Requirements

NOTE: Feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

14

63B34G05 Jun 04 Suppl 1a PRACTICAL EXERCISE STUDENT GUIDE Title References Cut Metal Using Oxyacetylene NUMBER TC 9-237 Terminal Learning Objective TITLE Welding Theory and Application DATE May 93 Additional Information None

At the completion of this lesson you (the student) will: ACTION: CONDITION (S): STANDARD: Perform selected oxyacetylene cutting operations In a field environment, given the necessary tools, equipment, and reference materials IAW applicable references

Safety Requirements

1. Ensure all welding equipment is inspected and serviceable prior to use. 2. Inspect item to be cut to see that no flammable substances are on it or in the immediate vicinity. 3. Do not operate equipment with excessive pressure. 4. Do not allow oil or grease to come in contact with oxyacetylene equipment. 5. Store and use cylinders in an upright position only. 6. Follow all WARNINGS, CAUTIONS and NOTES listed in the TM. 7. Never use acetylene at a pressure greater than 15 PSI (cylinder could explode). 8. Use soapy water to test all oxyacetylene cutting equipment. 9. Remove all jewelry and ID tags 10. Know where the fire extinguishers, fire lanes, and fire exits are located. 11. Always operate oxyacetylene equipment with all protective clothing and equipment i.e. leathers, gloves, goggles, and earplugs. When welding, ensure that clear goggles are to the rear of the neck, to prevent melting them. 12. Light torch using an igniter only. 13. Never leave torch unattended. 14. After completing a weld, quench the metal using pliers and gloves. When approaching the quench tank, hold the metal below waist level and sound off with HOT METAL. 15. After the metal has been quenched, hand the metal to an instructor using bare hands. 16. Shut off all gases prior to lunch and before the close of the day. 17. During shut down, shut off the acetylene first and then the oxygen. If an injury or medical emergency occurs, notify an instructor at once Low.

Risk Assessment Level Environmental Considerations

Use proper procedures for containment, leakage, recovery, disposal, and storage of any hazardous material. Comply with all Federal, State, and local regulations. Ensure that there is a current Material Safety Data Sheet (MSDS) for the consumable material used during this lesson. Ensure soldiers read and comply

63B34G05 Suppl 1

with the MSDS before using the material. Gases will escape into the atmosphere while connecting or disconnecting hoses or gages. Procedures Note: Note: Refer to TC 9-237, Pg. 14 and 15, Para. 2-6 If you have questions, stop and contact the Instructor. 1. Read safety precautions Warning: Do not stand facing cylinder valve outlets of oxygen, acetylene, or other compressed gases when opening them. 2. Perform Oxyacetylene equipment setup procedures, 2-6 General, (o), steps (1) thru 3 (Lighting a torch). 3. Stop: Read warning. Warning: Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can cause serious injury to personnel and damage to the equipment. 4. Perform steps (5) thru (7) 5. Stop: Read warning. Warning: Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can cause serious injury to personnel and damage to the equipment. 6. Perform steps (8) thru (11). Note: STOP, have instructor verify your work. 7. Perform steps p., (1) thru (5) Oxyacetylene equipment shut down procedures (shutting off a torch). Stop, have instructor verify your work. Cut armor plate using Oxyacetylene equipment 1. Obtain the necessary tools and equipment. 2. Obtain the necessary tools and equipment. Caution: Warning: Warning: If acetylene cylinders have been stored or transported horizontally (on their sides), stand cylinders vertically for 45 minutes prior to (before) use. Do not stand facing cylinder valve outlets of oxygen, acetylene, or other compressed gases when opening them. Purge both acetylene and oxygen lines (hoses) prior to igniting torch. Failure to do this can cause serious injury to personnel and damage to the equipment. 3. Setup oxyacetylene welding equipment. 4. Adjust regulator-working pressure.

63B34G05 Suppl 1

5. Place metal between the firebricks and mark area to be cut. 6. Turn on acetylene and light torch. 7. Adjust torch to neutral flame. 8. Adjust torch to neutral flame. 9. Perform cutting. CAUTION RAPID COOLING OF THE ARMOR AFTER WELDING WILL CAUSE CRACKS TO FORM IN THE HAZARD ZONES. 10. Turn off torch. 11. Quench metal. 20. Clean kerfs and remove slag. 22. Have your work evaluated by the instructor. 23. Upon successful completion of this practical exercise, shut down the oxyacetylene equipment, clean, service, and store tools and equipment. Feedback Requirements The material tested in examination 63B33G05 will be reviewed with the class upon completion of scoring. END OF TASK

Feedback Requirements

63B34G05 Suppl 1

63B34G05 Jun 04 Suppl 1b PRACTICAL EXERCISE INSTRUCTORS GUIDE Title References Cut Metal Using Oxyacetylene NUMBER TC 9-237 Terminal Learning Objective TITLE Welding Theory and Application DATE May 93 Additional Information None

At the completion of this lesson you (the student) will: ACTION: CONDITION (S): STANDARD: Perform selected oxyacetylene cutting operations In a field environment, given the necessary tools, equipment, and reference materials IAW applicable references

Safety Requirements

1. Ensure all welding equipment is inspected and serviceable prior to use. 2. Inspect item to be cut to see that no flammable substances are on it or in the immediate vicinity. 3. Do not operate equipment with excessive pressure. 4. Do not allow oil or grease to come in contact with oxyacetylene equipment. 5. Store and use cylinders in an upright position only. 6. Follow all WARNINGS, CAUTIONS and NOTES listed in the TM. 7. Never use acetylene at a pressure greater than 15 PSI (cylinder could explode). 8. Use soapy water to test all oxyacetylene cutting equipment. 9. Remove all jewelry and ID tags 10. Know where the fire extinguishers, fire lanes, and fire exits are located. 11. Always operate oxyacetylene equipment with all protective clothing and equipment; leathers, gloves, goggles, and earplugs. When welding, ensure that clear goggles are to the rear of the neck, to prevent melting them. 12. Light torch using an igniter only. 13. Never leave torch unattended. 14. After completing a weld, quench the metal using pliers and gloves. When approaching the quench tank, hold the metal below waist level and sound off with HOT METAL. 15. After the metal has been quenched, hand the metal to an instructor using bare hands. 16. Shut off all gases prior to lunch and before the close of the day. 17. During shut down, shut off the acetylene first and then the oxygen. 18. If an injury or medical emergency occurs, notify an instructor at once.

Risk Assessment Level

Low.

63B34G05 Suppl 1

Environmental Considerations

Use proper procedures for containment, leakage, recovery, disposal, and storage of any hazardous material. Comply with all Federal, State, and local regulations. Ensure that there is a current Material Safety Data Sheet (MSDS) for the consumable material used during this lesson. Ensure soldiers read and comply with the MSDS before using the material. Gases will escape into the atmosphere while connecting or disconnecting hoses or gages.

Procedures: 1. Ensure all equipment and stations are set up with all required equipment and that the equipment is safe and operational. 2. Restate any safety precautions and training objective 3. Divide the class into groups. Assign assistant instructor (s) as necessary. Assign each group to a station. 4. Refer students to 63B33G05, suppl 2, Directions to the Student and have them to follow the instruction throughout the lesson. 5. Use the Practical Exercise Check Sheet to track each students progress during the practical exercise. 6. If student completes all requirements of the practical exercise before the allotted time, assign additional tasks that will reinforce enabling skills and knowledge. 7. All students must complete the requirements of the practical exercise in the allotted time. 8. Check all work, have students clean work area, and store equipment Feedback Requirements You must receive a Go in all areas. If Not, you will repeat the entire process until you are able to achieve a Go. Direct supervision will be provided, if necessary to assist you in achieving this objective.

END OF TASK

63B34G05 Suppl 1

63B34G05 Jun 04 Suppl 1c PRACTICAL EXERCISE CHECKLIST COURSE: SUBJECT: REFERENCES: WHEEL VEHICLE MECHANIC (BNCOC) 63B33-MOSC Cut Metal Using Oxyacetylene TC 9-237

DIRECTIONS TO THE INSTRUCTOR: 1. Complete this form as the group performs the task. Once the group has correctly performed a step, place a check in that column. After the tasks have been completed, fill out the student data sheet. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands-on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a group needs remedial training for longer then the PE allows, then conduct this remedial training IAW TRADOC REG 350-6, pg 18, Para 3-18. 6. Conduct a detailed review to ensure that each student can accomplish the following performance measures: _____ a. _____ b. _____ c. _____ d. _____ e. _____ f. _____ g. Observe and apply all safety principles. Open oxygen cylinder valve all the way. Open acetylene cylinder valve 1/4 to turn. Adjust oxygen and acetylene working pressure. Cut metal. Close the torch acetylene valve first during shutting down the equipment. Clean the equipment.

INSTRUCTOR COMMENTS: STUDENT NAME _____________________________________________________________ ROSTER NUMBER ________________________ CLASS NUMBER _________________

START TIME ____________ STOP TIME ____________ TOTAL TIME ____________ INSTRUCTOR'S ___________________________________ DATE ___________________ SIGNATURE

63B34G05 Suppl 1