We recently undertook a plasma cutting workshop for a family-owned company that has been operating for thirty years, providing waste processing, sample testing and recycling, specialising in hazardous wastes.
The company offers fuel tank monitoring and cleaning, surface degreasing and new tank installation. As part of this they must occasionally remove old tanks on-site and needed to have a team trained up on plasma cutting in order to carry out the work safely.
What is plasma cutting?
Plasma cutting is a thermal cutting method that uses a jet of ionized gas, at temperatures above 20,000°C, to cut through electrically conductive materials.
So, how does plasma cutting work?
During the process, an electric arc is struck between an electrode (cathode) and the workpiece (anode). The electric current ionizes a gas, such as air, argon, nitrogen, or oxygen, which is then forced through a narrow nozzle. This creates a plasma arc. The plasma arc melts the material being cut and the gas flow ejects the molten metal from the cut.
Plasma cutting is used in many industries, including:
- Fabrication shops
- Automotive repair and restoration
- Industrial construction
- Salvage and scrapping operations
Plasma cutting has several advantages, including:
- High speed and precision cuts
- Low cost
- Ability to cut all conductive materials, such as;
- Thick metal plates
- Sheet metal
- Medium-thickness stainless steel and aluminium
Who did we train?
The client needed four of its operators trained to ensure that they could operate the plasma cutting equipment safely.
Prior to the training only one of the group was experienced with the process, one had limited experience and the other two were complete novices.
What did the training cover?
During the training we discussed in depth, all the safety issues around the work the trainees were about to carry out. With particular attention given to fume and the correct controls to have in place (local exhaust ventilation (LEV), air fed masks) to meet the current HSE expectations and more importantly, to protect themselves.
The staff were instructed in how to set up the equipment safely, paying special attention to the selection and connection of the torch consumables (cutting tips, nozzles etc). We also covered the importance of maintaining the tip and nozzle and at what point to replace them in order to maintain cutting speeds and quality.
Prior to the training, the operators had experienced problems with the air pressure to the cutter when using their petrol driven air compressor. Fortunately, this occurred during the practical and our trainer was able to rectify the problem. This proved to be a valuable learning experience as the operators now know how to address the issue if it occurs again.
Our trainer also discussed alternative solutions such as using a compressed air cylinder supply. This option would provide the consistent pressures they required and it would be more portable. In addition, the air would be cleaner and drier, which would improve the life of the consumables.
The practical session concentrated on how to pierce the metal without damaging the consumables, how to cut free-hand and how to use a straight edge. By the end of the course all four operators felt confident they could set up and use the equipment correctly and safely.
Client feedback
We received some great feedback from the client:
Thank you for your email and for the support you provided in arranging the training session. Although I was unavailable on the day, our Technical Manager, who oversaw the session in my absence, shared the very positive feedback regarding the overall process.
The staff were particularly impressed by the clarity and depth of the content, the trainer’s expertise, and the practical relevance of the skills covered. The session was highly organised and well-structured, ensuring that participants were fully engaged and able to take away valuable insights to apply to their roles.
We greatly appreciate the effort and dedication that went into making the training a success.
If you require any practical process training on MIG, TIG, MMA, or Plasma cutting please contact us on 01270 758890 or admin@gassafeconsultants.co.uk
