BOILER MAKING REPORT

COMPILED BY

LAINHARD MACHOKOTO

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Checked by Signature Date

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Electrical Engineering supervisor Signature Date

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HR Advisor Signature Date

Table of Contents
1 Introduction...................................................................................................................................4
1.1 Boiler Welding Safety..........................................................................................................4
1.1.1 Welding safety starts with having the right protective gear. This includes:................4
2 WELDING...................................................................................................................................5
2.1 Types of Welding Machine..................................................................................................5
2.1.1 Arc Welding Machine..................................................................................................6
2.1.2 MIG Welding Machine................................................................................................6
2.1.3 TIG Welding Machine.................................................................................................6
2.1.4 Spot Welder..................................................................................................................6
2.2 Types of Welding Machines................................................................................................6
2.2.1 Oxyacetylene Welding Machine..................................................................................7
2.2.2 Thyristor MIG welding machine................................................................................7
2.2.3 Shielded metal arc welding machine..........................................................................7
2.2.4 Energy beam welding machine...................................................................................7
2.2.5 Flux core arc welding...................................................................................................8
2.2.6 Atomic hydrogen welding machine.............................................................................8
2.2.7 Submerged arc welding machines...............................................................................8
2.2.8 Transformer welding machine....................................................................................9
2.2.9 Rectifier welding machine...........................................................................................9
2.2.10 Converter welding machine........................................................................................9
2.2.11 Plastic welding machine.............................................................................................10
2.2.12 Multi-purpose welding machine...............................................................................10
2.3 Marking out tools...............................................................................................................10
2.3.1 Marking out tools – basic types.................................................................................11
2.3.2 In turn, for spatial marking out the following tools are used:...................................11
2.3.3 Scribers.......................................................................................................................11
2.3.4 Measuring compasses................................................................................................12
2.3.5 Surface plates.............................................................................................................12

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 2.3.6 Other marking-out tools............................................................................................12
2.3.7 Conclusion..................................................................................................................12

1 Introduction
Boiler making plays a critical role at RZM Murowa diamonds mining industry by providing
fabrication of structures, infrastructural and welding of screens, liners, pumps, chutes,
conveyers as well as maintenance of mining equipment for effective production of diamonds.
1.1 Boiler Welding Safety
Special attention should be given to boiler safety when welding and other hot work is being
performed. Workers should use welding screens and implement fire protection strategies
around the site in question when welding or hot cutting. Properly-rated clothing and
protective coverings should be used, and welding tanks should be kept out of confined
spaces. Welding tanks should also be capped when they are not in use and they should be
held securely in an upright position. All necessary certifications and permits should also be
acquired before any work begins.

Welding safety starts with an understanding of what could go wrong, and preparation for
when it does.
Risks include electric shock, injuries related in inhalation of toxic fumes, eye injury, and skin
burns.
To start, protective clothing and equipment must be worn during all welding operations
including helmets and shields.
For arc welding, the electric arc is a very powerful source of light, including visible,
ultraviolet, and infrared.
During all electric welding processes, operators must use safety goggles and a hand shield or
helmet equipped with a suitable filter glass to protect against the intense ultraviolet and
infrared rays.
When others are in the vicinity of the electric welding processes, the area must be screened so
the arc cannot be seen either directly or by reflection from glass or metal.
During all oxyacetylene welding and cutting processes, operators must use safety goggles to
protect the eyes from heat, glare, and flying fragments of hot metals.
Also be sure to keep MSDS sheets (Material Safety Data Sheets) for all hazardous materials.
Every manufacturer provides MSDS sheets to keep you informed regarding any potential
hazards, such as if a respirator is needed when working on a project.

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1.1.1 Welding safety starts with having the right protective gear. This includes:
 Respirator/Welders Mask: There are multiple types of respirators. Buy the one that
is made for welders and the type of projects you will be performing. If purchasing a
mask with a filter, match the filter to the types of metals and coatings used.
 Keep the area clean and check any gasses for signs of leaks.
 Ventilation: All welding areas should have proper ventilation. Poor ventilation leads
to “plume poisoning”. If you suspect that be inhaled a toxic plume seek medical help
immediately.
 Storage: All flammables should be stored in a flammable liquids locker.
 Eye protection: welding eye protection protects against injuries from debris and from
the effects of ultraviolet light. Different types of helmets are made to protect you
when performing different types of welding. These vary by shade number, having
a passive or auto-darkening lens (automatically adjusts to welding rays) and
comfort/fit.
 Fire protection: Sparks created during the welding process can start fires. For
welding, Class C extinguishers are often used since these are for electrical fires. Sand
and water can also help to extinguish fires.
 Protective Clothing: All skin areas need to be protected to protect against molten
metal and sparks. This includes:
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 Long sleeve shirts

 Pants that cover the tops of shoes
 Gloves
 Shoes or boots
 Hair is protected with something called a welders beanie
 Leather jackets are also effective for protection from slag and sparks
 Leather aprons provide some protection when sitting down
 Shoe covers called spats protect shoes, something helpful if you are working
on a project that produces sparks and slag (molten metal)
Welding Safety Tip: Use pliers when handling metals. If you believe a metal is cool, use the
back of the hand and slowing bring it closer to the metal. You’ll feel the heat as you get
closer if it is too hot to handle.

2 WELDING

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It is a process used to join two or more pieces of metal together by melting and fusing them.
There are many types of welding machines, each with its advantages and drawbacks.
Knowing which type is best for your situation can help you get the job done quickly and
safely. Look at some of the most popular welding machines on the market today.

2.1 Types of Welding Machine

2.1.1 Arc Welding Machine

Arc welding machines use electricity to generate an arc between consumable electrodes that
hold the work pieces together. This machine is ideal for working with heavy metals such as
steel, aluminium, cast iron, and stainless steel. It’s also highly efficient and cost-effective,
making it an excellent choice for hobbyists looking for a reliable home-project machine.

2.1.2 MIG Welding Machine

MIG (metal inert gas) welding machines use a combination of inert gas and electric current to
create an arc between two pieces of metal held together by a filler material. This machine is
best suited for thin metals like aluminium, brass, copper, magnesium, nickel alloys, and
stainless steel because it doesn’t require additional materials or tools beyond the machine
itself. MIG welders also offer fast setup times and minimal post-weld clean-up requirements,
making them ideal for large-scale industrial projects where speed is essential.

2.1.3 TIG Welding Machine

TIG (tungsten inert gas) welding machines use tungsten electrodes to heat the work piece
until it reaches its melting point. This machine produces clean welds with minimal spatter or
splatter due to its low heat input levels – making it ideal for delicate jobs such as jewellery
repair or thin sheet metal fabrication projects. TIG welders can also be used on thicker metals
but require more skill from the operator since they operate at lower temperatures than MIG or
arc welders.

2.1.4 Spot Welder

Spot welders are specialized machines designed to combine thin metal sheets quickly and
easily without requiring extensive post-weld clean-up time. These machines use electrodes to
deliver high-temperature electrical pulses that rapidly heat the work piece before cooling
down just as quickly – resulting in clean joints with minimal distortion or warping in the
finished product. Spot welders are often used in automotive manufacturing jobs because they

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can join two sheets of thin metal together in seconds without affecting nearby components or
parts.

2.2 Types of Welding Machines

2.2.1 Oxyacetylene Welding Machine

Oxyacetylene welding machines use oxygen and acetylene gases to create extremely high
temperatures that allow users to melt two pieces of metal together quickly and efficiently –
even if those pieces are made from different kinds of metals or alloys! This type of welder is
great if you need to do any repairs on thick sections where other types won’t cut it – plus, it’s
portable enough that you can take it anywhere you need it!

2.2.2 Thyristor MIG welding machine

A thyristor MIG welding machine is an essential tool for those working in the fabrication and
welding industries. It is an advanced piece of equipment with a range of adjustable settings,
enabling it to be tailored to any welding task that needs completing. The thyristor technology
works by controlling the current which results in high-precision repeatability while providing
increased safety compared to traditional TIG machines. The added benefit of a thyristor MIG
welding machine is that it can cut costs due to its higher power efficiency. This makes it a
great option for small businesses and garages looking for cheaper alternatives when making
large quantities of items. With its ease-of-use and reliable performance, there’s no better
choice than a thyristor MIG welding machine when tackling any type of welding job.

2.2.3 Shielded metal arc welding machine

Shielded metal arc welding machines offer great precision and control when working on
metal structures. As its name suggests, it can produce high-quality welds using a shielding

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gas that creates an inert arc between the electrode and the work piece to minimize oxidation
while welding. This can be used in construction, from manufacturing skyscrapers or building
submarines. It is also economically friendly since it can make strong enough welds with very
little electricity because of the low amperage required for these operations. Its low cost makes
this machine an attractive choice for many professional and personal purposes. This reliable
machine will ensure every welding project has a solid foundation.

2.2.4 Energy beam welding machine

An energy beam welding machine is a popular option for industries and serious welders alike.
This powerful tool can quickly join metals without affecting their structural integrity by using
lasers that generate a narrow, precise beam of intense light. It’s also incredibly effective in
enclosed spaces and tight corners where traditional welding methods require more effort.
This welding machine offers higher accuracy and faster turnaround times than ever, making it
the perfect choice for various projects. Better still, with its minimal filler material, the results
are often more aesthetically pleasing.

2.2.5 Flux core arc welding

Flux core arc welding is widely favoured in metal and industrial fabrication industries due to
its ability to join materials quickly and effectively. Its simplicity, accuracy, and high-quality
welds make it an ideal option for experienced professionals or those learning the craft. Flux
core arc welding machines are designed to make this demanding process simpler and more
efficient. They feature an easy-to-use yet powerful design that can be adjusted for any
application for maximum control over all aspects of the welding job. With a flux core arc
welding machine by their side, metalworkers will have the confidence to take on any project
with ease!

2.2.6 Atomic hydrogen welding machine

Atomic hydrogen welding machines provide a powerful and precise method of joining two
pieces of metal together. This method eliminates any slag or hazardous by-products generated
from other welding methods, making it a much safer process with less clean-up afterwards.

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This machine operates by forcing atomic hydrogen through an electric spark and adding heat
energy to the resulting fusion to achieve welding temperatures up to 40000°C. By utilizing
hydrogen’s unique properties, welders can decrease the risk of burnouts and operate at more
efficient speeds compared to many traditional welding techniques. With its built-in safety
settings and low emissions, Atomic Hydrogen Welding is the go-to choice for many
professionals in the industry today.

2.2.7 Submerged arc welding machines

Submerged arc welding machines are an invaluable tool for modern welders. They offer users
unparalleled convenience and speed by allowing them to weld large pieces quickly and
conveniently. Using a submerged arc welding machine is an efficient way of completing
projects since it produces fewer sparks than traditional methods, reduces air contamination,
and increases productivity with less labour. Furthermore, its exceptional arc control
capabilities enable consistent welds and superior penetration of delicate materials. With the
ease of setup and long-lasting wearing of parts, this machine can handle any job without
sacrificing quality. Submerged arc welding machines offer unrivalled results for small and
large projects, making them a worthwhile investment for anyone needing to accomplish
various tasks quickly.

2.2.8 Transformer welding machine

A transformer welding machine is an invaluable tool for many fabrication businesses. The
transformer machine allows for quick and efficient welding of materials ranging from
aluminium to mild steel and is designed for long-term reliability. This tool eliminates clamps
and other bulky tools, allowing workers to complete welding jobs with minimal effort
quickly. Because of the unit’s lighter weight and ergonomic design, fatigue and injuries are
drastically reduced compared to traditional welding equipment. Besides their efficiency and
convenience, transformer machines have a wide range of applications, making them an ideal
choice for any welding job in various industries.

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2.2.9 Rectifier welding machine

A rectifier welding machine brings efficiency and convenience to any job site, allowing for
easy and precise welding without requiring an extensive setup. Designed with low-power
input, these machines are perfect for any high-space or remote areas where power may be
limited and can help cut costs while providing the same performance and quality as
professional-grade welders. Utilizing mains or generator-supplied power, these welding
machines are designed to give cost savings through operational efficiency gains by reducing
wasted energy. Whether working on your home backyard project or taking on a large
commercial, or industrial project, rectifier welding machines have all the features you need
for success.

2.2.10 Converter welding machine

Converter welding machines are multi-functional tools used to join materials–such as metal
sheets and pipes–together using the welding process. The name “converter” comes from the
device’s ability to convert electricity into a form that can be used for welding. By utilizing
this powerful machine, welders can make tight connections with precision and speed that
would be impossible through any other method. Converter welding machines provide the
necessary control to work with fragile, thin metal materials, ensuring safety and accuracy
throughout projects. The manual flexibility of these devices makes them suitable for
numerous applications far beyond basic welding operations, including cutting metal and
shaping it into any desired shape or size. With so many remarkable capabilities, it is no
surprise that converter welding machines are essential tools on construction sites worldwide.

2.2.11 Plastic welding machine

Plastic welding is an invaluable tool for many industries, and a plastic welding machine
allows precise welding jobs to be done easily. Automated plastic welding machines have
greatly reduced the complexity of many large projects and provide consistent, high-quality
welds in materials such as polyethene, vinyl, acetyl, polypropylene, ABS, and many other

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types of thermoplastics. With advanced safety features and modern technology often found in
these models, they can be used in any shop setting ranging from home use to professional
industrial environments. Plastic welding machines offer a cost-effective solution that can save
time and money for anyone working with plastic parts or needing quick repairs.

2.2.12 Multi-purpose welding machine

Multi-purpose welding machines are a great addition to any hobbyist or professional’s

toolkit. They can be used for traditional welding, cutting, carving, and branding materials like
wood, plastic, and metal. Users can easily customize the machine to fit their needs with the
wide range of accessories that come with most machines—making these welding machines a
reliable and versatile option for anyone looking to bring a new level of detail.

2.3 Marking out tools

Marking out is the process of transferring or drawing a design or pattern on the surface of a
material. It is essential in order to precisely cut various shapes, such as holes. The first step is
creating a drawing, which should include information where to place the cuts and holes,
together with the dimensions and the edges. The second step is transferring the drawing to the
material. There are two types of marking out:

The first involves drawing lines (including axes of symmetry) on a surface. The second type
is also about drawing lines, but on the surface of a solid material. Before you start marking
out, always check the condition of the material or object to be processed. Special tools are
used for marking out, enabling drawing lines and taking measurements.

2.3.1 Marking out tools – basic types

Each of the types presented above requires different marking out tools. Drawing lines on a
surface requires the use, among others, of a:

 Stylus,
 Calliper
 Scriber

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  Measuring compass,
 Punch
 Ruler
 Square
 Centre head
 Fixing clamp

2.3.2 In turn, for spatial marking out the following tools are used:
 Divider,
 Surface plate,
 Bar markers
 Line measures,
 Marking out boxes,
 Marking out plates.

2.3.3 Scribers

A scriber is equipped with a needle or a knife, which is used to trace horizontal lines, transfer
dimensions and determine preliminary cutting lines on wood.

2.3.4 Measuring compasses

The height of an object is measured with a divider, otherwise called a measuring compass. To
do this, place the tool and work piece on a flat surface, preferably a surface plate. The result
is then read on the vertical guide.

2.3.5 Surface plates

The above-mentioned surface plate is the reference surface for marking-out measurements.
Surface plates can be made of granite, ceramics and cast iron. They have a smooth surface on
top to enable precise measurements.

Marking-out plates are used to place the objects on the surface. In addition, bar markers, line
rules and marking boxes are used during spatial marking out. Painting equipment is usually
on hand for additional support. Special paints are used for marking, and thus making it easier
to see the designated lines.

2.3.6 Other marking-out tools

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Marking out tools are a wide range of equipment that complement other tools for wood and
metal processing. In addition to scribers, dividers and plates, styluses (for drawing scratches),
punch marks (for marking the surface by hitting with a hammer) and compasses (for drawing
borders) are also used. Callipers equipped with a stylus let you mark and measure lines or
shapes for future processing. A ruler with a stand is necessary for measuring distances,
drawing horizontal lines and setting markers. If, on the other hand, you want to determine a
right angle, you should use a square. A centre head is used to determine the central point on a
flat surface of a round object. Fixing clamps will come in handy for stabilising cylindrical
elements, especially for processing using a milling machine. They come in the shape of
cuboids or cubes with cut-outs resembling the letter V.

2.3.7 Conclusion

Boiler making, welding, and fabrication plays a critical role at RZM Murowa diamonds
mining industry, as it is used in the construction and maintenance of mining equipment and
infrastructure.

Boiler making involves the construction of metal structures by shaping and welding steel
plates and sections.

Welding, on the other hand, is used to join metals together to create strong and durable
structures. Diamond mining equipment such as screens, crushers, pumps, and conveyors
require welding to hold structural elements together to withstand the high compression of
earth and rock being processed. Welding is also used for repairing mining equipment and
infrastructure, which is essential to ensure continuity in the mining process.

Fabrication involves the cutting, bending and forming of metal structures, and it is used to
produce mining equipment and infrastructure. At RZM Murowa diamonds mining industry,

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fabrication is used to create metal structures such as support beams, walkways, and platforms
that are needed to enable the mining process.

Overall, Boiler making, welding and fabrication play a vital role at RZM Murowa diamonds
mining industry by providing mining equipment and infrastructure, maintaining existing
equipment and infrastructure, and ensuring continuity in the mining process. The industry
requires well-trained and skilled professionals in these areas to ensure the safe and effective
operation of the diamond mine.

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