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Welding & Cutting
Introduction:
Welding is the most common method of joining metals in industry today.
When welded, two pieces of similar metals are fused (melted) together.
Once completed, the welded joint is as strong or stronger than the pieces
from which the joint is formed. General hazards of welding include impact,
penetration, harmful dust, smoke, fumes, heat and light radiation. The proper
personal protective equipment can protect you from these hazards.
Welding Hazards:
AHealth Hazards of Welding:
Welding “smoke” is a mixture of very fine particles (fumes) and gases.
Many of the substances in welding smoke , such as chromium, nickel,
arsenic, asbestos, manganese, silica, beryllium, cadmium, nitrogen oxides,
phosgene, acrolein, fluorine compounds, carbon monoxide, cobalt, copper,
lead, ozone, selenium, and zinc can be extremely toxic.
Generally, welding fumes and gases come from:
• The base material being welded or the filler material that is used;
• Coatings and paints on the metal being welded, or coatings covering
the electrode;
• Shielding gases supplied from cylinders;
• Chemical reactions which result by the action of ultraviolet light from
the arc, and heat;
• Process and consumables used;
• Contaminants in the air, for example vapors from cleaners and
degreasers.
Exposure to welding smoke may have short-term and long-term health
efects. These effects are described below:
1Short-term (acute) health effects:
• Exposure to metal fumes (such as zinc, magnesium, copper, and
copper oxide) can cause metal fume fever. Symptoms of metal fume
fever occur 4 to 12 hours after exposure, and include chills, thirst,
fever, muscle ache, chest soreness, coughing, wheezing, fatigue,
nausea, and metallic taste in the mouth.
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• Welding smoke can also irritate the eyes, nose, chest, and respiratory
tract, and cause caughing, wheezing, shortness of breath, bronchitis,
pulmonary edima (fluid in the lungs) and pneumonitis (inflammation
of the lungs). Gastrointestinal effects, such as nausea, loss of appetite,
vomiting, cramps, and slow digestion, have also been associated with
welding.
• Some compounds of welding fume, for example cadmium, can be
fatal in a short time. Gases given off by the welding process can also
be extremely dangerous. For example, ultraviolet radiation given off
by welding reacts with oxygen and nitrogen in the air to form ozone
and nitrogen oxides. These gases are deadly at high doses, and can
also cause irritation of the nose and throat and serious lung disease.
• Ultraviolet rays given off by welding can react with chlorinated
hydrocarbon solvents, such as trichloroethylene, 1,1,1-trichloroethane,
methylene chloride, and perchloroethylene, to form phosgene gas.
Even a very small amount of phosgene may be deadly, although early
symptoms of exposure – dizziness, chills, and cough usually take 5 or
6 hours to appear. Arc welding should never be performed within 200
feet of degreasing equipment or solvents.
2-
Long-term (chronic) health effects:
• Studies of welders, flame cutters, and burners have shown that
welders have an increased risk of lung cancer, and possibly cancer of
the larynx (voice box) and urinary tract. These findings are not
surprising in view of the large quantity of toxic substances in welding
smoke, including cancer-causing agents such as cadmium, nickel,
beryllium, chromium, and arsenic.
• Welders may also experience a variety of chronic respiratory (lung)
problems, including bronchitis, asthma, pneumonia, emphysema,
pneumoconiosis (refers to dust-related diseases), decreased lung
capacity, silicosis (caused by silica exposure), and siderosis (a dustrelated disease caused by iron oxide dust in the lungs).
• Welders exposed to heavy metals such as chromium and nickel have
also experienced kidney damage.
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3Other Health Hazards:
Heat:
The intense heat of welding and sparks can cause burns. Eye injuries have
resulted from contact with hot slag, metal chips, sparks, and hot electrodes.
Visible Light, and Ultraviolet and Infrared Radiation:
The intense light associated with arc welding can cause damage to the retina
of the eye, while infrared radiation may damage the comea and result in the
formation of catracts.
Invisible ultraviolet light from the arc can cause “arc eye” or “welder’s
flash” after even a brief exposure (less than one minute). The symptoms of
arc eye usually occur many hours after exposure to UV light. And include a
feeling of sand or grit in the eye, blurred vision, intense pain, tearing,
burning, and headache.
BSafety Hazards of Welding:
1Electrical Hazards:
Even though welding generally uses low voltage, there still a danger of
electric shock. The environmental conditions of the welder (such as wet or
cramped spaces) may make the likelihood of a shock greater.
Dry gloves should always be worn to protect against electric shock. The
welder should also wear Rubber-soled shoes, and use an insulating layer,
such as a dry board or a rubber mat, for protection on surfaces that can
conduct electricity.
The piece being welded and the frame of all electrically powered machines
must be grounded. The insulation on electrodes holders and electrical cables
should be kept dry and in good condition.
2Fire and Explosions:
The intense heat and sparks produced by welding, or the welding flame, can
cause fire or explosions if combustible or flammable materials are in the
vicinity.
Welding or cutting should only be performed in areas that are free of
combustible materials, including trash, wood, paper, textiles, plastics,
chemicals, and flammable dusts, liquids and gases.
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Never weld on containers that have held flammable or combustible material
unless the container is thoroughly cleaned or filled with an inert (nonreactive) gas.
GENERAL REQUIREMENTS:
A. FIRE PREVENTION AND PROTECTION
1.
If the object to be welded or cut cannot readily be moved, all movable
fire hazards in the vicinity shall be taken to a safe place.
2.
If the object to be welded or cut cannot be moved and if all the fire
hazards cannot be removed, then guards shall be used to confine the
heat, sparks, and slag, and to protect the immovable fire hazards.
3.
If the above requirements cannot be met, then welding and cuttings
shall not be performed.
4.
Suitable fire extinguishing equipment shall be maintained in a state of
readiness for instant use. Such equipment may consist of pails of
water, buckets of sand, hose or portable extinguishers depending upon
the nature and quantity of the combustible material exposed.
5.
Fire watchers are required whenever welding or cutting is performed
in locations where other than a minor fire might develop, or any of the
following conditions exist:
i)
Appreciable combustible materials, in building construction or
contents, closer than 35 feet to the point of operation.
ii)
Appreciable combustibles more than 35 feet away but are easily
ignited by sparks.
6.
A fire watch shall be maintained for at least a half hour after
completion of welding or cutting operations to detect and extinguish
possible smoldering fires.
7.
Fire watchers shall have fire extinguishing equipment readily
available and be trained in its use. They shall be familiar with
facilities for sounding an alarm in the event of a fire. They shall watch
for fires in all exposed areas, try to extinguish them only when
obviously within the capacity of the equipment available, or otherwise
sound the alarm. A fire watch shall be maintained for at least a half
hour after completion of welding or cutting operations to detect and
extinguish possible smoldering fires.
8.
Floors. Where combustible materials such as paper clippings, wood
shavings, or textile fibers are on the floor, the floor shall be swept
clean for a radius of 35 feet (10.7m). combustible floors shall be kept
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9.
•
•
•
10.
wet, covered with damp sand, or protected by fire-resistant shields.
Where floors have been wet down, personnel operating arc welding or
cutting equipment shall be protected from possible shock.
Cutting or welding shall not be permitted in the following situations:
In areas not authorized by management.
In sprinklered buildings while such protection is impaired.
In the presence of explosive atmospheres (mixture of flammable
gases, vapors, liquids, or dusts with air), or explosive atmospheres that
may develop inside uncleaned or improperly prepared tanks or
equipment which have previously contained such materials, or that
may develop in areas with an accumulation of combustible dusts.
Welding or Cutting Containers
No welding, cutting, or other hot work shall be performed on used
drums, barrels, tanks or other containers until they have been cleaned
so thoroughly as to make absolutely certain that there are no
flammable materials present or any substances such as greases, tars,
acids, or other materials which when subjected to heat, might produce
flammable or toxic vapors. Any pipe lines or connections to the drum
or vessel shall be disconnected or blanked.
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11.
12.
13.
14.
Confined Spaces:
When arc welding is to be suspended for any substantial period of
time, such as during lunch or overnight, all electrodes shall be
removed from the holders and the holders carefully located so that
accidental contact cannot occur and the machine be disconnected from
the power source.
In order to eliminate the possibility of gas escaping through leaks or
improperly closed valves, when gas welding or cutting, the torch
valves shall be closed and the gas supply to the torch positively shut
off at some point outside the confined area whenever the torch is not
to be used for a substantial period of time, such as during lunch hour
or overnight. Where practicable, the torch and hose shall also be
removed from the confined space.
Combustible walls. Where cutting or welding is done near walls,
partitions, ceiling or roof of combustible construction, fire-resistant
shields or guards shall be provided to prevent ignition.
Noncombustible walls. If welding is to be done on a metal wall,
partition, ceiling or roof, precautions shall be taken to prevent ignition
of combustibles on the other side, due to conduction or radiation,
preferably by relocating combustibles. Where combustibles are not
relocated, a fire watch on the opposite side from the work shall be
provided.
PROTECTION OF PERSONNEL
1.
A welder or helper working on platforms, scaffolds, or runways
shall be protected against falling through the use of railings,
safety belts, life lines, or some equally effective safeguards.
2.
Welding cable. Welders shall place welding cable and other
equipment so that it is clear of passageways, ladders, and
stairways.
3.
Helmets or hand shields shall be used during all arc welding or
arc cutting operations, excluding submerged arc welding.
Helpers or attendants shall be provided with proper eye
protection.
4.
Helmets and hand shields shall be made of a material which is
an insulator for heat and electricity. Helmets, shields and
goggles shall not be readily flammable and shall be capable of
withstanding sterilization.
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5.
6.
7.
8.
9.
10.
Helmets and hand shields shall be arranged to protect the face,
neck and ears from direct radiant energy from the arc.
Welders should always select clothing materials which will
provide maximum protection from sparks and hot metal.
Protective eyewear, safety shoes, fire-resistant clothing, and
fire-resistant gauntlet gloves are recommended. Additionally,
the shirt should have full sleeves, no pockets and should be
worn outside the trousers with collar buttoned. The trousers
should have no cuffs and should extend well down to the safety
shoes.
Goggles or other suitable eye protection shall be used during all
gas welding or oxygen cutting operations. Spectacles without
side shields, with suitable filter lenses are permitted for use
during gas welding operations on light work, for torch brazing
or for inspection.
All operators and attendants of resistance welding or resistance
brazing equipment shall use transparent face shields or goggles,
depending on the particular job, to protect their faces or eyes, as
required.
Helmets shall be provided with filter plates and cover plates
designed for easy removal.
Protective clothing – General requirements. Employees exposed
to the hazards created by welding, cutting, or brazing operations
shall be protected by personal protective equipment in
accordance with the requirements of 1910.132. Appropriate
protective clothing required for any welding operation will vary
with the size, nature and location of the work to be performed.
HEALTH PROTECTION AND VENTILATION
1.
Mechanical ventilation is required when welding or cutting is
done with materials not specifically mentioned in this section.
These materials – fluorine compounds, zinc, lead, beryllium,
cadmium, mercury, cleaning compounds, and stainless steel are
partially hazardous and have specific control requirements.
2.
Screens. When welding must be performed in a space entirely
screened on all sides, the screens shall be so arranged that no
serious restriction of ventilation exits. It is desirable to have the
screens so mounted that they are about 2 feet (0.61m) above the
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3.
4.
5.
6.
7.
floor unless the work is performed at so low a level that the
screen must be extended nearer to the floor to protect nearby
workers from the glare of welding.
Maximum allowable concentration. Local exhaust or general
ventilating systems shall be provided and arranged to keep the
amount of toxic fumes, gases, or dusts below the maximum
allowable concentration as specified in 1910.1000 of this part.
Mechanical ventilation shall be provided:
•
In a space of less than 10.000 cubic feet (284 m3) per
welder.
•
In a room having a ceiling height of less than 16 feet (5m)
Minimum rate. Such ventilation shall be at the minimum rate of
2.000 cubic feet (57m3) per minute per welder, except where
local exhaust hoods and booths, or airline respirators approved
by the U.S. Bureau of Mines for such purposes are provided.
Natural ventilation is considered sufficient for welding or
cutting operations where restrictions are not present.
Hoods. Freely movable hoods intended to be placed by the
welder as near as practicable to the work being welded and
provided with a rate of air-flow sufficient to maintain a velocity
in the direction of the hood of 100 linear feet (30m) per minute
in the zone of welding when the hood is at its most remote
distance from the point of welding.
Oxygen for ventilation. Oxygen shall never be used for
ventilation.
HOT WORK PERMIT
A written permit must be obtained prior to starting any welding,
cutting or hot work operations. Ensuring that all safety precautions
have been taken.
Gas Welding and Cutting
A.
GENERAL REQUIREMENTS:
1.
Maximum pressure. Under no condition shall acetylene be generated,
piped (except in approved cylinder manifolds), or utilized at a
pressure in excess of 15 psig (pounds per square inch gauge) or 30
psia (pounds per square inch absolute) .
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2.
3.
4.
5.
Apparatus. Only approved apparatus such as torches, regulators or
pressure-reducing valves, acetylene generators, and manifolds shall be
used.
Using acetylene at pressures in excess of 15 psi gauge pressure (or
about 30 psi absolute pressure) is a hazardous practice. Free gaseous
acetylene is potentially unstable at pressures above 15 psig and could
decompose with explosive violence. Experience indicates that 15 psig
is generally acceptable as a safe upper pressure limit.
The decomposition characteristics of acetylene gas are avoided by
keeping the gas in liquid solution and storing it in cylinders of unique
construction. Internally, acetylene cylinders are not designed like
other kinds of compressed gas cylinders. Acetylene cylinders are
never hollow. These cylinders contain a porous, calcium silicate filler
and a suitable solvent, usually acetone, because, under pressure,
acetylene by itself is unstable. Acetone is used because it has the
ability to absorb over 400 times its own volume of acetylene at 70 F.
Millions of microscopic pores make up the calcium silicate filler.
Although it appears to fill the steel shell, approximately 90 percent of
the filler’s volume consists of “pore space” for holding and evenly
distributing the acetylene/acetone solution.
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6.
7.
When absorbed in this filler, the acetylene is divided into such small
units that, should acetylene decomposition take place in one pore, the
heat released is not enough to raise the temperature of the acetylene in
surrounding pores to the point where it, too, will decompose.
Acetylene is usually supplied in cylinders which have a capacity of up
to 300 cubic feet of dissolved gas under pressure of 250 psig at 70 F.
PROTECTIVE EQUIPMENT, HOSE, AND REGULATORS
1.
The operator must use the proper hose. Fuel gas hose is usually red
(sometimes black) and has a left-hand threaded nut for connecting to
the torch. Oxygen hose is green and has a right-hand threaded nut for
connecting to the torch.
2.
Hose and hose connections shall be clamped or otherwise securely
fastened in a manner that will withstand, without leakage, twice the
pressure to which they are normally subjected in service, but in no
case less than a pressure of 300 psi. Oil-free air or an oil-free inert gas
shall be used for the test.
3.
Hose showing leaks, burns, worn places, or other defects rendering it
unfit for service shall be repaired or replaced. When inspecting hoses,
look for charred sections close to the torch. These may have been
caused by flash-back. Also check that hoses are not taped up to cover
leaks.
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4.
5.
Pressure-reducing regulators shall be used only for the gas and
pressures for which they are intended.
All gas welding and gas cutting equipment must be fitted with flash
arrestots to minimise the risk of injury to workers or damage to
equipment if and when flashback occurs.
USING OXYACETYLENE EQUIPMENT:
An oxyacetylene welding outfit is basically made up of the following:
cylinders of oxygen and acetylene, regulators, hoses, and a torch.
Oxygen and acetylene are stored in separate cylinders. A great deal of gas is
forced into each cylinder. This result in very high pressures. The high
pressures are controlled and adjusted by the regulators.
Hoses carry the gases from the cylinders to the torch. The green hose carries
oxygen. The red hose carries acetylene.
The gases are mixed inside the torch. When burned, they produce a very hot
flame. The flame is regulated (adjusted and controlled) by interchangeable
torch tips and by the torch valves.
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OXYACETYLENE CUTTING
To cut steel using an oxyacetylene outfit, use a cutting torch instead of a
welding torch. Adjust the regulators for the torch tip and the thickness of the
metal to be cut.
1.
Light the torch, and adjust it to a neutral flame.
2.
Locate the inner core of the flame
flame just above the work surface.
3.
Tilt the tip slightly, and preheat the metal in a single spot. Keep
heating until it is cherry red.
4.
Push down on the oxygen cutting lever. A jet stream of oxygen burns
through the metal.
5.
Position the torch at a 90-degree
90
angle
ngle to the work surface, and
continue cutting along the desired line. Move the torch smoothly.
ARC WELDING AND CUTTING
INTRODUCTION:
The electric arc welder remains one of our most useful and timesaving
pieces of shop equipment. Most of these welders are typically AC/DC, 240
volt transformer types using electricity as the energy source. Portable
welders are of the diesel/gasoline engine powered type. Properly installed
and used the arc welder is very safe, but if used improperly the operator can
be exposed to a number of hazards including toxic fumes, dusts, burns, fires,
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explosions, electric shock, radiation, noise, and heat stress. Any of these
hazards can cause injury or death.
Arc welding uses the heat from an electric arc to melt and fuse base metals
and welding-rod metal into one piece. The heat from the arc melts the flux
(cleaner) coating on the rod.
There are two basic kinds of arc welding machines. Some provide direct
current (DC). Others provide alternating current (AC).
SELECTING THE ARC WELDER:
When purchasing an arc welder you can be assured of design safety and
safety standards for arc welders as determined by the Underwriters
Laboratories (UL). Be sure that the welder you purchase carries the seal of
approval of UL.
APPLICATIONS
Voltage
The following limits shall not be exceeded:
Alternating Current (AC)
Direct Current (DC)
Manual
80 Volts
100 Volts
Automatic
100 Volts
100 Volts
For AC welding under wet conditions or warm surroundings where
perspiration is a factor, the use of reliable automatic controls for reducing
no-load voltage is recommended to reduce the shock hazard. Some of the
older AC machines do not have an automatic control and are on load all the
time. It is easy to receive an electric shock when the equipment is not
handled properly.
INSTALLING THE ARC WELDER
Prior to installing the arc welder you should determine if your present
electrical system is adequate to handle the increased load required by the
welder. Your local power supplier or a qualified electrician can assist you in
determining this. It is very important for your safety to install the welder by
a qualified electrician. Failure to do so could cause fire, a ground fault, or
equipment failure. The following rules are not a complete list but are
especially important guidelines which should be adhered to:
1.
The frame or case of welder shall be properly grounded.
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2.
3.
A safety-type disconnecting switch or controller shall be located near
the machine.
The welder or welders shall be protected by a properly sized fuse or
circuit breaker on an independent circuit.
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VENTILATION
The welder should be located in an area with adequate ventilation. In
general, when welding is being done on metals not considered hazardous, a
ventilation system that will move a minimum of 2000 cubic feet per minute
(CFM) of air per welder is satisfactory.
However, many materials are considered very hazardous and should be
welded only in adequately ventilated areas to prevent the accumulation of
toxic materials or to eliminate possible oxygen deficiency not only to the
operator but to others in the immediate vicinity. Such ventilation should be
supplied by an exhaust system located as close to the work as possible.
When welding or cutting metals with hazardous coatings such as galvanized
metal the operator should use a supplied-air type respirator or a respirator
specially designed to filter the specific metal fume. Materials included in the
very hazardous category are welding rod fluxes, coverings, or other
materials containing fluorine compounds, zinc, lead, beryllium, cadmium,
and mercury.
FIRE PREVENTION
The arc welder is capable of producing temperatures in excess of 10.000
degrees F., therefore it is important that the workplace be made firesafe. This
can be accomplished by using metal sheets or fire resistant curtains as fire
barriers. The floor should be concrete or another fire resistant material.
Cracks in the floor should be filled to prevent sparks and hot metal from
entering. When work cannot be moved to a firesafe area then the area should
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be made safe by removing or protecting combustibles from ignition
undetected until the welder has finished the job.
Suitable fire extinguishing equipment such as buckets of sand or a dry
chemical extinguisher of the ABC type should be readily available.
PERSONAL PROTECTION
It is essential that the operator and helpers be properly clothed and protected
because of the heat, ultra-violet rays, and sparks, produced by arc welder.
For body protection, a pair of fire retardant long sleeved coveralls without
cuffs is a good choice. Always avoid clothing with tears, snags, rips, or worn
spots as these are easily ignited by sparks. The sleeves and collars should be
kept buttoned. The hands should be protected with leather gauntlet gloves. A
pair of high to leather shoes, preferably safety shoes, is good protection for
the feet. Eyes should be protected by transparent goggles if the person wears
prescription glasses or safety glasses if not. A welding helmet or hand shield
with filter plate and cover plate is mandatory for eye protection from the
harmful rays of the arc. A flameproof skull cap to protect the hair and head
as well as hearing protection in noisy situations is recommended.
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•
•
Plastic disposable cigarette lighters are very dangerous around heat
and flame. It is important that they not be carried in the pockets while
welding.
Filter Lens (Shade Numbers):
Filter Lens Shade Number Guide
Welding Operation
Shade Number
Shield Metal Arc Welding up to 4 mm electrode
10
Shield Metal Arc Welding (4.8 to 6.4 mm) electrodes
12
Shield Metal Arc Welding (6.4 mm) electrode
14
Gas Metal Arc Welding (Nonferrous)
11
Gas Metal Arc Welding (ferrous)
12
Gas Tungsten Arc Welding
12
Carbon Arc Welding
10 – 14
Torch Soldering
2
Torch Brazing
3 or 4
Light cutting up to 25 mm
3 or 4
Medium cutting 25 to 150 mm
4 or 5
Heavy cutting over 150 mm
5 or 6
Gas welding (light) up to 3.2
4 or 5
Gas welding (medium) 3.2 to 12.7
5 or 6
Gas welding (heavy) over 12.7
6 or 8
SAFE OPERATION OF THE WELDER
1.
It is important that anyone operating an arc welder be instructed on its
safe use by a qualified person or welder.
2.
Because of their potentially explosive nature, we strongly recommend
that no welding, cutting, or hot work be attempted on used drums,
barrels, tanks, or other containers under any circumstances.
3.
The welder cables should be positioned so that sparks and molten
metal will not fall on them. They should also kept free of grease and
oil and located where they will not be driven over.
4.
Only use cables that are free from repair or splices for 10 feet (3 m)
from the electrode holder.
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5.
6.
7.
8.
9.
10.
Electric welders can kill by electric shock. If the welding operation
must be done on steel or other conductive material an insulating mat
must be used under the operator. If the welding area is wet or damp or
the operator is actively perspiring then he/she should wear rubber
gloves under the welding gloves.
It is easier and safer to establish an arc on a clean surface than a dirty
or rusty one. Therefore, metal should always be thoroughly cleaned by
wire brushing or other method prior to welding. When chipping slag
or wire brushing the finished bead the operator should always be sure
to protect his eyes and body from flying slag and chips. Unused
electrodes and electrode stubs should not be left on the floor as they
create a slipping hazard.
Hot metal should be handled with metal tongs or pliers. When
quenching hot metal in water it should be done carefully to prevent
painful burns from the escaping steam.
Any metal left to cool should be carefully marked “HOT”.
When welding is finished for the day or suspended for any length of
time electrodes should be removed from the holder.
The holder should be placed where no accidental contact could occur,
and the welder should be disconnected from the power source.
SAFETY PRECAUTIONS FOR ENGINE POWERED WELDERS
1.
Always operate in an open well-ventilated area or vent the engine
exhaust directly outdoors.
2.
Never fuel the engine while running or in the presence of an open
flame.
3.
Wipe up spilled fuel immediately and wait for fumes to disperse
before starting the engine. “Never” remove the radiator pressure cap
from liquid cooled engines while they are hot to prevent scalding
yourself.
4.
Stop the engine before performing any maintenance or trouble
shooting. The ignition system should be disabled to prevent accidental
start of the engine.
5.
Keep all guards and shields in place.
6.
Keep hands, hair, and clothing away form moving parts.
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FIRST AID
The welding area should always be equipped with a fire blanket and a well
stocked first aid kit. It is desirable that one person be trained in first aid to
treat the minor injuries that may occur. All injuries, no matter how minor
they may seem can become more serious if not properly treated by trained
medical personnel.
KEY POINTS TO REMEMBER
1.
Be sure the welder is properly installed and grounded.
2.
Never weld without adequate ventilation.
3.
Take proper precautions to prevent fires.
4.
Protect your entire body with fire retardant clothing, shoes, and
gloves.
5.
Wear eye protection at all times.
6.
Weld only in a firesafe area.
7.
Never do any welding, cutting, or hot work on used drums, barrels,
tanks, or other containers.
8.
Mark metal “HOT” with a soapstone.
9.
Keep a well-stocked first aid kit.
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