FHM TRAINING TOOLS
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Welding Safety
►►►
These materials have been developed based on applicable federal laws and regulations in place at the time the materials were created. The program
is being provided for educational and informational purposes only and does not constitute and is not intended to provide OSHA compliance certification,
regulatory compliance, a substitute for any "hands on“ training required by applicable laws and regulations, or other legal or professional advice or
services. By accessing the materials, you assume all responsibility and risk arising from the use of the content contained therein.
©2010 Grainger Safety Services, Inc.
Learning Objectives
Objectives:
►
Recognize the hazards associated with welding
►
Gas cylinder usage requirements
►
Understand requirements for welding equipment
►
Have work practices implemented
Agenda
Presentation Agenda:
► Hazards
of welding
► Transporting,
handling, and storing
gas cylinders
► Using
► Work
welding equipment
practices
Section 1
Hazards of
Welding
Welding Hazard Statistics
Statistics:
►
About 562,000 employees are at
risk for welding hazards
►
Welders flash accounts for 5% of
eye injuries
Fatalities
Deaths and serious injuries have
occurred from:
► Explosions
► Electrocutions
► Asphyxiation
► Falls
and crushing injuries
Welding Health Hazards
There are numerous health hazards:
►
Heavy metal poisoning
►
Lung cancer
►
Metal fume fever
►
Flash burns
Metal Fume Fever
Symptoms:
►
Respiratory disturbances
►
Fever with chills and shivering
►
Trembling, nausea, and vomiting
Dangers
Additional hazards:
► The
arc can reach 6,000°F
► Ultraviolet
and infra-red rays can be
harmful
► Symptoms
sunburn
similar to extreme
Volatile Combination of Heat and Gas
Drums and containers:
►
Containers may explode from
welding or cutting
►
Ensure that previous contents
doesn’t cause explosions
Section 2
Transporting,
Handling, and
Storing Gas
Cylinders
Transporting Gas Cylinders
Transporting:
►
Valve protection caps in place and secure
►
Cylinders hoisted on cradle, sling board, or pallet
►
No magnets or choker slings
►
Move by tilting and rolling on edge
►
Secure upright when transported
by powered vehicle
Moving Gas Cylinders
Moving:
►
Prepare cylinders for movement
when carts are unavailable
►
Regulators removed
►
Valve protection caps in place
Gas Cylinders in Use
Secure cylinders in use:
►
Cylinder truck, chain or other
steadying device can be used
Closing the Cylinder Valve
The cylinder valve shall be closed:
►
When work is finished
►
When cylinders are empty
►
When cylinders are moved
Securing Gas Cylinders
Securing cylinders:
►
Always secure in upright position
►
Except for hoisting or carrying
Storing Gas Cylinders
Storing gas cylinders:
►
Separate oxygen and fuel
cylinders by 20 feet
Interior Storage
Separate cylinders inside buildings:
►
Minimum of 20 feet for storage of
oxygen and combustibles
►
5-foot high non-combustible barrier
with fire rating of 1/2 hour
Reference Documents
Compressed Gas Association Pamphlet
P-1-1965 required for all in-plant:
►
Handling
►
Storage
►
Utilization of all compressed gases
Section 3
Using Welding
Equipment
Protecting the Cylinders
Sparks, hot slag, and flame:
►
Protect cylinders from sparks and hot slag
►
No striking the electrode to strike an arc
Confined Space Welding
Confined space:
►
Never take oxygen or acetylene
cylinders into confined spaces
Safe Use of Fuel Gas
Safe use of fuel gas:
►
Instruct employees
►
Reduce pressure through regulators before burning
►
Clear valves of dirt before connecting regulator
Cracking the Cylinder Valve
Never crack cylinders:
►
In the presence of open flames
►
Where gas could reach welding work or sparks
Stand to the side when cracking cylinders
Opening Cylinders
Opening cylinders:
►
Always open the cylinder valve slowly
►
Open the cylinder 1 and 1/2 turns
►
Leave the valve wrench in place when in use
►
Close valve and bleed the regulator before
removing the regulator
Use of Regulators
Regulators:
►
Use of regulators required
►
Close valve and release gas from
regulator before removing
Fuel Gas and Oxygen Manifolds
Manifold hose connections:
►
Green hose for oxygen and right-hand thread
►
Red for acetylene and left-hand thread
►
Hose couplings must rotate to disconnect
Welding Hose
Welding hose:
►
Cover no more than four of twelve inches
with tape
►
Inspect fuel hose prior to each shift
►
Remove defective hose from service
Torches
Condition:
►
Clogged tips clean with suitable
devices
►
Torches inspect prior to each shift
Torches lit by approved methods:
►
No matches
►
Never off of hot work
Oxygen
Using or handling oxygen:
►
Avoid handling with oily clothes, hands, or gloves
►
Keep away from oil or grease
►
Never use oxygen inside a
storage tank or vessel
Arc Welding Electrode Holders
Manual electrode holders:
►
Must carry the maximum rated electrode current
►
Only fully insulated holders to contact hands
Arc Welding Cables
Arc welding cables:
►
Must be completely insulated and flexible
►
Free of splice 10 feet from electrode cable end
►
Cables in need of repair not allowed
Arc Welding Return Cables
Ground return cables:
►
Must have capacity for maximum voltage
►
No grounding on pipelines containing flammables
When using pipelines for ground return:
►
Verify ground continuity for all joints
Arc Welding Work Practices
Employers instruct employees:
►
Remove electrodes from holders when unattended
►
No hot electrodes dipped in water
►
Machine power opened when
leaving machine or stopping work
►
Faulty equipment reported
to supervisor
Shielding Arc Welding Processes
Shielding arc welding:
►
Always shield operations with
flame-proof screens
Section 4
Work
Processes
Work Area Preparation
Work area:
►
Move objects to be welded to safe location
►
Remove fire hazards from the area
►
Confine heat, sparks, and slag
Extinguishing Equipment Present
No welding when:
►
Paint or dust hazards are present
►
Extinguishing equipment isn’t
available and ready
Fire Watch
Fire watch:
► When
needed assign personnel to guard against
fires
► Trained
to recognize welding fire hazards
Controlling Sparks
Controlling sparks:
►
Take precautions for sparks
Confined Space Welding
Welding in confined spaces:
►
Remove torch and hose when complete
►
Eliminate hazardous atmospheres in
confined spaces
Welding on Drums or Hollow Structures
For objects that contained toxic or
flammables either:
► Completely
fill with water
before proceeding
► Thoroughly
► Ventilate
► Test
clean
Welding Ventilation
Ventilation:
► General
ventilation
► Mechanical
exhaust
ventilation or local
Eye Protection
Eye protection during welding:
►
Suitable eye protective equipment
Eye and Face Protector
Types of eye protection:
►
Goggles
►
Spectacles
►
Face shield
►
Welding helmets
Guide for Selection of Shade Numbers
WELDING OPERATION
SHADE #
Shielded Metal Arc Welding 1/16, 3/32, 1/8, 5/32 Inch Electrodes
10
Gas-Shielded Arc Welding (nonferrous) 1/16, 3/32, 1/8, 5/32 Inch Electrodes 11
Gas-Shielded Arc Welding (ferrous) 1/16, 3/32, 1/8, 5/32 Inch Electrodes
12
Shielded Metal Arc Welding 3/16, 7/32, 1/4 Inch Electrodes
12
Shielded Metal Arc Welding 5/16, 3/8 , Inch Electrodes
14
Atomic Hydrogen Welding
10-14
Carbon Arc Welding
14
Preservation Coatings
Scrapings:
►
Test surface scrapings to determine
flammability
►
If scrapings burn, coatings must be
removed
Additional Information
29 CFR 1926.350(a)(9) Securing of Compressed Gas
Cylinders. STD 03-08-002 [STD 3-8.2],
(1981, March 11)
Replacement Welding Tips. STD 01-14-001
[STD 1-14.1], (1978, October 30)
Welding, Cutting, or Heating of
Metals Coated with Lead-Bearing
Paint.
STD 03-08-001 STD 03-08-001
[STD 3-8.1], (1978, October 30)