Module 1
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Upon completion of this module, you will be able to:
1. Identify some common hazards in welding.
2. Explain and identify proper personal protection
used in welding.
3. Describe how to avoid welding fumes.
4. Explain some of the causes of accidents.
5. Identify and explain uses for material safety data
sheets.
6. Explain safety techniques for storing and handling
cylinders.
7. Explain how to avoid electric shock when welding.
8. Describe proper material handling methods.
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There is a lot more to welding
than simply applying an electric
arc to the base metals.
Welding safety and safe practices
are paramount in the welding
industry.
Welders must be trained on how
to act safely to ensure that no
one gets hurt or killed.
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Many hazards are associated
with welding, cutting, and
related processes.
Some of these are electric
shock, infrared rays,
ultraviolet (UV) rays, hot
metal, slag, sparks and
associated welding fumes.
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Beginning Welders must understand the
hazards of welding and develop the proper
attitude toward safety.
Welders must understand the need for proper
clothing, eye protection, and face protection,
along with general shop safety.
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Accident can often be traced to personal
factors such as poor health, lack of
experience, and the improper use of alcohol
and medications.
Studies show that a person who lacks
experience is more likely to take risks that
cause accidents.
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An inexperienced person often is not able to
foresee the outcome of an action or just lacks
the knowledge to know what works and what
doesn’t.
People who consume alcohol or use illegal
drugs while working risk their lives and the
lives of their co-workers, and will not be
tolerated.
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Personal protective
equipment (PPE).
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Leather and fire
resistant protective
coverings.
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Foot Protection:
OSHA requires that protective footwear be
worn when working where falling, rolling, or
sharp objects pose a danger of foot injuries
and where feet are exposed to electrical
hazards.
Safety shoes or boots 8 inches or taller
should be worn.
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Hand Protection:
Gloves must be selected
on the basis of the
hazards involved.
Gauntlet-type welding
gloves must be worn
when welding or
cutting.
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Soft, flexible, leather
gloves can be used for
light-duty work and
operations such as
GMAW, GTAW, TB, OFC
and OAW.
Do not use gloves if
they have oil on them
or if they have holes.
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Ear Protection:
Welding areas can be
very noisy, ear plugs
and/or ear muffs should
be worn at all times.
Ear protection can also
keep sparks out of your
ear canals.
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Eye, Face and Head
Protection:
The heat and light
produced by cutting or
welding operations can
damage the skin and eyes.
Injury to the eyes may
result in permanent loss of
vision.
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Proper lens shade
selection:
Make sure you use
the proper shade
for the type of
work you are
doing.
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Many varieties of
helmets are available.
You should choose the
right welding helmet for
the right type of job.
Passive lenses.
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Auto Darkening
welding helmets
Can choose
different shades
with the touch of
a button.
Shade 3 to 4
when turned off.
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The gases, fumes, and dust produced by
welding and cutting processes can be
hazardous.
Adequate ventilation must be provided to
prevent workers from breathing these
products.
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There are three methods to remove fumes and
gases:
1. Natural ventilation:
◦ The movement of air through the work place caused
by natural forces is often sufficient to remove fumes
and gases.
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2. Mechanical ventilation
◦ If natural ventilation is not adequate, portable or
fixed fans can be used to provide the necessary
ventilation.
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3. Source extraction
◦ This method uses a mechanical device to capture
welding fumes at or near the arc.
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Regardless of the ventilation method used, it
is important to avoid breathing in the
welding fumes.
This means keeping your head up and away
from the fume plume.
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In addition to the fume plume, some
consumables and base metals contain toxic
materials that require special ventilation.
These materials include:
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Barium
Cadmium (found in some steel and fasteners)
Chromium (found in stainless steel)
Base metal coatings such as paint
Cobalt
Copper
Manganese
Nickel
Silica
Zinc (found in galvanized metals)
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Respirators:
Special metals require the use of respirators
to protect welders from harmful fumes.
There are three types of respirators:
◦ Air-purifying respirators
◦ Supplied-air respirators (SARs)
◦ Self-contained breathing apparatus (SCBA)
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Types Respirators:
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Air-purifying respirators:
◦ Provide the lowest level of protection.
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Supplied-air respirators (SARs):
◦ Provide a supply of air for extended periods of time
via high pressure hose.
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Self-contained breathing apparatus (SCBA):
◦ Can be used in oxygen-deficient atmospheres, in
poorly ventilated or confined spaces.
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Typical respirator.
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A belt-mounted
respirator.
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Reusable half-mask
air purifying
respirator.
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Powered air-purifying
respirator (PAPR).
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Supplied-air respirator.
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Self-contained
breathing apparatus.
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Use the right
respirator for the
job.
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Respiratory Program:
A respirator must be properly selected (based
on the contaminant present and its
concentration level), properly fitted, and used
in accordance with the manufacturer’s
instructions.
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A confined space refers to a relatively small
or restricted space, such as storage tank,
boiler, or pressure vessel or small
compartments, such as underground utility
vaults, small rooms or the unventilated
corners of a room.
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Effects of an Increase
or Decrease in
Oxygen Levels.
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Worker entering a
confined space with a
restricted opening for
entry and exit.
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An important factor in area safety is good
housekeeping. The working area should be
picked up and swept clean.
The floors and workbenches should be free of
dirt, scrap metal, grease, oil, and anything
that is not essential to accomplishing the
given tasks.
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It is important to keep flammable liquids as
well as rags, wood scraps, piles of paper, and
other combustibles out of the welding area.
Sparks can smolder for hours and then burst
into flames.
The most common welding accident is
burned hands and arms.
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Report all accidents, no matter how minor, to
the instructor.
Always write the word “HOT” on any hot
metal, tools, tables, etc. that you leave
unattended.
Turn off all electrical equipment before
working on it.
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Always have a fire extinguisher nearby.
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Always have first-aid equipment nearby.
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Eliminate tripping hazards.
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Keep floor free of electrodes.
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Work in a dry area, don’t use wet gloves.
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Use portable screens
to protect other
personnel from the
arc or reflected glare.
Screens are not a
replacement for
welding helmets. Do
not stare at the arc
through a screen.
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Hot Work Permits:
Are official
authorization from
the site manager to
perform work that
may pose a fire
hazard.
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Fire Watches are needed when welding or
cutting on or around any flammable material.
Someone other than the person welding or
cutting has to be the fire watch.
Fire watches must constantly scan the work
area for fires.
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Fire watches must only be watching for fires
and should not be distracted by any other
type of work.
Fire watch personal must have ready access to
fire extinguishers and alarms and know how
to use them.
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Most welding environment fires occur during
oxy-fuel gas welding or cutting.
Never point a torch tip at anyone when
lighting it or using it.
Never point the torch at the cylinders,
regulators, hoses or anything else that may
be damaged and cause a fire or explosion.
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Never lay a lighted torch down on the bench
or work piece, and do not hang it up while it
is lighted. If the torch is not in the operator's
hands, it must be turned off.
When cutting or welding with oxy-fuel gas
equipment, clear the area of all combustible
materials.
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Never use oxygen as a substitute for
compressed air.
Do not use damaged or leaking equipment or
cylinders.
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Do not tamper with equipment or cylinders.
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Do not force open or close cylinder valves.
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Only use approved
torch lighter.
Keep the striker to
the side of the gas
flow when lighting a
torch.
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As a general rule you should never cut into a
container, unless you know what used to be
stored in it.
Containers must be cleaned by steam
cleaning, flushing with water, or washing
with detergent until all traces of the material
have been removed.
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After cleaning the container, fill it with water
or a purging gas, such as carbon dioxide,
argon, or nitrogen to displace the explosive
fumes.
Without oxygen, combustion cannot take
place.
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When using water, position
the container to minimize
the air space.
When using an inert gas,
provide a vent hole so the
inert gas can purge the air.
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Oxygen and fuel gas cylinders or other
flammable materials must be stored
separately.
Inert gas cylinders may be stored separately
or with either fuel cylinders or oxygen
cylinders.
Empty cylinders must be stored separately
from full cylinders.
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Always store cylinders
vertically with their safety
caps on.
Always secure cylinders so
they cannot fall over.
Always store cylinders
away from sparks and
heat sources.
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Never use Acetylene gas at pressures greater
than 15 pounds per square inch.
Never withdraw Acetylene gas at a rate
greater than 1/7th the total contents of the
cylinder.
Never use a damaged cylinder.
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All power tools must be properly grounded to
prevent electric shock.
Never use a power tool that you have not
been properly trained to use.
Never alter or remove any power tool’s guard
or other safety device.
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Always wear protective equipment when
using power tools.
Always use the proper size extension cord.
Do not use power tools near flammable
materials.
Only use power tools in a dry environment.
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Electric shock from welding and cutting
equipment can kill or cause severe burns by
coming in contact with bare skin.
The amount of current the passes through
the human body determines the outcome of
an electric shock.
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The higher the voltage, the greater the
chance of a fatal shock.
Electric current flows along the path of least
resistance to return to its source.
If you come in contact with a live conductor
you become a load.
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The potential for shock increases
dramatically if the skin is damp.
Currents of less than 1 amp can severely
injure and even kill a person.
Under the right conditions, even a small
current can cause serious injury or death.
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This figure shows
how much
resistance the
human body
presents under
various
circumstances and
how this converts
into amps or
milliamps when the
voltage is 110 volts.
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All manufactures of potentially hazardous
materials must provide detailed information
regarding possible hazards resulting from the
use of their product in the form of a material
safety data sheet (MSDS).
Any MSDS must be provided to anyone using
the product or anyone working in the area
where the product is in use.
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Proper lifting, moving, and handling of large,
heavy, welded assemblies is important to the
safety of the workers and the weldment.
When lifting a heavy object, distribute the
weight of the object evenly between both
hands.
Use your legs to lift, not your back.
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Do not try to lift a large or bulky object
without help if the object is heavier than you
can lift with one hand.
Improper work habits can cause serious
personal injury and/or damage to equipment
and materials.
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Planning is critical to safety.
Accidents occur if you let them, but if you
anticipate and plan ways to avoid them,
accidents can be reduced or eliminated.
The jobsite should always be evaluated to
reveal any hazard such as confined spaces,
unguarded openings, possible electrical
hazards and environmental hazards.
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Are there any questions?