FHM TRAINING TOOLS This training presentation is part of FHMs commitment to creating and keeping safe workplaces. Be sure to check out all the training programs that are specific to your industry.

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. Welding Safety

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 welding equipment Work practices

Hazards of Welding Section 1

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 similar to extreme sunburn

Volatile Combination of Heat and Gas Drums and containers: Containers may explode from welding or cutting Ensure that previous contents doesnt cause explosions

Transporting, Handling, and Storing Gas Cylinders Section 2

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 required for all in-plant: Handling Storage Utilization of all compressed gases

Using Welding Equipment Section 3

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

Work Processes Section 4

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 isnt 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 clean Ventilate Test

Welding Ventilation Ventilation: General ventilation Mechanical ventilation or local exhaust

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 Carbon Arc Welding 14

Preservation Coatings Scrapings: Test surface scrapings to determine flammability If scrapings burn, coatings must be removed

Additional Information 29 CFR (a)(9) Securing of Compressed Gas Cylinders. STD [STD 3-8.2], (1981, March 11) Replacement Welding Tips. STD [STD ], (1978, October 30) Welding, Cutting, or Heating of Metals Coated with Lead-Bearing Paint. STD STD [STD 3-8.1], (1978, October 30)