1. 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.

2. 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

3. Learning Objectives Objectives: Recognize the hazards associated with welding Gas cylinder usage requirements Understand requirements for welding equipment Have work practices implemented

4. Agenda Presentation Agenda: Hazards of welding Transporting, handling, and storing gas cylinders Using welding equipment Work practices

5. Hazards of Welding Section 1

6. Welding Hazard Statistics Statistics: About 562,000 employees are at risk for welding hazards Welders flash accounts for 5% of eye injuries

7. Fatalities Deaths and serious injuries have occurred from: Explosions Electrocutions Asphyxiation Falls and crushing injuries

8. Welding Health Hazards There are numerous health hazards: Heavy metal poisoning Lung cancer Metal fume fever Flash burns

9. Metal Fume Fever Symptoms: Respiratory disturbances Fever with chills and shivering Trembling, nausea, and vomiting

10. Dangers Additional hazards: The arc can reach 6,000°F Ultraviolet and infra-red rays can be harmful Symptoms similar to extreme sunburn

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

12. Transporting, Handling, and Storing Gas Cylinders Section 2

13. 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

14. Moving Gas Cylinders Moving: Prepare cylinders for movement when carts are unavailable Regulators removed Valve protection caps in place

15. Gas Cylinders in Use Secure cylinders in use: Cylinder truck, chain or other steadying device can be used

16. Closing the Cylinder Valve The cylinder valve shall be closed: When work is finished When cylinders are empty When cylinders are moved

17. Securing Gas Cylinders Securing cylinders: Always secure in upright position Except for hoisting or carrying

18. Storing Gas Cylinders Storing gas cylinders: Separate oxygen and fuel cylinders by 20 feet

19. 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

20. Reference Documents Compressed Gas Association Pamphlet P-1-1965 required for all in-plant: Handling Storage Utilization of all compressed gases

21. Using Welding Equipment Section 3

22. Protecting the Cylinders Sparks, hot slag, and flame: Protect cylinders from sparks and hot slag No striking the electrode to strike an arc

23. Confined Space Welding Confined space: Never take oxygen or acetylene cylinders into confined spaces

24. 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

25. 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

26. 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

27. Use of Regulators Regulators: Use of regulators required Close valve and release gas from regulator before removing

28. 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

29. 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

30. 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

31. 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

32. Arc Welding Electrode Holders Manual electrode holders: Must carry the maximum rated electrode current Only fully insulated holders to contact hands

33. 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

34. 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

35. 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

36. Shielding Arc Welding Processes Shielding arc welding: Always shield operations with flame-proof screens

37. Work Processes Section 4

38. Work Area Preparation Work area: Move objects to be welded to safe location Remove fire hazards from the area Confine heat, sparks, and slag

39. Extinguishing Equipment Present No welding when: Paint or dust hazards are present Extinguishing equipment isnt available and ready

40. Fire Watch Fire watch: When needed assign personnel to guard against fires Trained to recognize welding fire hazards

41. Controlling Sparks Controlling sparks: Take precautions for sparks

42. Confined Space Welding Welding in confined spaces: Remove torch and hose when complete Eliminate hazardous atmospheres in confined spaces

43. Welding on Drums or Hollow Structures For objects that contained toxic or flammables either: Completely fill with water before proceeding Thoroughly clean Ventilate Test

44. Welding Ventilation Ventilation: General ventilation Mechanical ventilation or local exhaust

45. Eye Protection Eye protection during welding: Suitable eye protective equipment

46. Eye and Face Protector Types of eye protection: Goggles Spectacles Face shield Welding helmets

47. 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

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

49. 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)