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Chapter 2 Safety in Welding
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Objectives Burn classifications and emergency treatment
Dangers of types of light, and avoiding eye and ear injuries Use a chart to select eye and face protection Describe various types of respiratory protection Avoid dangerous fumes and gases
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Objectives (continued)
The purpose of Material Safety Data Sheets The benefits of recycling waste material General work clothing and special protective clothing Safely handle, secure, and store cylinders Protect against fire danger when welding
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Objectives (continued)
The importance of planned maintenance Tools commonly used by welders Good electrical safety practices Types of metal cutting machines Safely lift heavy assemblies Ladder safety
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Introduction No substitute for caution and common sense
Each person must take personal responsibility Welding has a number of potential safety hazards Most large welding companies have mandated safety classes
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Burn Classification Burns are one of the most common and painful injuries Caused by ultraviolet light rays and contact with hot welding torches All burns must receive proper medical treatment Burns are divided into three classifications
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First-Degree Burns The surface of the skin is reddish
Tender and painful No broken skin Put the burned area under cold water or apply a cold compress Cover the area with sterile bandages Never apply butter or grease
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Second-Degree Burns The surface of the skin is severely damaged
Blisters and possible breaks in the skin Put the area under cold water or use cold water compresses Pat the area with a dry lint-free towel and cover with a sterile bandage Seek medical attention
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Figure 2-2 Second-degree burn
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Third-Degree Burns Surface of the skin appears white, charred
Never remove any clothing Never put ice water or ice, ointments, sprays, etc. If the victim is on fire, smother the fire with a blanket, rug or jacket Cover the burn with a thick sterile dressing Call for an ambulance
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Burns Caused by Light Some types of light can cause burns
Three types of light include: Ultraviolet Infrared Visible Arc welding produces all three types of light Light from the welding process can be reflected from walls, ceilings, and floors
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Ultraviolet Light The most dangerous
Causes first and second degree burns to eyes or exposed skin The closer the welder is to the arc and the higher the current, the quicker a burn may occur A welder's eyes can receive a flash burn in seconds
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Figure 2-6 The eye can be burned on the white or retina by ultraviolet light.
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Infrared Light The light wave is felt as heat
A person will immediately feel this type of light Burns can be easily avoided Protective action should be taken to cover yourself
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Visible Light The light that we see
Produced in varying quantities and colors May cause temporary night blindness Too little visible light may cause eye strain Visible light is not hazardous
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Face Eye and Ear Protection
Eye protection must be worn in the shop at all times Safety glasses with side shields Goggles Full face shield Flash glasses Welding light damage often occurs without warning
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Welding Helmets Even with quality welding helmets, the welder must check for potential problems Undetectable leaks of ultraviolet light can cause a welder's eyes to itch or feel sore Ensure lens gasket is installed correctly Tape can be used as a temporary repair
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Safety Glasses Adequate for general use
Not suitable for heavy grinding, chipping, or overhead work Must be worn under an arc welding helmet at all times
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Ear Protection Welding environment can be very noisy
Hot sparks can drop into an open ear, causing severe burns Earmuffs cover the outer ear completely Earplugs fit into the ear canal Damage caused by high sound levels may not be detected until later in life – hearing will not improve with time
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Respiratory Protection
Welding and cutting produce harmful by-products Respirators protect against welding by-products Welders are responsible for following the shop's written respiratory protection policy Training should include: Proper use of respirator Maintenance schedules and respirator selection Procedures for testing the proper fitting and use Regular evaluation of the program
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Equipment Some types of respiratory protection equipment:
Air-purifying respirators Atmosphere-supplying respirators Demand respirators Positive pressure respirators Powered air-purifying respirators Self-contained breathing apparatus Supplied-air respirators
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Fume Sources Paints, coating, or plating on metals can cause respiratory problems Before welding or cutting any painted metal, the surface must be cleaned Marine industry still uses lead-based paints Exposure to cadmium fumes can cause lung and kidney damage The best way to avoid problems is to provide adequate ventilation.
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Vapor Sources Ozone gas is produced by ultraviolet radiation
Ozone irritates mucous membranes The collection of fumes and gases can go unnoticed Concentrated fumes can cause a fire or explosion
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Ventilation Welding area should be well ventilated
Natural ventilation is best Forced ventilation may be required Large enough areas may not require forced ventilation
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Figure 2-15 A room with a ceiling 16 ft
Figure 2-15 A room with a ceiling 16 ft. high may not require forced ventilation
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Forced Ventilation Small shops or shops with many welders require forced ventilation Forced ventilation Can be general or localized Fixed or flexible exhaust pickups Forced ventilation is required when welding on metals that contain dangerous fumes
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Material Safety Data Sheets
Material safety data sheets (MSDS) provide details of possible hazards Often posted on a bulletin board or put in a convenient place where products are used If injured while using a product, take the material's MSDS when you seek treatment
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Waste Material Disposal
Welding shops generate a lot of waste materials All scrap metal can be recycled Hazardous waste materials include: Burned flux Cleaning solvents Dust collected in the filtration system Throwing hazardous material away is illegal
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General Work Clothing Guidelines for work clothing:
Shirts must be long-sleeved Pants must be long enough to cover the tops of the boots and must be without cuffs Boots must have high tops Caps should be thick Clothing must be free of frayed edges or holes There is no safe place to carry a butane lighter or matches while welding
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Special Protective Clothing
Extra protection is needed for each person who is in direct contact with hot materials Hand protection Body Protection Waist and Lap Protection Arm Protection Leg and Foot Protection Leather is often the best material to use
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Handling and Storing Cylinders
Store oxygen and fuel gas cylinders separately Store inert gas cylinders separately or with the same type of fuel cylinders Store all cylinders vertically Securely fasten the protective cap
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Securing and Storing Gas Cylinders
Secure cylinders with a chain or other device Chain cylinders attached to a manifold or stored in a special room Cylinder storage area must be away from halls, stairwells, and exits Storage areas should be away from heating units and welding sparks Secure storage areas from unauthorized people
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Cylinders with Valve Protection Caps
Must have the cap in place unless the cylinder is in use The cap prevents the valve from being broken off Never lift the cylinder by the safety valve When moving cylinders, the valve protection cap must be on All cylinders must be handled with care
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General Precautions Any cylinders with a defect must be identified
If a leak cannot be stopped Move cylinder to a vacant lot Slowly release pressure Post a warning sign Acetylene cylinders Must be upright for four hours before use Otherwise may draw acetone from the cylinder
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Figure 2-25 Move a leaking fuel gas cylinder out of any work area
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Fire Protection Fire is a constant danger
Highly combustible materials should by 35 feet away from any welding site A fire watch can be provided by any person who knows how to sound an alarm The fire extinguisher must be the type required to put out a fire for the type of combustible material
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Fire Extinguishers There are four types of fire extinguishers
Type A: combustible solids Type B: combustible liquids Type C: electrical fires Type D: fires involving combustible metals Some fire extinguishers can be used on more than one type Using the wrong type of extinguisher can be dangerous
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TYPE A FIRE
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TYPE B FIRE
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TYPE C FIRE
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TYPE D FIRE
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Location of Fire Extinguishers
Fire extinguishers should be easily removed Should be easily lifted Location marked with red paint and signs Should be marked near the floor
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LOCATION
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Use Extinguishers cool the fire and remove oxygen
Use foam, carbon dioxide, a pump tank, or dry chemicals CO2 extinguisher – direct the discharge as close to the fire as possible Dry chemical extinguisher – direct toward the base of the flames
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Figure 2-34 Point the extinguisher at the material burning, not the flames
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Equipment Maintenance
Planned maintenance (PM) detects problems Hoses must be used for the gas or liquids for which they were designed Green hoses are used only for oxygen Red hoses are used only for fuel gases Never use oil grease, or other pipe-fitting compounds on joints Any leaking joints must be repaired
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Work Area Should be picked up and swept clean
Arc welding area painted with a flat dark color Portable screens used if welding outside the welding booth If a piece of hot material is left unattended, write hot on it before leaving
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Hand Tools Used for assembly and disassembly of parts
The adjustable wrench is the most popular tool Fewer points = stronger Mushroomed heads of chisels, punches, and the faces of hammers should be ground off Always use the correct tool for the job
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Electrical Safety Injuries and death can be caused by electrical shock
Resistance is lowered in the presence of water or moisture Electrically powered machines must be grounded Welding circuits must be turned off when the work station is left unattended
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Electrical Safety Systems
Two safe systems for electrical power tools: External grounding A wire runs from the housing to a third prong Third prong plug fits into grounded receptacle Double insulation Extra layer of insulation Eliminates need for grounded outlet
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Voltage Warnings Voltage is the same as specified on the tool
A voltage greater than the tool can lead to injury A voltage lower than the tool can damage the motor Amperes (Amps) measures electrical current
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Extension Cords Use only three-wire, grounded extension cords
When using extension cords: Connect the cord of tool into the extension first Extension cords should be long enough The cord does not come in contact with sharp objects Check for loose or exposed wires Clean before storing
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Figure 2-41 Two types of grounding plugs
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Safety Rules for Portable Electric Tools
Some general rules: Know the tool and ground the tool when needed Do not expose to water Keep the area well lighted Do not use near propane, or flammable vapors Wear eye protection Secure your work with clamps Maintain power tools
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Grinders Grinding using a pedestal or portable grinder is required to do many welding jobs Before a grinding stone is put on a machine, it should be tested for cracks Each grinding stone is made for grinding specific types of metal Stone should not be used when are worn down Gloves should never be worn when grinding
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Drills Center punch holes before drilling
If the bit gets caught, stop the motor Securely clamp all metal before drilling Sharp metal shavings should be avoided
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Metal Cutting Machines
Before operating any power tool for the first time, read the manufacturer's instructions Welders use shears and punches in the fabrication of metal for welding Cut off machines use abrasive wheels or special saw blades Band saws are vertical or horizontal Some can be used in either position
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Material Handling Improper work habits can cause serious personal injury Improper handling can cause damage to tools and materials When lifting, the weight of the object should be evenly distributed between both hands The capacity of hoists or cranes should be checked before lifting a heavy load
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Ladder Safety Improper use of ladders is often a factor in falls
All ladder use poses a danger In case of a fall, keep the area around the ladder clear Step ladders and straight ladders are used extensively in welding shops
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Figure 2-52 Make sure the ladder is leaning at the proper angle.
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Ladder Inspection and Safety
Over time, ladders can become damaged Look for loose or damaged parts Check that all hardware is tight Check wooden ladders for cracks Never use a defective ladder If a ladder cannot be repaired, replace it Read the entire ladder manufacturer's list of safety rules for ladder use Never use a ladder that is too short for the job Climb and descend cautiously
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Summary Safety is of the utmost importance
The safety officer ensures welders comply with safety rules Wear proper clothing, shoes, and protection Have established plans in case of accidents Check equipment periodically Further information is available in Safety for Welders by Larry E. Jeffus
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