1. Welding, Cutting, And Brazing
Slide Show Notes
Welcome to the training session about welding, cutting, and brazing safety.
The applicable OSHA regulations are located at 29 CFR to 255 (Subpart Q)

2. Session Objectives You will be able to:
Identify major safety and health hazards of welding
Select appropriate PPE for welding, cutting, and brazing
Implement controls to prevent or control fires
Slide Show Notes
By the end of the training session, you will be able to:
Identify major safety and health hazards of welding
Select appropriate PPE for welding, cutting, and brazing
Implement controls to prevent or control fires

3. Types of Welding Welding includes 60 or more process variations
Electric welding and oxy-fuel gas welding
Welding/cutting occurs at most businesses at some point
Slide Show Notes
Welding is a general term that describes 60 or more processes that use heat to fuse metals together.
The processes include electric “arc” welding as well as oxygen or “oxy” – fuel gas cutting or welding.
Cutting or welding occurs at most business at one time or another as part of construction, maintenance, or repairs. Welding is part of the core business for some industries such as metal fabrication.
Discuss the types of welding done at your facility.
Modify this slide to describe the specific types of welding at your facility.

4. Welding Hazards Fires—caused by unsafe welding or cutting operations
Burns
Electric Shock
Light radiation— ultraviolet, infrared, and intense visible light
Air Contaminants (gases, fumes, smoke)
Slide Show Notes
About 6% of industrial fires causing loss of human life are due to unsafe welding or cutting operations. Such fires start when sparks from small pieces of molten metal or slag (larger pieces of molten metal) come in contact with flammable or combustible materials.
Burns to the body.
Electric shock and burns from electric (arc) welding.
Radiation: ultraviolet causes flash burns; infrared causes heat burns, irritation; intense visible light causes headache and eye strain.
Air Contaminants: Combustion gases, material – metallic oxides, mineral dusts, toxic fumes.
Ask the participants to discuss specific incidents that have happened at your facility or in your industry.

5. Basic Fire Prevention Inspect welding area before starting
Remove fire hazards
Install guards
Welding or cutting must NOT take place unless hazards removed or guards installed
Obtain a hot work permit before starting operations to ensure that all fire hazards are controlled
Post a fire watch person 1/2 hour after operation ceases
Slide Show Notes
Inspect the welding area before operations begin to eliminate possible fire sources.
It is best to perform welding in a designated area when possible to avoid additional hazards, otherwise remove fire exposures from the immediate area if possible.
If the fire hazard cannot be removed, guards must be installed
If fire hazards are not removed, or guards are not installed, the welding or cutting operation must not take place.
Be sure to obtain a hot work permit before performing any welding jobs. This will help ensure that all hazards are controlled.
Someone must also be posted as a fire watch from the time welding begins to at least 1/2 hour after the job is done.

6. Fire Prevention (cont.)
Never weld in explosive atmospheres
Do not weld on used containers
Test potentially explosive containers for flammable atmospheres
Shut off cylinder valves when not in use
Slide Show Notes
Here are fire prevention techniques associated with welding.
Never weld in the presence of explosive atmospheres.
Do not weld on used drums, barrels, tanks, or other containers.
Test potentially explosive containers for flammable atmospheres.
Shut off cylinder valves when they are not in use. It may be necessary to use special techniques such as inerting the space inside a container to eliminate flammable/explosive vapors prior to welding or cutting.

7. Ventilation
Three factors govern the amount of contamination to which welders may be exposed:
Dimensions of the space
Number of welders
Possible evolution of hazardous fumes
Management must ensure welders have proper protection and ventilation
Slide Show Notes
Three factors govern the amount of contamination to which welders may be exposed:
Dimensions of the space
Number of welders
Possible evolution of hazardous fumes
Management is responsible for ensuring welders have proper protection and ventilation

8. Oxygen-Fuel Gas Welding
Acetylene
Flammable
Unstable
Cannot be used above 15 psi
Oxygen
Added to support fuel gas flame and obtain high temperature for melting steel (welding)
Slide Show Notes
The primary fuel gases for welding, cutting, and brazing operations are:
Acetylene, which is flammable, unstable, and cannot be used above 15 pounds per square inch (psi).
Oxygen
Added to support fuel gas flame and obtain high temperature for melting steel (welding).

9. Basic Rules for Oxy-acetylene Welding
Ensure the safety fuse plug or disk is functional
Attach regulator
Stand to one side of regulator
Open cylinder valve slowly
Not more than 15 psi
Slide Show Notes
O2 and Acetylene have different fittings and hose colors so they cannot be misconnected. Here are the basic rules to follow when working with Oxy-acetylene gas-fueled systems:
Compressed gas cylinders must have a safety fuse plug or disk; check it to make sure it is functioning.
Never use oxygen or fuel gases directly from the cylinder; there must be a regulator attached to the valve.
Stand to one side of regulator to avoid injury if it malfunctions.
Open the cylinder valve slowly.
Use 3-7 psi for O2, and 1-12 psi for acetylene, but never over 15 psi.

10. Basic Rules for Oxy-acetylene Welding (cont.)
Purge oxygen and acetylene lines
Light the acetylene
Never use oil or grease near oxygen
Do not use oxygen to clean or blow off dirt or clothing
Keep your work area clean
Slide Show Notes
Purge oxygen and acetylene lines
Light the acetylene
Don’t mix oxygen with grease or oil
Mixture can cause spontaneous combustion and fire. Remember that oxygen and most other gases are stored under high pressure (2200 psi).
Do not use oxygen to clean or blow off dirt or clothing because it dramatically increases the combustibility of the material
Keep work area clean so as not to introduce unnecessary fire hazards

11. Store Gas Cylinders Safely
The storage area must be well ventilated
Keep fuel cylinders 20 feet or more from combustibles
Close valves, ensure valves are protected
Limit inside storage to 2,000 cubic feet
Store cylinders in the upright position and secured from falling
Separate oxygen from fuel gas
Slide Show Notes
Storage area must be well ventilated
Fuel cylinders must be at least 20 feet from combustibles
Valves must be closed. Regulators should only be on cylinders in use, not on those that are stored. Valve protection must be in place. Valve protection caps are designed to take a blow should the cylinder fall, thus preventing the cylinder from impersonating a rocket.
Inside storage must be limited to 2,000 cubic feet
Cylinders must be stored in upright position and secured from falling. Never lay the cylinder down; store it upright, and always secure it during storage
Oxygen storage. Keep fuel gas and oxygen separated by at least 20 feet, or keep separated by a 5-foot-high barrier with at least a half-hour fire rating.

12. Follow Gas Cylinder Precautions
Never lift cylinders by the service valve or valve protection (use slings, net, or other approved means)
Keys, handles, and hand wheels must be present
Use the proper regulator
Open acetylene valve no more than 11/2 turns
If in doubt about a cylinder, don’t use it
Slide Show Notes
Handling cylinders properly is important because of the extreme pressure contained in each cylinder. Use these precautions at all times.
Never lift cylinders by the service valve or valve protection (use slings, net, or other approved means).
Keys, handles, and hand wheels must be present.
Use the proper regulator.
Open acetylene valve no more than 11/2 turns.
If you are uncomfortable with the way a cylinder looks, don’t use it.

13. Use Protective Devices
Pressure relief valves, backflow preventers or check valves
Flash back arrestors
Fuel gas hose—red (sometimes black)
Oxygen hose—green
Hose protection required
Pressure-reducing regulators
Slide Show Notes
Make sure that a system that has been approved for use remains intact, and that approved regulators have not been substituted with other regulators such as high-pressure regulators. The following types of safety devices are important to prevent potential fires and/or explosions:
Pressure relief valves, and backflow preventers or check valves
Flash back arrestors
Fuel gas hose—red (sometimes black)
Oxygen hose—green
Hose protection required
Pressure-reducing regulators

14. Protect Yourself Keep working surfaces clean and clear
Light torches with a striker, not a lighter!
Wear face and eye protection
Use safety glasses under welding hood and burning goggles with proper shading
Wear protective body clothing
Avoid synthetic clothing
Use leather gloves with gauntlet
Slide Show Notes
Keep working surfaces clean and unobstructed.
Light torches with a striker. Do not use butane lighters. Welders have been killed by slag or sparks hitting a lighter in their pocket and causing an explosion.
Wear eye protection
Use safety glasses under welding hood and burning goggles with proper shading to protect against ultraviolet and infrared exposure. Face and eye protection is imperative to avoid possible welder’s flash, which can permanently damage your eyesight.
Protective clothing must be worn during welding, cutting, and brazing operations.
Avoid synthetic clothing – synthetic clothing melts readily. Wear cotton or wool.
Wear leather gloves w/gauntlet.
Show samples of personal protective equipment for use while welding (i.e., helmets, gloves, aprons, etc.).

15. Lens Shades Generally, use a 4–5 shade for: Torch brazing
Oxy-fuel gas cutting/welding
Slide Show Notes
Because the shades vary for the different types of welding, it is important that routine inspections be conducted to ensure that the proper shades are used on the various welding operations. Check the manufacturer or OSHA charts for specific welding applications.
Generally a 4 – 5 shade is used for:
Torch brazing
Oxy-fuel gas cutting/welding
Show welding helmets, glasses, or goggles.

16. Oxy-Acetylene Welding—Any Questions?
Any questions about oxy-acetylene welding safety?
Slide Show Notes
Are there any questions about the safety specifications or safe work practices for oxy-acetylene welding?

17. Arc Welding—Common Processes
Shielded metal arc welding (stick welding)
Gas metal arc welding (MIG welding)
Gas tungsten arc welding (TIG welding)
Flux cored arc welding
Submerged arc welding
Arc cutting
Plasma arc cutting
Slide Show Notes
The following are the various types of arc welding processes.
Shielded metal arc welding (stick welding)
Gas metal arc welding (MIG welding)
Gas tungsten arc welding (TIG welding). Arc welding such as TIG and MIG use a shielding gas.
Flux cored arc welding
Submerged arc welding
Arc cutting
Plasma arc cutting
Modify this slide to describe the arc welding process(es) at your facility.

18. Arc Welding Hazards and Safety Measures
Arc gives off ultraviolet and infrared rays the same as those causing sunburn
Exposure within several inches to a few feet can cause flash burn to eyes and skin
Safety measures
Avoid wet or damp areas—promotes electric shock hazard
Avoid oil, grease, and flammables as they pose a fire hazard
Slide Show Notes
Arc welding is very common. A high percentage of industrial welding is arc or “stick” welding. Electric current fuses parent metal and welding rod. The typical electrical current = amps at up to 80 volts. Arc welding is indispensable in metal working. It is used for carbon and alloy steels and nonferrous metals.
The safety hazards of arc welding are:
Arc gives off ultraviolet and infrared rays the same as those causing sunburn
Exposure within several inches to a few feet can cause flash burn to eyes and skin
Safety measures for avoiding hazards of arc welding include:
Avoid wet or damp areas – promotes electric shock hazard
Avoid oil, grease and flammables as they pose a fire hazard

19. Shielding and Flash Screens
Air must be kept away from weld area
Shielding protects the integrity of the weld joint
Flux or gas mixture is used as a “shield”
Welders need to erect flash screens around them to protect others in area
Slide Show Notes
Air must be kept away from the weld area so as not to introduce contaminants.
Shielding protects the integrity of the weld joint.
Shielded gas welding uses an inert gas to keep air away from the weld area and protect the integrity of the weld.
Using flash screens protects others in the area from the flash associated with welding.

20. Maintain Equipment Properly
Welding machines must be grounded
Work area must be dry and free of hazards
Connections must be tightly made
Cable splices within 10 feet of holder are prohibited
Cables must be maintained and conductors well insulated
Slide Show Notes
Follow these straightforward rules for the safe maintenance of welding equipment.
Welding machines must be grounded
Work area must be dry and free of hazards
Connections must be tightly made
Cable splices cannot be within 10 feet of holder
Cables must be maintained and conductors must be well insulated

21. Protect Yourself
Wear welding helmets with proper shading depending on type of arc
DO NOT use brazing goggles
Wear safety glasses under helmet
Wear leather gloves with gauntlets
Use ventilation or respirators
Wear leather bibs, sleeves, or jackets to prevent burns from slag, sparks, and ultraviolet
Slide Show Notes
Here are some procedures to follow in order to protect yourselves from injury.
Wear welding helmets with proper shading depending on type of arc.
DO NOT use brazing goggles.
Wear safety glasses under helmet.
Wear leather gloves with gauntlets.
Use ventilation or respirators.
Wear leather bibs, sleeves or jackets to prevent burns from slag, sparks and ultraviolet.

22. Lens Shades Generally, use a 10–14 shade for: Shielded metal arc
Gas metal arc
Gas tungsten arc
Slide Show Notes
Because the shades vary for the different types of welding, it is important that routine inspections be conducted to ensure that the proper shades are used on the various welding operations. Check the manufacturer or OSHA charts for specific welding applications.
Generally a 10 – 14 shade is used for:
Shielded metal arc welding
Gas metal arc welding
Gas tungsten arc welding
Show any welding helmets, glasses, or goggles that may be available.

23. Arc Welding—Any Questions?
Any questions about arc welding?
Slide Show Notes
Are there any questions about the safety specifications or safe work practices for arc welding?

24. Key Points to Remember Major hazards include:
Fire
Burns
Shock
Toxic exposures
Follow proper procedures to prevent fires
Use appropriate engineering controls
Wear appropriate PPE
Slide Show Notes
All types of welding processes used today involve high heat and potential for fires, burns and other hazards. Know the hazards in your area. Some of these hazards include:
Fire
Burns
Shock
Toxic exposures to fumes, gases and vapors.
Follow proper procedures to prevent fires.
Use appropriate engineering controls such as ventilation, shields and screens to protect you or others in the area.
Wear appropriate PPE such as gloves, safety glasses, helmets, and aprons.