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raghuvaran chakkaravarthy

Safety Requirements for Arc Welding and Cutting Equipments - Arc Welding Machines

Arc welding machines should be of suitable quality.

Construction of arc welding machines should be such that they can operate satisfactorily even under condition of :

(i) Saltish or moist air as in coastal areas,

(ii) Dust, smoke, fumes and gases,

(iii) Excessive shock or vibrations,

(iv) Steam and corrosive atmosphere, etc.

Arc welding machines should have open circuit or no-load voltage as low as possible consistent with good welding and the types of electrodes used and it should not exeed 100 volts for single operator DC welding and AC welding machines and 75 volts for constant voltage, multiple operator DC welding machines. All welding equipment shall be inspected periodically and maintained in safe working order at all times.

Welding equipment used in the open shall be protected from inclement weather conditions. Welding equipment if it has been wetted shall be thoroughly dried before being used. Arc welding machines should be properly ground (earthed).

Proper terminals should be used on the arc welding machines for the power line voltage connection. One should not work on the wiring of an arc welding machine unless qualified to do so.

In the case of DC arc welding motor generator machines

All parts of shall be suitably enclosed and protected meet the usual service conditions.

(ii) Neither terminal of the welding generator shall be bonded to the frame of the welding machine.

(iii) Periodically clear out the accumulated dust from the welding machine with a suction cleaner as this will not blow dust into other parts of the machine.

(iv) Lubricate regularly; but overgreasing may foul the commutator.

(v) Check and, if necessary, clean commutators periodically, using fine sand paper.

(vi) Excessive sparking may result in a worn commutator which may be cured by skimming in a lathe.

(vii) Brushes should move freely and have adequate spring tension.

This can be tested by lifting and releasing them. Brushes should snap back firmly against the commutator.

In the case of AC arc welding machines

(i) In transformers, the secondary circuit shall be thoroughly insulated from the primary.

(ii) Input terminals shall be completely enclosed and accessible only by means of tools.

(iii) The primary side of the transformer shall be provided with suitable wire terminals inside the machine case.

(iv ) Welding ( secondary) terminals shall be so arranged that current carrying parts are not exposed to accidental contact.

(v) In a transformer, the welding circuit should be quite separate from the power circuit, so that there is no risk of the welder suffering serious shock or burns through power voltage appearing across the electrode holder.

(vi) At or near each welding machine, a disconnecting switch shall be provided.

(vii) Control apparatus provided with the welding machine shall be enclosed except for the operating wheels, levers, etc.

(viii) Transformer windings be suction or compressed air cleaned periodically.

(ix) Greasing points need attention periodically.

(x) Switch contacts should be cleaned periodically.

(xi) Before undertaking any maintenance work on welding machines, disconnect them from the main supply.

As regards other arc welding equipment

(i) Electrode holders should be soundly connected to the welding lead. They should be of adequate rating for the maximum welding current to prevent them from heating up and becoming too hot to handle.

Electrode holders shall be provided with discs or shields to protect the hands of the welder from heat of the arc.

Insulation of all metallic or current carrying parts, including the jaws which grip the electrodes, is recommended.

Hot electrode holders shall not be permitted to dip in water because the retained moisture may cause an electric shock.

(ii) Welding cables shall be of completely insulated, flexible type. They should be capable of handling the maximum current requirements of the work in progress, taking into account the duty cycle under which the welder is working.

In case the cable insulation is damaged, do not operate the equipment. The welding cable should be free from repair or splices up to a minimum distance of 3 metres from the electrode holder. Fully insulated cable connectors of capacity at least equivalent to that of the cable shall be used to connect two cables together.

Welding cables shall be kept dry and free from grease and oil to avoid premature breakdown of the insulation.

(iii) The body or the frame of the welding machine shall be efficiently earthed.

Pipe lines containing gases or inflammable liquids or conduits carrying electrical conductors shall not be used for a ground return circuit. All earth connections shall be mechanically strong and electrically adequate for the required current.

Hope information helps. . .

From United States, Fpo
raghuvaran chakkaravarthy

Protection of Welders - Workers need to be protected from

(i) The welding rays.

(ii) Flying sparks, metal globules (spatter), hot slag particles and hot electrode stubs.

(iii) Fumes and gases when welding in confined spaces, e.g., rail tank wagon.

(iv) Falling when welding at a height from the ground.

Protection from Welding Rays

Welding are, in addition to being very bright, is a source of infrared and ultraviolet light also; consequently the operator must useeither a helmet or a hand shield fitted with a special filter glass. Exposing the eyes and face to infrared rays would lead to the face becoming uncomfortably hot and it might induce serious eye troubles.

Excess ultraviolet light can cause an effect similar to sunburn on the skin.

Protection of Welders from Sparks and Spatter (Protective Clothing)

The welder's body and clothing are protected from radiation and burns caused by sparks and flying globules of molten metal with the help of the following:

(i) Gloves protect the hands of a welder.

(ii) Leather or asbestos apron is very useful to protect welder's clothes and his trunk and thighs while seated he is doing welding.

(iii) For overhead welding, some form of protection for the head is required. Leather skull cap or peaked cap will do the needful.

(iv)Leather jackets and leather leggings are also available as clothes for body protection.

(v) If cutting or deep gouging is being carried out by metal arc processes, the amount of spatter is considerably greater than with normal arc welding and leather spats would be particularly useful to prevent burns to the ankles and feet.

(vi)Safety boots are necessary to protect the feet of the welder from hot slag and, in particular, from falling off cuts.

Persons working in the vicinity of a welding arc, including other welders, can be caused discomfort by stray radiation from the arc. Where possible, each arc should be screened in such a way that this radiation is kept to a minimum. If possible, individual welding booths may be made and painted with a matt, absorbent type of paint with a very low reflecting quality.

Ventilation and Health Protection

A welder is likely to suffer from the ill effects of

(i) Welding fumes.

(ii) Gases

(iii) Dusts (containing Pb, Zn, Cd, fluorine, etc.), if adequate ventilation is not available.

Fumes are produced

(i) at the arc in metal arc welding with covered electrodes and in arc cutting.

Fumes can be very injurious to health, if the electrode coating contains fluorides and ii metal being arc welded/cut has a high chromium content.

(ii) when the metal being arc or flame welded is galvanised.

Therefore, either a welder should work out of doors or a portable fume extractor with a built in fan driven by an electric motor should be employed.

Gases are present at the place of welding as a result of

(i) application of heat to certain materials.

(ii) combustion (CO), the absorption of oxygen in the process of combustion, and the oxidation of nitrogen in the air (nitrous fumes).

(iii) the escape of gases used for combustion in welding and cutting blowpipes.

Welding fumes and gases become much more dangerous when welding is carried out in Confined Spaces such as a rail tank wagon.

Under such situation.

(i) either a mobile fume extraction fan unit,

(ii) or breathing apparatus should be used by the welder.

Extreme care must also be taken in making welded repairs to tanks, etc., which have contained inflammable material such as petrol. The responsibility for deciding whether a vessel is safe to weld or not should rest with a person of authority.

To Conclude, hazards of fumes, gases and dusts can be minimized by

(i) improving general ventilation of the place where welding is carried out,

(ii) using local exhaust units,

(iii)wearing individual respiratory protective equipment

From United States, Fpo
raghuvaran chakkaravarthy

Explosion, Fire and Other Hazards in Welding and Cutting - Explosion and fire hazards are by far the greatest in connection with gas welding and flame cutting.

Explosions take place when

(i) Oil or grease is likely to come into contact with any pipe, valve, etc., carrying oxygen.

(ii) Copper is used to repair acetylene generators or welding &cutting blowpipes. Copper, when exposed to the action of acetylene, forms copper acetylide; a highly explosive solid compound which, by heat or friction, gets readily detonated.

(iii) Gas or arc welding or cutting of a closed vessel, containing in flammable liquid or gas, is carried out.

(iv) Backfire from welding or cutting blowpipes reaches an acetylene generator.

Backfire is caused by the accidental blocking up of the flame nozzle in the tip, either by molten weld metal splashing up or by the tip of blowpipe being dipped into the weld pool. Backfire is in general more likely to cause fire than explosion.

(v) Fuel gas cylinders are exposed to high temperatures. This may happen if cylinder is kept in the sun, or a lighted blowpipe, accidentally, impinges upon the cylinder or backfire takes place when the welder by his habit has wound the spare length of rubber hose round the cylinder, etc.

If, under such conditions, the cylinder becomes hot (and it is found before explosion), the cylinder should be submerged in water and cylinder valve should be opened a little to allow any generated pressure to escape.

(vi) Naked lights or electrical apparatus are used in generator houses or carbide stores.

(vii) Partially spent carbide is used for recharging an acetylene generator.

Other hazards. They are

(a) Fire

(b) Shock

(c) Overheating.

Fire hazards involve loss of life and damage to property.

Fire hazards result due to

(i) damaged insulation of current carrying ables in arc welding. If insulation is damaged, there may occur local arcing between cable and any adjacent metal work at earth potential. This will cause fire.

(ii) burns from freshly welded metal.

(iii) sparks, molten metal globules and hot slag falling on flammable material* lying in the welding area.

(iv) hot electrode stubs.

v) welding cable of inadequate capacity. Overheating, therefore, will lead to damaged insulation and fire.

(vi) inadequate connections which result in overheating and lead to severe burns and fire.

(vii) inadequate return path. Current leakage through surrounding metalwork will lead to overheating and thus fire.

(viii) leaking valves on fuel gas cylinders and blowpipes.

(ix) leaking fuel gas rubber hoses.

(x) Backfire from blowpipes.

To prevent fire hazards, one should avoid the occurrence of above. Moreover, suitable fire extinguishing equipment should be maintained in a state of readiness for instant use.

Shock hazards cause severe burns and loss of life. Shock results due to:

(i) damaged insulation of cables.

(ii) lack of welding earth/lack of adequate earthing.

Overheating hazards. Overheating causes damage to equipment and leads to fire.

Overheating may result due to

(i) Oversize fuses.

(ii) Welding cables of inadequate capacity.

(iii) Inadequate connections.

From United States, Fpo
raghuvaran chakkaravarthy

Safety Recommendations for Welding and Cutting Operations

Working area and floor should be kept clean and clear of electrode stubs, metal scrap, etc.

The equipment should be fed from a switch fuse so that it can be isolated from the main supply. Easy access to this switch must be provided at all times. Before starting welding ensure that the welding equipment is adequately earthed.

Welder should wear dry and fireproof protective clothes (i.e., apron, gloves, etc.) to prevent the arc rays from reaching his body. One should not look at an electric arc with the naked eye. To prevent welder's head from radiation, spatter and hot slag, a helmet or hand shield must be worn. Eye trouble caused by arc flashes may be soothed by bathing with the following solution.

Screens should be erected to protect other persons, working nearby, from the arc rays. Welder should be completely insulated from the floor/work when changing electrodes.

Welder should not leave the electrode holder on the table or in contact with a grounded metallic surface. Welder should make use of goggles with clear glasses while he is chipping off scale, slag, etc. Adequate ventilation should be provided at the place where welding is carried out.

Temporary or permanent booths may be installed to carry out welding operations. To avoid reflection, inner walls of booths should be painted dead black with lamp black.

To avoid being dazzled by the flash of the arc when first struck, the welder should keep the electrode close to the work at the starting point of the weld, lower his helmet and strike the arc. Welding operation should preferably be carried out in clean, dry locations.

Welding should not be carried out in closed containers or on containers that have held combustible materials. Cutting should be done away from the operator to avoid the possibility of molten metal spraying into the face or onto clothing. Never weld unless qualified to do so.

From United States, Fpo
raghuvaran chakkaravarthy

Safety Recommendations for Hose OR Gas Tubing. . .
Use the correct colour hose for oxygen (green/black) and acetylene (red) and never use oxygen hose for acetylene or vice versa. Always protect hose from being trampled on or run over. Avoid tangle and kinks. Never leave the hose so that it can be tripped over.
Hose connections shall be made through substantial fittings and clamped or otherwise securely fastened to these connections in such a manner as to withstand without leakage a pressure twice as great as the maximum delivery pressure of the pressure regulators provided on the system.
Protect the hose from flying sparks, hot slag, hot workpiece and open flame. If dirt goes into hose, blow through (with oxygen, not acetylene) before coupling to torch or regulator. Store hose on a reel (an automobile wheel will do) when not in use.

From United States, Fpo
raghuvaran chakkaravarthy

Safety Recommendations for Gas Welding Pressure Regulators
Use the correct pressure regulator for a gas. For example, never use acetylene pressure regulator with any other gas.
A pressure regulator shall be used, only, at pressures for which it is intended. Handle pressure regulators carefully. Cylinder valves should be opened slowly to avoid straining the mechanism of pressure regulators. Do not move the cylinder by holding the pressure regulator. For repairs, calibrations or adjustments purposes the pressure regulators should be sent to the supplier. Do cracking before connecting pressure regulator to the gas cylinder.
Union nuts and connections on regulators shall be inspected before use to detect faulty seats which may cause leakage of gas when the regulators are attached to the cylinder valves. Never use oil, grease or lubricant of any kind on regulator connections.

From United States, Fpo
raghuvaran chakkaravarthy

Nature of hazards As part of the process of safety self-regulation, all persons engaging in this activity should identify the hazards, assess their significance and manage the potential risks including any additional hazards not mentioned here

Hazards that may be encountered in operating gas heating, welding and cutting equipment include:

inhalation (gases, toxic fumes)

heat (hot metals, naked flames)

explosion (igniting of leaking or escaping fuel gas, blowback)

fire (as a result of an explosion, combustible materials); and

flame (excessive eye exposure to intense brightness).

The primary hazards of oxyacetylene welding are burns from hot materials, toxic fumes, fire and explosion.

Toxic fumes produced during the welding of galvanised metal, manganese steel, cadmium zinc and some other non-ferrous metals may be very dangerous and toxic and very harmful to students. Additional precautions should be taken when welding these materials.

No welding or cutting should be carried out on containers, which have held flammable materials, because of the risk of explosions.

Level of risk The categorisation of these conditions is subjective and offered as a starting point for risk management planning. The actual degree of risk is best ascertained by persons with intimate local knowledge present at the site of the activity.

Gas heating, welding and cutting operations are divided into three categories, depending on:

the complexity of the operation

the degree of risk associated with the operation of the equipment; and

the severity of the consequences of any potential accident.

The risk levels for this activity are:

Medium risk (level 2):

Fixed flame (where a fixed flame is used in a fixed position and cannot be moved by students)

High risk (level 3):

Mobile flame (where the burner is made mobile to enable the activity to be carried out)

Very high risk (level 4):

Mobile flame (mobile flames using oxygen acceleration and where molten metal is a derivative of the activity).

A fire extinguisher and/or fire blanket should be situated in close proximity to the welding area. Extinguishers should be identified with Standard Specification Identification Code signs.

The welding site should be adequately ventilated and lit.

Protective clothing should be worn and should conform with Australian Standard 1558 (Protective Clothing for Welders).

Hazard reduction Lighting-up and closing-down procedures should be in accordance with the manufacturer's operating instructions.

The supervisor should ensure that additional precautions are taken to prevent metal discards causing injury to any person.

Acetylene, oxygen, liquid petroleum (LP) or other gas cylinders should be stored and used in an upright position. Gas cylinders should also be securely restrained to prevent them from falling over, particularly when they are used as a mobile plant.

Gas welding and electric welding should be carried out in separate areas to prevent the possibility of ignition of gas cylinders. If this cannot be achieved, the teacher should ensure that only one form of welding is carried out at any one given time.

The use of flammable liquids in or near the fuel gas area should be avoided.

The operator should leave the welding benches, accessories and equipment in a safe, clean and tidy condition.

Equipment that is lit should not be left unattended.

Worker should wear appropriate personal protective equipment while heating, cutting, welding or aiding in the processes of welding. It is recommended that students do not wear clothing that is at risk of ignition, such as some forms of synthetic cloth.

All worker engaged in the activity should wear appropriate footwear with substantial uppers.

Flashbacks and explosions can be limited through correct closing-down procedures, correct tip selection, correct gas pressure and ensuring students do not use dirty welding or cutting tips.

Hot materials left unattended after heating operations have the potential for combustion. It is recommended that correct cooling down and disposal of materials be undertaken.

Combustible or flammable materials should not be used in the vicinity of the heating and welding activity.

Only flint, electronic spark or gas station igniters should be used for lighting up.

In the event of a flashback, close the oxygen blowpipe valve first then close the fuel gas valve. Arrange inspection of equipment by qualified personnel before relighting.

In the event of an acetylene leak around the spindle, close the valve and tighten the gland.

If an acetylene cylinder is heated accidentally or becomes hot through severe flashback, the following action should be taken promptly:

shut the cylinder valve

clear all personnel from the area

cool the cylinder with a copious supply of water; and

notify the fire brigade/department-108(india). . .

From United States, Fpo
raghuvaran chakkaravarthy

Plasma Cutting Safety Makes Sense

Plasma arc cutting technology has allowed metal workers to rip through any kind of electricity conducting metals for the last 50 years. However, since the mid-1990s, the implication of inverter technology has sparked phenomenal growth in the use of plasma arc cutters in every applicable industry. Inverter technology has allowed these units to be manufactured as a much smaller, compact, light weight, and very portable affordable priced plasma arc cutter. The remarkable speed and efficiency at which the portable plasma arc cutter performs in comparison to the traditional cutting methods of saws, snips, or oxyacetylene torches has inspired everyone from artists to do-it-yourselfrers. Although we are excited to see the growing interest of the many applications of this technology, this also mean that there are many new and inexperienced users. Therefor the Longevity Facility Testing Team has put together this very easy to learn guide to proper plasma arc cutting safety procedures.

Fire Hazards

Heat and sparks have the potential to ignite flammable materials both around your work space and on your person. Keep all flammable materials at least 35 feet away from the work space and cover yourself with the proper flame retardant gear.

Protect your eyes with approved safety glasses with side shield or use a face shield and helmet in addition to safety glasses. Be sure to consult your owner's manual for the correct safety equipment.

Stray sparks and hot metal blown from the work piece can ignite the clothes on your body and cause severe burns. Use clothing made from tightly woven material such as leather, wool, heavy denim, or industrial strength work pants.

High top leather boots provide the best protection for your feet.

Button shirt cuffs and sleeves.

Do not keep matches or butane lighters in your pockets or anywhere in the work area.

Do not ever grip the material near the cutting path.

A Longevity Pilot Arc Plasma Cutter can cause burns in clothing and skin, so avoid contact before during or just after you press or release the trigger.

Keep the torch tip of the Longevity Plasma Cutter pointed away from you at all times.

Never use a Longevity Plasma Cutter near flammable gasses, vapors, liquids, dust, or in any location bearing the potential for explosion.

In order to significantly decrease the possibility of fire while you are working, always maintain a clean dry work area.

Well Grounded

The hazards of electric shock are one of the most serious risks facing a person using any brand of plasma cutter. Contact with equipment or metal parts that are electrically "hot" can cause injury or death from the shock or from a fall that results from reaction to the shock. There are two manners of shock a person can receive. An operator of a plasma cutter or any welding device could potentially suffer a primary voltage shock or a secondary voltage shock. Primary voltage shock comes from touching a lead inside the welding power source while you have your body or hand in contact with the welder case or other grounded metal. Turning the equipment's power switch "off" does not turn power off inside the case. Never remove panels without unplugging the input power cord or turning the power disconnect switch off. Secondary voltage shock comes from touching part of the welding circuit, such as a bare spot on the electrode cable, while also touching the grounded metal work piece. Inspect these items daily and replace, not repair, any worn cables or broken connections.

All Longevity Plasma Cutters feature two built-in safety measures; an internal fan keeps the machine cool and dry, while a fail safe measure forces the machine to properly and safely shut down should there be an intense increase in voltage from your power supply. Always remember to keep the area around the vent of your Longevity Plasma Cutter clear of dust and debris as this will ensure the safe and consistent performance of your Longevity Plasma Cutter. Also, plasma arc cutting torches are typically designed with safety interlock systems that turn off the machine if operators loosen the shield cup or if the tip touches the electrode inside the nozzle.

We all know water can conduct electricity very well and since your Longevity Plasma Cutter uses a plasma arc formed by electrical current igniting an extremely heat intense flame, the best idea is to keep the work area very dry and protected.

You want to make sure the work piece is connected to a proper earth ground. Be sure the ground cable is connected flush to an appropriate clean grounding surface as close to the area as possible. And lastly try to find a non flammable, dry piece to stand on while you work. Avoid wood and rubber in and around the work area as much as possible. And whenever possible cover any flammable material with flame retardant protection.

The Longevity Facility Testing Team recommends a thorough sweep of the area at least twice to make sure all potential hazards have been addressed.

Dim the Lights

Always take the precaution to warn the people around you and any observer that you are going to ignite your Longevity Plasma Cutter. The plasma arc for both High frequency and Pilot Arc technology exude and incredible amount of visible and invisible (ultraviolet and infrared) light rays the have the potential to burn unprotected eyes and skin. Consult the owner's manual of your Longevity Plasma Cutter in determining the appropriate eye protection.

Clear the Air

Because the combination of electricity and compressed air forms an incredibly hot plasma arc when cutting various metals, a lot of different gasses are released by the intensely heated metals. Do not breathe them in! The fumes and gases that result from the welding process can cause acute or chronic health effects if proper precautions are ignored. If you need a better view of the plasma arc cutting process hold your head to the side as opposed to looking directly over it. Also, in this case it is necessary to where an air-supplied respirator that meets current ANSI standards. If the metal being cut is coated (i.e. galvanized steel, lead, or cadmium plated steel) remove the coating from the area being cut. Ventilate the cutting area with an exhaust hood or suction system positioned at or on the plasma arc to maintain a safe breathing area. Natural ventilation may be used under certain conditions. For welding or cutting mild steel, natural ventilation is usually sufficient if a room has at least 10,000 cubic feet per welder, with a ceiling height of at least 16 feet. Cross ventilation should not be blocked, and welding should not be done in a confined space.

Gas Systems

A Longevity Plasma Cutter uses compressed air to ignite the plasma arc. However, these units also feature additional settings that allow for TIG welding or stick welding, which may require an alternative gas flow. The care and maintenance of the air flow is equally as important as operating the machine correctly. The Longevity Facility Testing Team has these suggestions:

Securely chain any and all cylinders containing gasses to a stationary, upright support or cart at all times.

Fasten the threaded protector cap to the top of the cylinder during movement or storage.

Immediately remove any faulty air flow regulator for service or repair.

Do not attempt to repair a faulty regulator on your own.

Use only Longevity Global Inc. recommended ferrules or clamps designed to connect hoses to fittings.

Never use ordinary wire for a substitute.

Always suspend the hose off the ground to keep it from being run over, stepped on or otherwise damaged.

Avoid long runs or coil excess hose to prevent kinks and tangles.

Examine all hose regularly for leaks, wear and loose connections.

Replace leaky or worn hoses, or repair them by cutting out damaged area and properly splicing in a new section.

Never splice hoses with tape. This does not ensure a safe seal

Hope its helps. . .

From United States, Fpo
raghuvaran chakkaravarthy

Welding is the union of pieces of metal by fusing the opposing surfaces, which have been made molten by heat. Processes similar to welding include brazing and soldering. Allied processes include the removal and cutting of metals. Common heat sources are the electric arc and oxy - gas flames. With electric arc welding the source of heat is an arc struck between the metals to be joined and an electrode. The electrode normally melts contributing to the molten pool between the pieces being joined. Gas welding/cutting entails heat being applied to the metal by the flame from a torch in which a gas, such as acetylene, is burnt with a supply of oxygen or air.


Physical injury - burns/eye injuries/electrocution/strains etc. from manual handling.

Gases - nitrogen oxides, ozone and others.

Fumes - from the electrode, parent metals or coating/ contamination of the parent metal.

Fire and explosion.

Discomfort - Fumes and heat.

Radiation - producing skin irritation or arc eye.HSE welding guidance


Protective clothing to suit the hazard (i.e. gloves, boots, overalls, aprons, eye protection) Appropriate selection, care and maintenance of equipment.

Suitable electrical protection (e.g. insulation and earthing) to be ensured. Efficient and convenient, means of switching off the power supply.

Observance of safe working practices .

Adequate information, instruction and training for employees.

Inspection and maintenance of all equipment by a competent person, with particular attention being paid to electrode holders, cables, plugs, sockets, clamps and earthing.


(The most commonly used gases are acetylene and propane)

HAZARDS include:

ˇ leaks (from joints, fittings etc.) causing fires and explosions.

ˇ enhanced fires and explosions due to oxygen.

ˇ fire and explosions inside the equipment due to :

ˇ burns

ˇ eye injuries (heat, intense light, ultra-violet radiation).

ˇ explosion from over pressurisation.

ˇ manual handling injuries from cylinders.


1. Provision of appropriate equipment and installations

ˇ Materials to be compatible with the gases used (construction, lubricants etc)

ˇ Oxygen service equipment in particular to be free of any

solid or liquid inorganic or organic contamination.

ˇ Cylinders to comply with the Pressure Systems Safety

ˇ Use of appropriate pressure regulators, capable of safely

handling the maximum supply pressure.

ˇ Use of suitable pressure gauges (cylinder contents and

outlet pressures)

ˇ Use of suitable rubber hose is recommended. These have reinforced outer

protective cover and resistant lining. Colour codings to be:

- red for acetylene and other fuel gases except LPG

- orange for LPG

- blue for oxygen

- black for non-combustible gases.

ˇ Use of suitable hose connections.

ˇ Use of suitable blow pipes suitable for the gases and process involved, producing a stable, adjustable flame and resistant to backfire.HSE welding guidance

2. Storage and Handling of Cylinders

ˇ Storage of LPG - See element on Liquefied Petroleum Gas (LPG) in this manual

ˇ Storage of other gases - preferably in clear open air;

secure; free or well separated from toxic/corrosive/combustible materials;

ˇ Cylinders for use to be stored and secured in upright position in a well, ventilated area within the workroom.

ˇ Avoid hazardous manual handling activities, use of wheeled trolleys etc.

3. Personal Protective Equipment (PPE)

ˇ Eye protection (goggles with double lenses to protect against glare and flying fragments (replaceable outer lens to be clear and the inner lens tinted)

ˇ Hand and arm protection

ˇ Flame retardant protective clothing

ˇ Safety footwear

4. Operating Procedures

ˇ Provision of adequate training for operatives and supervisors/managers

ˇ Establishment of emergency procedures including evacuation, backfires, acetylene cylinders in fires etc.

ˇ Prohibition on misuse of oxygen

ˇ Ensure good ventilation and working practices, to prevent exposure to substances above any Occupational Exposure Limits, and to prevent any dangerous accumulations of fuel gas.

5. Fire Procedures

ˇ Safe location for the work.

ˇ Removal or protection of combustible materials.

ˇ Provision of suitable fire-fighting equipment.

6. Maintenance, Examination and Testing of Equipment

ˇ In addition to pre-use checks it is recommended that the following are included in a system of regular examination:

- Leaks at connections.

- Damage to hoses.

ˇ The necessary frequency of such checks will depend on the frequency of use of the equipment and work conditions.

From United States, Fpo
hansa vyas

Dear Raghu,
great matter on welding safety.
i mean we cant get such information all together.
thanks a lot for sharing....
Do u have any ppt in hindi regarding welding as i m planning to place some instructions in work shop.
Especially welding & cutting of acid pipe lines coz we had one accident of acid burn though very minor still.
Waiting for reply from other members too....

From India, Udaipur
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