Dear all,
Welding is a job subject to many dangers. However, taking proper precautions, like wearing protective gear, maintaining safety procedures, and keeping equipment away from open flames, can decrease traumas and injuries on the job.
[Welding Safety: Beyond the Shields and Gloves](http://www.safetyrisk.com.au/category/ppe/)
All welders and most laymen know that a welder needs to wear a helmet/shield and gloves; however, there are many more safety precautions that a welder can take to ensure their safety and the safety of anyone in their vicinity. Let’s look at the safety beyond the shields and gloves.
Other Protective Equipment
Other equipment is available to protect welders from harm. Clothing, shoes, goggles, and helmets with respirators are also protective equipment available and required to protect welders from injury. The following describes equipment available:
- Clothing: The leather apron, sleeves, leg apron, coat, and cape and bib are protective clothing available. Certain clothing may be required, depending on your job.
- Shoes: Steel-toed work boots protect you from injury if anything should land on your toes.
- Goggles: Chipper’s goggles are required whenever chipping and grinding. Electrical welding processes also require goggles because weld splatter can occasionally enter the mask and could get in a welder’s eyes if not protected.
- Helmets with respirators (if required): During some operations, welders are required to wear helmets with respirators to protect them from hazardous gases.
General Safety Procedures
Generally, there are some safety procedures that apply to all welding jobs. They include:
- Never allow anyone to use your equipment if they are not authorized, especially if they are not experienced or trained.
- Ensure the area is protected from fire hazards before cutting or welding. Since your visibility is greatly hindered by your face shield, have someone spot you while you weld, when possible, to watch for fires.
- Protect yourself and others by screening or shielding everybody’s eyes from electric arcs and flashes. Placing a screen between workers, for example, can minimize eye injuries from direct eye contact with the arc.
- Keep oxygen and fuel gas cylinders upright and protect them from falling.
- Make sure drums, barrels, tanks, or other containers never contained flammable materials or were properly cleaned before welding. Properly washing includes washing with soap and water and purging with Argon.
- Always use a spark lighter to light torches. Never use an open flame.
- Completely depressurize and close valves on empty compressed gas cylinders. Remove leaky cylinders from service. Store cylinders away from grease and oil.
- Always make sure ventilation is adequate for each job. A build-up of toxic gases can not only harm you, but gases can kill you without warning.
- Never weld in water, because you risk electrocution. Ensure that the ground is dry and free of puddles before you lay on the ground to weld.
- Do not keep a lighter in your pocket while you weld. Even a small spark can cause an explosion.
Please put your inputs/points on this thread. It helps us in providing effective training to our employees.
From United States, Fpo
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510Welding is a job subject to many dangers. However, taking proper precautions, like wearing protective gear, maintaining safety procedures, and keeping equipment away from open flames, can decrease traumas and injuries on the job.
[Welding Safety: Beyond the Shields and Gloves](http://www.safetyrisk.com.au/category/ppe/)
All welders and most laymen know that a welder needs to wear a helmet/shield and gloves; however, there are many more safety precautions that a welder can take to ensure their safety and the safety of anyone in their vicinity. Let’s look at the safety beyond the shields and gloves.
Other Protective Equipment
Other equipment is available to protect welders from harm. Clothing, shoes, goggles, and helmets with respirators are also protective equipment available and required to protect welders from injury. The following describes equipment available:
- Clothing: The leather apron, sleeves, leg apron, coat, and cape and bib are protective clothing available. Certain clothing may be required, depending on your job.
- Shoes: Steel-toed work boots protect you from injury if anything should land on your toes.
- Goggles: Chipper’s goggles are required whenever chipping and grinding. Electrical welding processes also require goggles because weld splatter can occasionally enter the mask and could get in a welder’s eyes if not protected.
- Helmets with respirators (if required): During some operations, welders are required to wear helmets with respirators to protect them from hazardous gases.
General Safety Procedures
Generally, there are some safety procedures that apply to all welding jobs. They include:
- Never allow anyone to use your equipment if they are not authorized, especially if they are not experienced or trained.
- Ensure the area is protected from fire hazards before cutting or welding. Since your visibility is greatly hindered by your face shield, have someone spot you while you weld, when possible, to watch for fires.
- Protect yourself and others by screening or shielding everybody’s eyes from electric arcs and flashes. Placing a screen between workers, for example, can minimize eye injuries from direct eye contact with the arc.
- Keep oxygen and fuel gas cylinders upright and protect them from falling.
- Make sure drums, barrels, tanks, or other containers never contained flammable materials or were properly cleaned before welding. Properly washing includes washing with soap and water and purging with Argon.
- Always use a spark lighter to light torches. Never use an open flame.
- Completely depressurize and close valves on empty compressed gas cylinders. Remove leaky cylinders from service. Store cylinders away from grease and oil.
- Always make sure ventilation is adequate for each job. A build-up of toxic gases can not only harm you, but gases can kill you without warning.
- Never weld in water, because you risk electrocution. Ensure that the ground is dry and free of puddles before you lay on the ground to weld.
- Do not keep a lighter in your pocket while you weld. Even a small spark can cause an explosion.
Please put your inputs/points on this thread. It helps us in providing effective training to our employees.
From United States, Fpo
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Dear Raghu,
We can add the following points for safety measures:
- Use safety devices like NRV and ELCB.
- Use only certified welding and cutting sets.
- Do not leave your cutting set inside confined spaces.
- Get the atmosphere tested again before entering a confined space.
- Inspect the surrounding area before performing any welding job involving combustible materials.
- Utilize spark collectors.
- Barricade the area if welding at a height.
- Ensure earthing and bonding are done wherever required.
- Keep a source of water or fire extinguishers nearby.
Regards,
Hansa Vyas
From India, Udaipur
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We can add the following points for safety measures:
- Use safety devices like NRV and ELCB.
- Use only certified welding and cutting sets.
- Do not leave your cutting set inside confined spaces.
- Get the atmosphere tested again before entering a confined space.
- Inspect the surrounding area before performing any welding job involving combustible materials.
- Utilize spark collectors.
- Barricade the area if welding at a height.
- Ensure earthing and bonding are done wherever required.
- Keep a source of water or fire extinguishers nearby.
Regards,
Hansa Vyas
From India, Udaipur
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And the top ten welding safety tips are.....
These are only Ten of the many many welding mistakes that can be fatal. I use a bit of coarse language here in an attempt to keep it fun and hopefully you will actually pay attention. It just gets ignored until there is a problem.
1. Hauling oxygen and acetylene cylinders in your trunk. A little leak here,,, a little leak there… a static spark…boom!! Your --- is Killed! This goes for truck tool boxes also. Throwing a set of pony bottles in your truck tool box can turn into a bomb and…you guessed it …………can Kill your ---!
2. Moving high pressure cylinders with no protective cap. The cylinder falls…the valve gets knocked off…2500 psi escapes out of a hole the size of a nickel and you have a missile….Oops! Your --- or someone else’s --- just got Killed!!
3. Making oxygen and acetylene balloon bombs. A little fuel gas like acetylene…a little oxygen…mixed together in a balloon so that you can impress the neighbors on July 4th…a static spark between the 5 balloons you so hid so cleverly in a plastic garbage bag…boom!! Your --- is Killed!
4. Welding inside a tank or any enclosed area with Mig or Tig. Both use Argon. Argon is an inert, colorless, odorless gas that is about twice as heavy as air. It is almost like an invisible liquid the way it can fill up an unventilated room. No air, no life. Breathing Air with no oxygen in it will kill Your ---. In fact it will often kill 2 ---. You and your working partner who comes to try to rescue Your ---.
5. Welding in Water Can Kill Your ---. Don’t get a mental picture of standing in a bucket of water. I am more thinking of lying underneath a pipe making a weld with a puddle of water on the concrete that you didn’t quite get dried up. Granted welding current is low voltage and high amperage but it can still kill your ---.
6. Welding without a fire watch when there is stuff around you that can catch on fire. Welding requires skill. Skill requires focus and attention. Put that together with the fact that you’re wearing a welding helmet and can’t see what might be catching on fire and you have a situation that could definitely Kill your ---.
7. Welding a gas tank or any container that held something flammable. Special precautions can be taken that can actually make it pretty safe (like washing the tank with soap and water and then purging with argon) but if you are not thorough enough or forget something or don’t purge well enough……You guessed it…It can totally Kill your ---.
8. Blowing off your clothes with oxygen from a cutting torch can turn you into a roman candle and you guessed it…Can Kill Your ---.!
9. Inflating a tire with Oxygen is a really bad idea and can be a lot worse than having a under inflated or flat tire. Why? I am glad you asked. Because it can explode and Kill your ---!
10. Keeping a Bic Lighter in your shirt pocket while welding is like playing Russian roulette. One little spark and you get to experience what its like to have an eighth of a stick of dynamite explode a few inches from your heart. Uh...I mean...I am no Doctor... but I am pretty sure this could Kill your --- too?
keep on share your expertise with us. . .
From United States, Fpo
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These are only Ten of the many many welding mistakes that can be fatal. I use a bit of coarse language here in an attempt to keep it fun and hopefully you will actually pay attention. It just gets ignored until there is a problem.
1. Hauling oxygen and acetylene cylinders in your trunk. A little leak here,,, a little leak there… a static spark…boom!! Your --- is Killed! This goes for truck tool boxes also. Throwing a set of pony bottles in your truck tool box can turn into a bomb and…you guessed it …………can Kill your ---!
2. Moving high pressure cylinders with no protective cap. The cylinder falls…the valve gets knocked off…2500 psi escapes out of a hole the size of a nickel and you have a missile….Oops! Your --- or someone else’s --- just got Killed!!
3. Making oxygen and acetylene balloon bombs. A little fuel gas like acetylene…a little oxygen…mixed together in a balloon so that you can impress the neighbors on July 4th…a static spark between the 5 balloons you so hid so cleverly in a plastic garbage bag…boom!! Your --- is Killed!
4. Welding inside a tank or any enclosed area with Mig or Tig. Both use Argon. Argon is an inert, colorless, odorless gas that is about twice as heavy as air. It is almost like an invisible liquid the way it can fill up an unventilated room. No air, no life. Breathing Air with no oxygen in it will kill Your ---. In fact it will often kill 2 ---. You and your working partner who comes to try to rescue Your ---.
5. Welding in Water Can Kill Your ---. Don’t get a mental picture of standing in a bucket of water. I am more thinking of lying underneath a pipe making a weld with a puddle of water on the concrete that you didn’t quite get dried up. Granted welding current is low voltage and high amperage but it can still kill your ---.
6. Welding without a fire watch when there is stuff around you that can catch on fire. Welding requires skill. Skill requires focus and attention. Put that together with the fact that you’re wearing a welding helmet and can’t see what might be catching on fire and you have a situation that could definitely Kill your ---.
7. Welding a gas tank or any container that held something flammable. Special precautions can be taken that can actually make it pretty safe (like washing the tank with soap and water and then purging with argon) but if you are not thorough enough or forget something or don’t purge well enough……You guessed it…It can totally Kill your ---.
8. Blowing off your clothes with oxygen from a cutting torch can turn you into a roman candle and you guessed it…Can Kill Your ---.!
9. Inflating a tire with Oxygen is a really bad idea and can be a lot worse than having a under inflated or flat tire. Why? I am glad you asked. Because it can explode and Kill your ---!
10. Keeping a Bic Lighter in your shirt pocket while welding is like playing Russian roulette. One little spark and you get to experience what its like to have an eighth of a stick of dynamite explode a few inches from your heart. Uh...I mean...I am no Doctor... but I am pretty sure this could Kill your --- too?
keep on share your expertise with us. . .
From United States, Fpo
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OCCUPATIONAL HEALTH AND HAZARDS - WELDING AND FLAME CUTTING FUMES
What are the health hazards of flame cutting?
Welding and flame cutting are so dangerous that there is a whole section dedicated to welding in the Occupational Health and Safety Act's General Safety Regulations.
Welding is not a straightforward hazard since there are many chemicals to consider when dealing with welding. For instance, the question needs to be asked: on what am I going to weld? Is the object that I am going to weld made of copper, aluminum, steel, etc.? With what is the object that I am going to weld coated? For example, it can be coated with paint, lead, tar, etc. The types of gases used during the welding process, like nitrogen oxide, propane, carbon monoxide, etc., are also dangerous towards the welder's health. All this causes different health hazards when melted during the welding process as it is breathed into the lungs. The radiation generated during the welding process also needs to be considered.
Why is welding and flame cutting so dangerous to my health?
When metal is melted above the melting point, it starts to condensate in the air. During the condensation period, it forms small dust particles that are so small that they are breathed into the deeper parts of your lungs. The welding fumes may comprise particles that contain chromium, copper, manganese, iron, etc., depending on what the welder is welding.
Exposure to welding fumes over many years may cause a metallic taste in the mouth, irritation of the eyes, nose, and throat, and a tight feeling in the chest.
Work-related diseases (occupational diseases) like occupational asthma or pneumoconiosis (a dusty lung) may develop over many years of exposure to welding fumes.
Metal fumes may also cause the welder to get "metal fume fever" or also called "Monday fever." Typical symptoms of metal fume fever are nausea, headache, painful limbs, and thirst. It usually occurs when the welder was off on the weekend and when he returns to work on a Monday, he is re-exposed to these fumes. From there, the name "Monday fever."
Most of the gases used during the welding process are asphyxiants (causing suffocation). Asphyxiants dilute atmospheric oxygen to below the required levels to maintain the oxygen levels in a person's body. Therefore, it is important that welding must take place in a well-ventilated area to prevent the suffocation of the welder. This is also the reason why welders mostly complain of tiredness because their oxygen levels in their bodies are suppressed by the gases they use during the welding process. Welding on ferrous alloys creates carbon monoxide that binds with your red blood cells, preventing the oxygen from being transferred from your blood to your body cells. Repeated exposure to carbon monoxide could affect your central nervous system, causing you to get dizzy, irritated, and impair your memory.
Arc welding emits radiation that causes the surface of your eyes to get ultraviolet burns that are just like sunburn to your eyes. Ultraviolet production is doubled during gas-shielded argon welding. The typical name under welders for this condition of the eyes is "arc eyes."
Welding in confined spaces or enclosed areas can be fatally dangerous, and the welder needs to establish if there are any toxic substances in the air before he starts with the welding process. If any toxic substances are present, the welder must ensure that the air is decontaminated from the substance and stays decontaminated during the welding process. A competent person must give the welder a permit that declares the confined space safe from toxic substances and/or explosives before he can commence welding.
What must my employer do to protect my health and safety during welding or flame cutting?
1. Your employer must establish safe work procedures and ensure that you are trained in them.
2. You must be provided with a face mask that is specifically designed to protect your breathing area from not breathing in these fumes. A general dust mask will not give you protection. The masks must be provided free of charge.
3. Your employer must have the air tested by an approved person according to the Occupational Health and Safety Act to determine the levels of metal fumes you are exposed to.
4. Your employer must supply you with the following protective clothing free of charge: body protection, hand protection, eye protection, face protection, foot protection, and protection of your breathing area. This is stipulated in the General Safety Regulations of the Occupational Health and Safety Act.
5. Your employer must have a copy of the Occupational Health and Safety Act and must show it to you upon request.
6. If you are a production welder, your employer can install an exhaust ventilation system in the area where you are welding and as close as possible to the source of welding to extract the fumes away from you.
7. If you are a maintenance welder, your risk is much higher since your environment is constantly changing, and your employer must expect you to do a hazard/risk assessment before you start welding.
8. Your employer must send you for medical examinations.
What must I do to protect my health and safety when working with welding or flame cutting?
1. You must look after your personal protective clothing and ensure that you wear all of it during the welding process.
2. You must ask your health and safety representative to show you the correct way to apply the mask to your face.
3. You must always do a risk/hazard assessment before commencing welding in a new environment.
4. Never commence welding in a confined space without the permit issued by a competent person.
5. Always go for your medical examinations when you are scheduled to do so. Remember, the Hazardous Chemical Substances Regulation of the Occupational Health and Safety Act requires you to undergo a medical surveillance program if exposed to significant levels of welding fumes!
6. Make sure that you know the contents of the safe work procedures.
What type of medical examinations must I get when I am a welder or flame cutter?
1. Before (or within the first 30 days after starting at a new company) you start working at a company, you must get an "entry" medical examination. This examination must include a chest x-ray as well as a lung function test. The chest x-ray is to determine a possible dusty lung and the lung function to determine possible damage to the normal ventilation of your lungs, as in the case of occupational asthma. This is also your proof of the status of your health before you start working at the company and is therefore also called your "Baseline" medical.
2. Then you need to get a chest x-ray and a lung function test every year to detect early deterioration of your lungs. This is important since lung disease is mostly irreversible. Your eyes and skin also need to be checked since welding poses a radiation risk to you.
3. If you are exposed to arsenic, cadmium, chromium, lead, fluorides, or carbon monoxide, biological monitoring needs to be done on you. This means that either a blood or urine sample must be collected from you and sent off to a laboratory to determine if there is any damage done by these substances to your body.
4. When you leave the service of the company, an exit medical examination needs to be done for the same reasons that the entry medical examination was done.
Hope it helps. . .
From United States, Fpo
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What are the health hazards of flame cutting?
Welding and flame cutting are so dangerous that there is a whole section dedicated to welding in the Occupational Health and Safety Act's General Safety Regulations.
Welding is not a straightforward hazard since there are many chemicals to consider when dealing with welding. For instance, the question needs to be asked: on what am I going to weld? Is the object that I am going to weld made of copper, aluminum, steel, etc.? With what is the object that I am going to weld coated? For example, it can be coated with paint, lead, tar, etc. The types of gases used during the welding process, like nitrogen oxide, propane, carbon monoxide, etc., are also dangerous towards the welder's health. All this causes different health hazards when melted during the welding process as it is breathed into the lungs. The radiation generated during the welding process also needs to be considered.
Why is welding and flame cutting so dangerous to my health?
When metal is melted above the melting point, it starts to condensate in the air. During the condensation period, it forms small dust particles that are so small that they are breathed into the deeper parts of your lungs. The welding fumes may comprise particles that contain chromium, copper, manganese, iron, etc., depending on what the welder is welding.
Exposure to welding fumes over many years may cause a metallic taste in the mouth, irritation of the eyes, nose, and throat, and a tight feeling in the chest.
Work-related diseases (occupational diseases) like occupational asthma or pneumoconiosis (a dusty lung) may develop over many years of exposure to welding fumes.
Metal fumes may also cause the welder to get "metal fume fever" or also called "Monday fever." Typical symptoms of metal fume fever are nausea, headache, painful limbs, and thirst. It usually occurs when the welder was off on the weekend and when he returns to work on a Monday, he is re-exposed to these fumes. From there, the name "Monday fever."
Most of the gases used during the welding process are asphyxiants (causing suffocation). Asphyxiants dilute atmospheric oxygen to below the required levels to maintain the oxygen levels in a person's body. Therefore, it is important that welding must take place in a well-ventilated area to prevent the suffocation of the welder. This is also the reason why welders mostly complain of tiredness because their oxygen levels in their bodies are suppressed by the gases they use during the welding process. Welding on ferrous alloys creates carbon monoxide that binds with your red blood cells, preventing the oxygen from being transferred from your blood to your body cells. Repeated exposure to carbon monoxide could affect your central nervous system, causing you to get dizzy, irritated, and impair your memory.
Arc welding emits radiation that causes the surface of your eyes to get ultraviolet burns that are just like sunburn to your eyes. Ultraviolet production is doubled during gas-shielded argon welding. The typical name under welders for this condition of the eyes is "arc eyes."
Welding in confined spaces or enclosed areas can be fatally dangerous, and the welder needs to establish if there are any toxic substances in the air before he starts with the welding process. If any toxic substances are present, the welder must ensure that the air is decontaminated from the substance and stays decontaminated during the welding process. A competent person must give the welder a permit that declares the confined space safe from toxic substances and/or explosives before he can commence welding.
What must my employer do to protect my health and safety during welding or flame cutting?
1. Your employer must establish safe work procedures and ensure that you are trained in them.
2. You must be provided with a face mask that is specifically designed to protect your breathing area from not breathing in these fumes. A general dust mask will not give you protection. The masks must be provided free of charge.
3. Your employer must have the air tested by an approved person according to the Occupational Health and Safety Act to determine the levels of metal fumes you are exposed to.
4. Your employer must supply you with the following protective clothing free of charge: body protection, hand protection, eye protection, face protection, foot protection, and protection of your breathing area. This is stipulated in the General Safety Regulations of the Occupational Health and Safety Act.
5. Your employer must have a copy of the Occupational Health and Safety Act and must show it to you upon request.
6. If you are a production welder, your employer can install an exhaust ventilation system in the area where you are welding and as close as possible to the source of welding to extract the fumes away from you.
7. If you are a maintenance welder, your risk is much higher since your environment is constantly changing, and your employer must expect you to do a hazard/risk assessment before you start welding.
8. Your employer must send you for medical examinations.
What must I do to protect my health and safety when working with welding or flame cutting?
1. You must look after your personal protective clothing and ensure that you wear all of it during the welding process.
2. You must ask your health and safety representative to show you the correct way to apply the mask to your face.
3. You must always do a risk/hazard assessment before commencing welding in a new environment.
4. Never commence welding in a confined space without the permit issued by a competent person.
5. Always go for your medical examinations when you are scheduled to do so. Remember, the Hazardous Chemical Substances Regulation of the Occupational Health and Safety Act requires you to undergo a medical surveillance program if exposed to significant levels of welding fumes!
6. Make sure that you know the contents of the safe work procedures.
What type of medical examinations must I get when I am a welder or flame cutter?
1. Before (or within the first 30 days after starting at a new company) you start working at a company, you must get an "entry" medical examination. This examination must include a chest x-ray as well as a lung function test. The chest x-ray is to determine a possible dusty lung and the lung function to determine possible damage to the normal ventilation of your lungs, as in the case of occupational asthma. This is also your proof of the status of your health before you start working at the company and is therefore also called your "Baseline" medical.
2. Then you need to get a chest x-ray and a lung function test every year to detect early deterioration of your lungs. This is important since lung disease is mostly irreversible. Your eyes and skin also need to be checked since welding poses a radiation risk to you.
3. If you are exposed to arsenic, cadmium, chromium, lead, fluorides, or carbon monoxide, biological monitoring needs to be done on you. This means that either a blood or urine sample must be collected from you and sent off to a laboratory to determine if there is any damage done by these substances to your body.
4. When you leave the service of the company, an exit medical examination needs to be done for the same reasons that the entry medical examination was done.
Hope it helps. . .
From United States, Fpo
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Dear All, Please see the attached Welding Cutting Brazing Safety training Presentation with Quiz. . . Hope its helps. . . Keep on sharing
From United States, Fpo
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From United States, Fpo
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Dear Raghu,
Great contribution and effort. I am sure a lot of members in the forum will benefit from this thread. Nice write-ups and presentations. Thanks for sharing.
Now, I am just sharing a photograph related to welding as my contribution to the thread. I would like to request all other members to come forward with your contributions, questions, or suggestions regarding the subject.
Thank you.
From India
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Great contribution and effort. I am sure a lot of members in the forum will benefit from this thread. Nice write-ups and presentations. Thanks for sharing.
Now, I am just sharing a photograph related to welding as my contribution to the thread. I would like to request all other members to come forward with your contributions, questions, or suggestions regarding the subject.
Thank you.
From India
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Dear all, Please take a look on attached Welding, Cutting and Brazing safety presentation. . . Hope its helps. . .
From United States, Fpo
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From United States, Fpo
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Fire Safety in Welding & Gas Cutting Operations
Welding and cutting are common industrial and construction operations. The associated hazards include fire and explosion, electric shock, burns, exposure to radiation, and toxic fumes and gases. Workers performing these operations must be fully conversant with all safe practices.
Safe Practices
OXY-ACETYLENE WELDING/CUTTING:
Equipment Check
Ensure that the torch tip is free from dirt and metal debris.
Move any leaking cylinder away immediately.
Check for leaks around regulators, hoses, fittings, and nozzles using a soap solution. Faulty equipment should be replaced promptly.
Equipment Set-up
Use a trolley for oxygen and acetylene cylinders and secure them with chains.
Arrange hoses to prevent tripping hazards.
Always use a red hose for acetylene and other fuel gases, and a black hose for oxygen, ensuring both are of equal length.
Before attaching the regulator to the cylinder, blow out foreign particles from the valve seat by shifting the valve.
Avoid using copper fittings on acetylene lines.
Attach flashback arresters to each regulator.
Select the appropriate welding/cutting nozzles.
Install a non-return valve in the fuel gas line.
Precautions
Stand back from the regulator when opening the cylinder valve. Turn the valve slowly to prevent damaging the regulator.
Leave key wrenches on cylinders in use for quick closure.
Do not exceed an acetylene pressure of 9 p.s.i.g.
Use only a friction/spark lighter to ignite the torch; never use matches, hot metal, or a welding arc.
When leaving a confined space, shut off the gas supply.
If gas runs out, extinguish the flame, connect the hose to a new cylinder, purge the line, and reignite the torch.
Purge regulators after welding and then turn them off.
Electrical Arc Welding: Equipment Check
Ensure splices are at least 3 meters away from the holder.
Regularly inspect insulation on the electrode holder, cables, and accessories; replace worn or damaged cables immediately.
Ensure cables and the power source are clean and free from dirt or grease.
Equipment Set-up
Ground the workpiece separately from the welding return connection. Never attach the ground cable to pipes containing flammable liquids or gases.
Arrange cables to avoid creating tripping hazards.
Cover lug terminals to prevent shorting out by a metal object.
Precautions
Use the current for which the cable is designed.
Place electrode stubs in containers.
Burn electrodes to a length of not less than 38 to 50 mm, as burning them further can damage the electrode holder.
After finishing a job, disconnect the welding machine from the power source and remove the electrode from its holder. Store the electrode holder safely.
General
Remove combustible materials from the work area or cover them with fire-resistant blankets before starting welding operations.
For work in a confined space, securely fasten cylinders and welding machines outside and provide proper ventilation.
Use a welder's screen of the correct specification.
Ensure all necessary personal protective equipment is used.
From United States, Fpo
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Welding and cutting are common industrial and construction operations. The associated hazards include fire and explosion, electric shock, burns, exposure to radiation, and toxic fumes and gases. Workers performing these operations must be fully conversant with all safe practices.
Safe Practices
OXY-ACETYLENE WELDING/CUTTING:
Equipment Check
Ensure that the torch tip is free from dirt and metal debris.
Move any leaking cylinder away immediately.
Check for leaks around regulators, hoses, fittings, and nozzles using a soap solution. Faulty equipment should be replaced promptly.
Equipment Set-up
Use a trolley for oxygen and acetylene cylinders and secure them with chains.
Arrange hoses to prevent tripping hazards.
Always use a red hose for acetylene and other fuel gases, and a black hose for oxygen, ensuring both are of equal length.
Before attaching the regulator to the cylinder, blow out foreign particles from the valve seat by shifting the valve.
Avoid using copper fittings on acetylene lines.
Attach flashback arresters to each regulator.
Select the appropriate welding/cutting nozzles.
Install a non-return valve in the fuel gas line.
Precautions
Stand back from the regulator when opening the cylinder valve. Turn the valve slowly to prevent damaging the regulator.
Leave key wrenches on cylinders in use for quick closure.
Do not exceed an acetylene pressure of 9 p.s.i.g.
Use only a friction/spark lighter to ignite the torch; never use matches, hot metal, or a welding arc.
When leaving a confined space, shut off the gas supply.
If gas runs out, extinguish the flame, connect the hose to a new cylinder, purge the line, and reignite the torch.
Purge regulators after welding and then turn them off.
Electrical Arc Welding: Equipment Check
Ensure splices are at least 3 meters away from the holder.
Regularly inspect insulation on the electrode holder, cables, and accessories; replace worn or damaged cables immediately.
Ensure cables and the power source are clean and free from dirt or grease.
Equipment Set-up
Ground the workpiece separately from the welding return connection. Never attach the ground cable to pipes containing flammable liquids or gases.
Arrange cables to avoid creating tripping hazards.
Cover lug terminals to prevent shorting out by a metal object.
Precautions
Use the current for which the cable is designed.
Place electrode stubs in containers.
Burn electrodes to a length of not less than 38 to 50 mm, as burning them further can damage the electrode holder.
After finishing a job, disconnect the welding machine from the power source and remove the electrode from its holder. Store the electrode holder safely.
General
Remove combustible materials from the work area or cover them with fire-resistant blankets before starting welding operations.
For work in a confined space, securely fasten cylinders and welding machines outside and provide proper ventilation.
Use a welder's screen of the correct specification.
Ensure all necessary personal protective equipment is used.
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Fire Safety in Welding & Gas Cutting Operations
Welding and cutting are common industrial operations. The associated hazards are fire and explosion, electric shock, burns, exposure to radiation, and toxic fumes and gases. Operations are required to be fully conversant with all safe practices.
Safe Practices
OXY-ACETYLENE WELDING/CUTTING:
Equipment Check
Ensure that the tip of the torch is free from dirt metal and move out any leaking cylinder immediately.
Check leaks around regulators, hoses/fittings & nozzle with soap solution. Faulty equipment should be changed immediately.
Equipment Set-up
Use a trolley for oxygen & acetylene cylinders and chain them.
Arrange hoses to avoid tripping hazards.
Always use a red hose for acetylene and other fuel gases and black for oxygen and ensure that both are in equal length.
Before attaching the regulator to the cylinder, it is necessary to shift the valve to blow out foreign particles from the valve seat.
Never use copper fittings on acetylene lines.
Attach flashback arresters to each regulator.
Select the proper welding/cutting nozzles.
A non-return valve should be installed in the fuel gas line.
Precautions
Always stand back from the regulator when opening the cylinder valve. Turn the valve slowly to avoid bursting the regulator.
Leave key wrenches on cylinders in use so they can be closed quickly.
Do not use an acetylene pressure greater than 9 p.s.i.g.
Use only a friction/spark lighter to light the torch. Never use matches, hot metal, or a welding arc.
When leaving a confined space (even if it is only for a break or lunch), shut off the gas supply.
If you run out of gas, extinguish the flame and connect the hose to the new cylinder. Purge the line before reigniting the torch.
Purge regulators after welding work is over and then turn off.
Electrical Arc Welding: Equipment Check
Make sure that splices are at least 3m away from the holder.
Regularly inspect insulation on the electrode holder, cables, and accessories; replace worn & damaged cables immediately.
Ensure the cable and power source are free from dirt/grease.
Equipment Set-up
Ground the workpiece separately from the welding return connection. Never attach the ground cable to pipes containing flammable liquids or gases.
Arrange cables so that they do not create tripping hazards.
Cover the lug terminals to prevent shorting out by a metal object.
Precautions
Use the current for which the cable is designed.
Place electrode stubs in containers.
Burn electrodes to not less than 38 to 50 mm in length. Burning them further damages the electrode holder.
When the job is finished, disconnect the welding machine from the power source and remove the electrode from its holder. Store the electrode holder in a safe place.
General
Remove combustible materials from the work area or cover them with fire-resistant blankets before starting the welding operations.
For work in a confined space, fasten cylinders/welding machines securely outside and provide proper ventilation.
Use a welder's screen of the correct specification.
Use all necessary personal protective equipment.
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Welding and cutting are common industrial operations. The associated hazards are fire and explosion, electric shock, burns, exposure to radiation, and toxic fumes and gases. Operations are required to be fully conversant with all safe practices.
Safe Practices
OXY-ACETYLENE WELDING/CUTTING:
Equipment Check
Ensure that the tip of the torch is free from dirt metal and move out any leaking cylinder immediately.
Check leaks around regulators, hoses/fittings & nozzle with soap solution. Faulty equipment should be changed immediately.
Equipment Set-up
Use a trolley for oxygen & acetylene cylinders and chain them.
Arrange hoses to avoid tripping hazards.
Always use a red hose for acetylene and other fuel gases and black for oxygen and ensure that both are in equal length.
Before attaching the regulator to the cylinder, it is necessary to shift the valve to blow out foreign particles from the valve seat.
Never use copper fittings on acetylene lines.
Attach flashback arresters to each regulator.
Select the proper welding/cutting nozzles.
A non-return valve should be installed in the fuel gas line.
Precautions
Always stand back from the regulator when opening the cylinder valve. Turn the valve slowly to avoid bursting the regulator.
Leave key wrenches on cylinders in use so they can be closed quickly.
Do not use an acetylene pressure greater than 9 p.s.i.g.
Use only a friction/spark lighter to light the torch. Never use matches, hot metal, or a welding arc.
When leaving a confined space (even if it is only for a break or lunch), shut off the gas supply.
If you run out of gas, extinguish the flame and connect the hose to the new cylinder. Purge the line before reigniting the torch.
Purge regulators after welding work is over and then turn off.
Electrical Arc Welding: Equipment Check
Make sure that splices are at least 3m away from the holder.
Regularly inspect insulation on the electrode holder, cables, and accessories; replace worn & damaged cables immediately.
Ensure the cable and power source are free from dirt/grease.
Equipment Set-up
Ground the workpiece separately from the welding return connection. Never attach the ground cable to pipes containing flammable liquids or gases.
Arrange cables so that they do not create tripping hazards.
Cover the lug terminals to prevent shorting out by a metal object.
Precautions
Use the current for which the cable is designed.
Place electrode stubs in containers.
Burn electrodes to not less than 38 to 50 mm in length. Burning them further damages the electrode holder.
When the job is finished, disconnect the welding machine from the power source and remove the electrode from its holder. Store the electrode holder in a safe place.
General
Remove combustible materials from the work area or cover them with fire-resistant blankets before starting the welding operations.
For work in a confined space, fasten cylinders/welding machines securely outside and provide proper ventilation.
Use a welder's screen of the correct specification.
Use all necessary personal protective equipment.
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General Safety Precautions for Gas Welding
Before starting gas welding or cutting, remove from the neighborhood any combustible material or anything that might be damaged by heat or sparks, which are often thrown a long distance. Containers that have held combustible or inflammable materials should be welded only after exercising proper precautions.
Fire extinguishers or sand should be available at hand. Do not weld in confined spaces without adequate ventilation or individual respiratory equipment. When welding inside boilers or other confined spaces, the gas cylinders must be kept outside, and the hose and its attachments thoroughly inspected for leakage. The gas flame should not be allowed to play even momentarily on the cylinders or their attachments. Do not pick up hot jobs or objects.
Use goggles with nonflammable lenses and frames. Never do any chipping or grinding without suitable goggles. Do not weld painted or galvanized surfaces in a badly ventilated space. Do not use matches for lighting torches as this may result in hand burns. Never attempt to relight a blowpipe that has blown out without first closing both valves and relighting in the proper manner.
If welding or cutting is to be stopped temporarily, release the pressure adjusting screws of the regulators by turning them to the left. If welding or cutting is to be stopped for a long time, close the cylinder valves and then release all gas pressures from the regulators and hose by opening the torch valves momentarily. Close the torch valves and release the pressure adjusting screws.
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Before starting gas welding or cutting, remove from the neighborhood any combustible material or anything that might be damaged by heat or sparks, which are often thrown a long distance. Containers that have held combustible or inflammable materials should be welded only after exercising proper precautions.
Fire extinguishers or sand should be available at hand. Do not weld in confined spaces without adequate ventilation or individual respiratory equipment. When welding inside boilers or other confined spaces, the gas cylinders must be kept outside, and the hose and its attachments thoroughly inspected for leakage. The gas flame should not be allowed to play even momentarily on the cylinders or their attachments. Do not pick up hot jobs or objects.
Use goggles with nonflammable lenses and frames. Never do any chipping or grinding without suitable goggles. Do not weld painted or galvanized surfaces in a badly ventilated space. Do not use matches for lighting torches as this may result in hand burns. Never attempt to relight a blowpipe that has blown out without first closing both valves and relighting in the proper manner.
If welding or cutting is to be stopped temporarily, release the pressure adjusting screws of the regulators by turning them to the left. If welding or cutting is to be stopped for a long time, close the cylinder valves and then release all gas pressures from the regulators and hose by opening the torch valves momentarily. Close the torch valves and release the pressure adjusting screws.
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Safety Requirements for Arc Welding and Cutting Equipment - Arc Welding Machines
Arc welding machines should be of suitable quality. The construction of arc welding machines should be such that they can operate satisfactorily even under conditions 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 exceed 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 grounded (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 shall be suitably enclosed and protected to meet the usual service conditions.
Neither terminal of the welding generator shall be bonded to the frame of the welding machine.
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.
Lubricate regularly; but overgreasing may foul the commutator.
Check and, if necessary, clean commutators periodically, using fine sandpaper.
Excessive sparking may result in a worn commutator which may be cured by skimming on a lathe.
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:
In transformers, the secondary circuit shall be thoroughly insulated from the primary.
Input terminals shall be completely enclosed and accessible only by means of tools.
The primary side of the transformer shall be provided with suitable wire terminals inside the machine case.
Welding (secondary) terminals shall be arranged so that current-carrying parts are not exposed to accidental contact.
In a transformer, the welding circuit should be separate from the power circuit to prevent the risk of the welder suffering serious shock or burns through power voltage appearing across the electrode holder.
At or near each welding machine, a disconnecting switch shall be provided.
Control apparatus provided with the welding machine shall be enclosed except for the operating wheels, levers, etc.
Transformer windings should be suction or compressed air cleaned periodically.
Greasing points need attention periodically.
Switch contacts should be cleaned periodically.
Before undertaking any maintenance work on welding machines, disconnect them from the main supply.
As for other arc welding equipment:
Electrode holders should be soundly connected to the welding lead and of adequate rating for the maximum welding current to prevent overheating.
Electrode holders shall be provided with discs or shields to protect the hands of the welder from the 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 to avoid potential electric shock.
Welding cables shall be completely insulated, flexible type capable of handling the maximum current requirements of the work, and kept dry and free from grease and oil to avoid premature breakdown of insulation.
The body or 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.
I hope this information helps.
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Arc welding machines should be of suitable quality. The construction of arc welding machines should be such that they can operate satisfactorily even under conditions 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 exceed 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 grounded (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 shall be suitably enclosed and protected to meet the usual service conditions.
Neither terminal of the welding generator shall be bonded to the frame of the welding machine.
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.
Lubricate regularly; but overgreasing may foul the commutator.
Check and, if necessary, clean commutators periodically, using fine sandpaper.
Excessive sparking may result in a worn commutator which may be cured by skimming on a lathe.
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:
In transformers, the secondary circuit shall be thoroughly insulated from the primary.
Input terminals shall be completely enclosed and accessible only by means of tools.
The primary side of the transformer shall be provided with suitable wire terminals inside the machine case.
Welding (secondary) terminals shall be arranged so that current-carrying parts are not exposed to accidental contact.
In a transformer, the welding circuit should be separate from the power circuit to prevent the risk of the welder suffering serious shock or burns through power voltage appearing across the electrode holder.
At or near each welding machine, a disconnecting switch shall be provided.
Control apparatus provided with the welding machine shall be enclosed except for the operating wheels, levers, etc.
Transformer windings should be suction or compressed air cleaned periodically.
Greasing points need attention periodically.
Switch contacts should be cleaned periodically.
Before undertaking any maintenance work on welding machines, disconnect them from the main supply.
As for other arc welding equipment:
Electrode holders should be soundly connected to the welding lead and of adequate rating for the maximum welding current to prevent overheating.
Electrode holders shall be provided with discs or shields to protect the hands of the welder from the 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 to avoid potential electric shock.
Welding cables shall be completely insulated, flexible type capable of handling the maximum current requirements of the work, and kept dry and free from grease and oil to avoid premature breakdown of insulation.
The body or 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.
I hope this information helps.
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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 is, in addition to being very bright, a source of infrared and ultraviolet light; consequently, the operator must use either 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 the 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. A 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 matte, absorbent type of paint with 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 if the metal being arc welded/cut has a high chromium content.
(ii) when the metal being arc or flame welded is galvanized.
Therefore, either a welder should work outdoors 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.
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(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 is, in addition to being very bright, a source of infrared and ultraviolet light; consequently, the operator must use either 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 the 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. A 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 matte, absorbent type of paint with 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 if the metal being arc welded/cut has a high chromium content.
(ii) when the metal being arc or flame welded is galvanized.
Therefore, either a welder should work outdoors 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.
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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 and 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 inflammable 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 the 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 the cylinder is kept in the sun, or a lighted blowpipe accidentally impinges upon the cylinder, or backfire takes place when the welder, by 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 the 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 include:
(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 cables in arc welding. If insulation is damaged, there may occur local arcing between the cable and any adjacent metalwork 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 cables 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 the 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.
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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 and 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 inflammable 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 the 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 the cylinder is kept in the sun, or a lighted blowpipe accidentally impinges upon the cylinder, or backfire takes place when the welder, by 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 the 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 include:
(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 cables in arc welding. If insulation is damaged, there may occur local arcing between the cable and any adjacent metalwork 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 cables 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 the 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.
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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.
The welder should wear dry and fireproof protective clothes (i.e., apron, gloves, etc.) to prevent the arc rays from reaching their body. One should not look at an electric arc with the naked eye. To prevent the 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. The welder should be completely insulated from the floor/work when changing electrodes.
The welder should not leave the electrode holder on the table or in contact with a grounded metallic surface. The welder should make use of goggles with clear glasses while chipping off scale, slag, etc. Adequate ventilation should be provided where welding is carried out.
Temporary or permanent booths may be installed to carry out welding operations. To avoid reflection, the 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 their helmet, and strike the arc. Welding operations 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.
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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.
The welder should wear dry and fireproof protective clothes (i.e., apron, gloves, etc.) to prevent the arc rays from reaching their body. One should not look at an electric arc with the naked eye. To prevent the 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. The welder should be completely insulated from the floor/work when changing electrodes.
The welder should not leave the electrode holder on the table or in contact with a grounded metallic surface. The welder should make use of goggles with clear glasses while chipping off scale, slag, etc. Adequate ventilation should be provided where welding is carried out.
Temporary or permanent booths may be installed to carry out welding operations. To avoid reflection, the 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 their helmet, and strike the arc. Welding operations 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
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Safety Recommendations for Hose or Gas Tubing.
Use the correct color hose for oxygen (green/black) and acetylene (red) and never use oxygen hose for acetylene or vice versa. Always protect the hose from being trampled on or run over. Avoid tangles 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 gets into the hose, blow through it (with oxygen, not acetylene) before coupling to the torch or regulator. Store the hose on a reel (an automobile wheel will do) when not in use.
From United States, Fpo
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Use the correct color hose for oxygen (green/black) and acetylene (red) and never use oxygen hose for acetylene or vice versa. Always protect the hose from being trampled on or run over. Avoid tangles 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 gets into the hose, blow through it (with oxygen, not acetylene) before coupling to the torch or regulator. Store the hose on a reel (an automobile wheel will do) when not in use.
From United States, Fpo
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Safety Recommendations for Gas Welding Pressure Regulators
Use the correct pressure regulator for a gas. For example, never use an 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 the 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 a lubricant of any kind on regulator connections.
From United States, Fpo
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Use the correct pressure regulator for a gas. For example, never use an 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 the 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 a lubricant of any kind on regulator connections.
From United States, Fpo
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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 galvanized metal, manganese steel, cadmium zinc, and some other non-ferrous metals may be very dangerous, toxic, and harmful to students. Additional precautions should be taken when welding these materials.
No welding or cutting should be carried out on containers that have held flammable materials because of the risk of explosions.
Level of Risk
The categorization 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 to 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 from 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.
Workers 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 workers 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
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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 galvanized metal, manganese steel, cadmium zinc, and some other non-ferrous metals may be very dangerous, toxic, and harmful to students. Additional precautions should be taken when welding these materials.
No welding or cutting should be carried out on containers that have held flammable materials because of the risk of explosions.
Level of Risk
The categorization 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 to 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 from 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.
Workers 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 workers 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
Acknowledge(0)Amend(0)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, lightweight, 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-yourselfers. Although we are excited to see the growing interest of the many applications of this technology, this also means that there are many new and inexperienced users. Therefore, 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 workspace and on your person. Keep all flammable materials at least 35 feet away from the workspace and cover yourself with the proper flame retardant gear.
Protect your eyes with approved safety glasses with side shields 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 workpiece can ignite the clothes on your body and cause severe burns. Use clothing made from tightly woven materials 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 gases, 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 the 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 workpiece. 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 failsafe 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 workpiece 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.
[B]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 exudes an incredible amount of visible and invisible (ultraviolet and infrared) light rays that 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.
[B]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 gases 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 wear 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.
[B]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 airflow is equally as important as operating the machine correctly. The Longevity Facility Testing Team has these suggestions:
Securely chain any and all cylinders containing gases 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 airflow 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 hoses regularly for leaks, wear, and loose connections.
Replace leaky or worn hoses, or repair them by cutting out the damaged area and properly splicing in a new section.
Never splice hoses with tape. This does not ensure a safe seal.
Hope it helps...
From United States, Fpo
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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.
ASSOCIATED HAZARDS (GENERAL)
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
ARC WELDING - PRECAUTIONS
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.
GAS WELDING
(The most commonly used gases are acetylene and propane)
HAZARDS include:
· leaks (from joints, fittings etc.) causing fires and explosions.
· enhanced fires and explosions due to oxygen.
· fire and explosions inside the equipment due to :
· burns
· eye injuries (heat, intense light, ultra-violet radiation).
· explosion from over pressurisation.
· manual handling injuries from cylinders.
PRECAUTIONS
1. Provision of appropriate equipment and installations
· Materials to be compatible with the gases used (construction, lubricants etc)
· Oxygen service equipment in particular to be free of any
solid or liquid inorganic or organic contamination.
· Cylinders to comply with the Pressure Systems Safety
· Use of appropriate pressure regulators, capable of safely
handling the maximum supply pressure.
· Use of suitable pressure gauges (cylinder contents and
outlet pressures)
· 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.
· Use of suitable hose connections.
· 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
· Storage of LPG - See element on Liquefied Petroleum Gas (LPG) in this manual
· Storage of other gases - preferably in clear open air;
secure; free or well separated from toxic/corrosive/combustible materials;
· Cylinders for use to be stored and secured in upright position in a well, ventilated area within the workroom.
· Avoid hazardous manual handling activities, use of wheeled trolleys etc.
3. Personal Protective Equipment (PPE)
· Eye protection (goggles with double lenses to protect against glare and flying fragments (replaceable outer lens to be clear and the inner lens tinted)
· Hand and arm protection
· Flame retardant protective clothing
· Safety footwear
4. Operating Procedures
· Provision of adequate training for operatives and supervisors/managers
· Establishment of emergency procedures including evacuation, backfires, acetylene cylinders in fires etc.
· Prohibition on misuse of oxygen
· 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
· Safe location for the work.
· Removal or protection of combustible materials.
· Provision of suitable fire-fighting equipment.
6. Maintenance, Examination and Testing of Equipment
· 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.
· The necessary frequency of such checks will depend on the frequency of use of the equipment and work conditions.
From United States, Fpo
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ASSOCIATED HAZARDS (GENERAL)
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
ARC WELDING - PRECAUTIONS
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.
GAS WELDING
(The most commonly used gases are acetylene and propane)
HAZARDS include:
· leaks (from joints, fittings etc.) causing fires and explosions.
· enhanced fires and explosions due to oxygen.
· fire and explosions inside the equipment due to :
· burns
· eye injuries (heat, intense light, ultra-violet radiation).
· explosion from over pressurisation.
· manual handling injuries from cylinders.
PRECAUTIONS
1. Provision of appropriate equipment and installations
· Materials to be compatible with the gases used (construction, lubricants etc)
· Oxygen service equipment in particular to be free of any
solid or liquid inorganic or organic contamination.
· Cylinders to comply with the Pressure Systems Safety
· Use of appropriate pressure regulators, capable of safely
handling the maximum supply pressure.
· Use of suitable pressure gauges (cylinder contents and
outlet pressures)
· 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.
· Use of suitable hose connections.
· 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
· Storage of LPG - See element on Liquefied Petroleum Gas (LPG) in this manual
· Storage of other gases - preferably in clear open air;
secure; free or well separated from toxic/corrosive/combustible materials;
· Cylinders for use to be stored and secured in upright position in a well, ventilated area within the workroom.
· Avoid hazardous manual handling activities, use of wheeled trolleys etc.
3. Personal Protective Equipment (PPE)
· Eye protection (goggles with double lenses to protect against glare and flying fragments (replaceable outer lens to be clear and the inner lens tinted)
· Hand and arm protection
· Flame retardant protective clothing
· Safety footwear
4. Operating Procedures
· Provision of adequate training for operatives and supervisors/managers
· Establishment of emergency procedures including evacuation, backfires, acetylene cylinders in fires etc.
· Prohibition on misuse of oxygen
· 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
· Safe location for the work.
· Removal or protection of combustible materials.
· Provision of suitable fire-fighting equipment.
6. Maintenance, Examination and Testing of Equipment
· 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.
· The necessary frequency of such checks will depend on the frequency of use of the equipment and work conditions.
From United States, Fpo
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Dear Raghu,
Great information on welding safety. It's not often we come across such comprehensive details in one place. Thank you for sharing.
Do you have any PowerPoint presentations in Hindi related to welding? I am planning to display some instructions in the workshop, particularly focusing on welding and cutting of acid pipelines due to a recent incident involving a minor acid burn.
I am also looking forward to hearing from other members.
Regards,
Hansa
From India, Udaipur
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Great information on welding safety. It's not often we come across such comprehensive details in one place. Thank you for sharing.
Do you have any PowerPoint presentations in Hindi related to welding? I am planning to display some instructions in the workshop, particularly focusing on welding and cutting of acid pipelines due to a recent incident involving a minor acid burn.
I am also looking forward to hearing from other members.
Regards,
Hansa
From India, Udaipur
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Dear Ragu,
Thank you very much for your valuable contribution. Today, I finally managed to go through this thread. You have covered the complete welding process, and I will delve into it leisurely, as your inputs are extensive. Dipil and Hansa, thank you for your contributions as well.
Please find some details from my side. Actually, the file named "Acetylene Cylinders" was initially prepared for Dipil. However, upon seeing this post, I decided to share it here too.
From India, Delhi
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Thank you very much for your valuable contribution. Today, I finally managed to go through this thread. You have covered the complete welding process, and I will delve into it leisurely, as your inputs are extensive. Dipil and Hansa, thank you for your contributions as well.
Please find some details from my side. Actually, the file named "Acetylene Cylinders" was initially prepared for Dipil. However, upon seeing this post, I decided to share it here too.
From India, Delhi
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Dear Raghu,
Good inputs again... Let's gather all that we need related to Welding here.
Dear KVS,
Thanks a lot for your concern and sharing information. The Acetylene cylinder write-up also did not clear my doubt. How will the acetone escape from the acetylene cylinder if it's idly kept in a horizontal condition? Is there a chance it will escape through the fusible plug? Please explain.
Dear All,
If anyone knows the answer, please come forward.
From India
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Good inputs again... Let's gather all that we need related to Welding here.
Dear KVS,
Thanks a lot for your concern and sharing information. The Acetylene cylinder write-up also did not clear my doubt. How will the acetone escape from the acetylene cylinder if it's idly kept in a horizontal condition? Is there a chance it will escape through the fusible plug? Please explain.
Dear All,
If anyone knows the answer, please come forward.
From India
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Dear all,
Please find the attached "ELECTRIC AND MAGNETIC FIELDS may be dangerous". Hope this information helps.
Dear KVS & Dipil,
Thanks for your input; it adds spirit to this thread.
Dear Hansa,
I have some documents in Hindi, but I do not know if they are related to hot work or not. (I only speak Hindi; I can't read it.) Sometimes, my friends explain Hindi articles. SORRY!
Thank you.
From United States, Fpo
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Please find the attached "ELECTRIC AND MAGNETIC FIELDS may be dangerous". Hope this information helps.
Dear KVS & Dipil,
Thanks for your input; it adds spirit to this thread.
Dear Hansa,
I have some documents in Hindi, but I do not know if they are related to hot work or not. (I only speak Hindi; I can't read it.) Sometimes, my friends explain Hindi articles. SORRY!
Thank you.
From United States, Fpo
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Dear all, Just take a look on attached "safety in gas welding and cutting similar process'' file. . . Hope this information’s helps Keep on sharing & gaining. . .
From United States, Fpo
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From United States, Fpo
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Dear Raghu,
Good work again... Thanks a lot and keep up the pace...
Dear All,
Let me provide more clarification regarding my last query.
Acetylene stored in a free state under pressure greater than 15 PSI can be made to break down by heat or shock and possibly explode. Under pressure of 29.4 PSI, acetylene becomes self-explosive, and a slight shock will cause it to explode spontaneously. However, when dissolved in acetone, it can be compressed into cylinders at pressures up to 250 PSI.
Acetylene, when not dissolved in a solvent (free acetylene), can begin to dissociate (decompose) at pressures above 15 pounds per square inch gauge (psig). The products of dissociation are carbon, in the form of lampblack, and hydrogen. Considerable amounts of heat are generated by dissociation, which may produce explosions of great violence.
To prevent the loss of acetone, which reduces the cylinder's ability to hold dissolved acetylene, always store and use acetylene cylinders in an upright position.
Now, my question is how the acetone will escape from the cylinder if we store it in a horizontal position? Does it always happen, or is there a probability for the same to occur?
Thank you.
From India
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Good work again... Thanks a lot and keep up the pace...
Dear All,
Let me provide more clarification regarding my last query.
Acetylene stored in a free state under pressure greater than 15 PSI can be made to break down by heat or shock and possibly explode. Under pressure of 29.4 PSI, acetylene becomes self-explosive, and a slight shock will cause it to explode spontaneously. However, when dissolved in acetone, it can be compressed into cylinders at pressures up to 250 PSI.
Acetylene, when not dissolved in a solvent (free acetylene), can begin to dissociate (decompose) at pressures above 15 pounds per square inch gauge (psig). The products of dissociation are carbon, in the form of lampblack, and hydrogen. Considerable amounts of heat are generated by dissociation, which may produce explosions of great violence.
To prevent the loss of acetone, which reduces the cylinder's ability to hold dissolved acetylene, always store and use acetylene cylinders in an upright position.
Now, my question is how the acetone will escape from the cylinder if we store it in a horizontal position? Does it always happen, or is there a probability for the same to occur?
Thank you.
From India
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Dear Dipil, Now I got your query frankly I say I am not aware of this it’s new to me. . . I am also waiting for seniors reply. . . Keep on sharing & gaining. . .
From United States, Fpo
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From United States, Fpo
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I had written a procedure on this subject sometime in 2006 for a client in Sudan. Maybe an useful addition to this discussion. Rgds Gopi
From Malaysia, Kuala Lumpur
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From Malaysia, Kuala Lumpur
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Welding Safety
Welding is the most common method of joining metals in the industry today. When welded, two pieces of similar metals are fused (melted) together. Once completed, the welded joint is as strong or stronger than the pieces from which the joint is formed.
General hazards of welding include impact, penetration, harmful dust, smoke, fumes, heat, and light radiation. The proper personal protective equipment can protect you from these hazards.
Types of Welding -- Gas Welding, Arc Welding, Oxygen and Arc Cutting
Gas Welding -- In gas welding, two metals are joined by melting or fusing their adjoining surfaces. This is done by directing a gas flame over the metals until a molten puddle is formed. The energy for gas welding comes from the combustion of a fuel with oxygen or air. A few of the most popular fuels are acetylene, Mapp gas, and hydrogen. Since gas welding is slower and easier to control than electric arc welding, it is often used in applications such as general maintenance work, brazing, and soldering.
Arc Welding -- Arc welding involves a different process - two metals are joined by generating an electric arc between a covered metal electrode and the base metals. Heat is produced by the arc which in turn melts the metal and mixes the molten deposits of the coated electrode. The arc energy is provided by a power supply unit that furnishes direct or alternating current. The electrodes carry the current to form the arc, producing a gas that shields the arc from the atmosphere, and add metal to control the weld shape.
When an arc is struck using a coated electrode, the intense heat melts the top of the electrode. The drops of metal from the electrode enter the arc stream and are deposited on the base metal.
The equipment needed for electric arc welding is a power supply, electrode holder, ground clamp, protective shield, and welder's protective clothing.
Oxygen and Arc Cutting -- Metal cutting in welding is the severing or removal of metal by a flame or arc. The most common cutting processes are:
Oxygen Cutting: Metal is heated by a gas flame and an oxygen jet does the cutting.
Arc Cutting: The intense heat of the electric arc melts away the metal.
Personal Protective Equipment
Eye and Face Protection -- Proper eye and face protection vary depending on the particular task being performed. A helmet, hand shield, goggles, and safety glasses, or a combination of these, are acceptable protection in various applications. All filter lenses and plates must meet the test for the transmission of radiant energy prescribed in the ANSI standard Z87.1968, Practice for Occupational and Educational Eye and Face Protection.
According to OSHA 29 CFR 1910.252, "Helmets and hand shields shall protect the face, forehead, neck, and ears to a vertical line in back of the ears, from the arc direct radiant energy, and weld splatter."
Welding helmets with filter plates are intended to protect users from arc rays and from weld sparks and spatters that strike directly against the helmet. They are not intended to protect against slag chips, grinding fragments, wire wheel bristles, and similar hazards that can ricochet under the helmet. Spectacles, goggles, or other appropriate eye protection must also be worn to protect against these impact hazards.
Protective Clothing -- According to ANSI Z49.1.88-Welding and Cutting (4.3), appropriate protective clothing for any welding and cutting operation will vary with the size, nature, and location of the work to be performed. Clothing shall provide sufficient coverage and be made of suitable materials to minimize skin burns caused by sparks, spatter, or radiation. Covering all parts of the body is recommended to protect against ultraviolet and infrared ray flash burn.
Dark clothing works best to reduce reflection under the face shield. Heavier materials such as wool clothing, heavy cotton, or leather are preferred as they resist deterioration. Materials that can melt or can cause severe burns due to sparks that may lodge in rolled-up sleeves, pockets of clothing, or pant cuffs are not recommended.
The ANSI standard requires all welders and cutters to wear protective flame-resistant gloves, such as leather welder's gloves, which provide the heat resistance needed for welding. A gauntlet cuff offers additional arm protection, and insulated linings should be used to protect areas exposed to high radiant energy.
Other protective clothing would include durable, flame-resistant aprons made of leather or other suitable materials to provide protection to the front of the body when additional protection against sparks and radiant energy is needed.
Ventilation
Ventilation refers to changes of room air as often as necessary to prevent welders and other workers from breathing high levels of airborne contaminants. Ventilation is a means of providing adequate breathing air, and must be provided for all welding, cutting, brazing, and related operations. Adequate ventilation depends on the following factors:
Volume and configuration of the space where the welding operations occur
Number and type of operations that are generating contaminants
Natural airflow rate where operations are taking place
Locations of the welders' and other workers' breathing zones in relation to the contaminants or sources
Proper ventilation can be obtained either naturally or mechanically.
Natural Ventilation -- Natural ventilation is considered sufficient for welding and brazing operations if the present work area meets these requirements:
Space of more than 10,000 square feet is provided per welder;
A ceiling height of more than 16 feet
Welding is not done in a confined space
Welding space does not contain partitions, balconies, or structured barriers that obstruct cross ventilation
If your specific operation does not fall within these guidelines, mechanical ventilation will be required.
Mechanical Ventilation -- Mechanical ventilation options generally fall into two basic categories. The first is the low vacuum system, which takes large volumes of air at low velocities. These systems consist of hoods positioned at a distance from the work area. The hood and housing may have to be repositioned by the worker to get maximum benefit from this means of ventilation. Hoods generally remove the fumes and contaminated air through ducting and exhaust the contaminants to the outdoors. Hoods should be placed as near as practical to the work and should provide effective airflow with a velocity of 100 linear feet (30m) per minute at its most remote distance from the point of welding. Processes where low vacuum systems work best are arc air gouging, taking afterburner, and arc cutting.
Another category of mechanical ventilation is the high vacuum system. These are close-range extractors that are aimed at capturing and extracting fumes as near to the work as possible. Fume extractors often have an immediate area of welding. By removing a small volume of air at high velocity, the potentially hazardous materials are effectively removed before reaching the welder's breathing zone. These systems often are equipped with a fan that pulls the contaminants into a filtration system, with a HEPA (High Efficiency Particulate Absolute) filter or combination of HEPA filter and prefilter and then recirculated the clean air back into the work area. Advantages of high vacuum systems are greater flexibility for job adaptation, more efficient means of fume removal, and greater visibility to the welder due to reduced clouds of fumes and vapors being created.
Fumes and gases from welding and cutting cannot be easily classified. The quantity of fumes and gases is relative to the metal being worked and the processes and consumable material being used (such as coatings, like paint, galvanizing, and platings), along with contaminants in the atmosphere (such as halogenated hydrocarbon vapors from cleaning and degreasing activities).
Air sampling to verify the concentration levels of toxic fumes and gases is necessary, and respiratory protection is required along with mechanical ventilation in the cutting and/or welding of certain metals and compounds. For more information, see OSHA 29 CFR 1910.252 on welding regulations.
Hope the information helps. Keep on sharing and gaining.
From United States, Fpo
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Welding is the most common method of joining metals in the industry today. When welded, two pieces of similar metals are fused (melted) together. Once completed, the welded joint is as strong or stronger than the pieces from which the joint is formed.
General hazards of welding include impact, penetration, harmful dust, smoke, fumes, heat, and light radiation. The proper personal protective equipment can protect you from these hazards.
Types of Welding -- Gas Welding, Arc Welding, Oxygen and Arc Cutting
Gas Welding -- In gas welding, two metals are joined by melting or fusing their adjoining surfaces. This is done by directing a gas flame over the metals until a molten puddle is formed. The energy for gas welding comes from the combustion of a fuel with oxygen or air. A few of the most popular fuels are acetylene, Mapp gas, and hydrogen. Since gas welding is slower and easier to control than electric arc welding, it is often used in applications such as general maintenance work, brazing, and soldering.
Arc Welding -- Arc welding involves a different process - two metals are joined by generating an electric arc between a covered metal electrode and the base metals. Heat is produced by the arc which in turn melts the metal and mixes the molten deposits of the coated electrode. The arc energy is provided by a power supply unit that furnishes direct or alternating current. The electrodes carry the current to form the arc, producing a gas that shields the arc from the atmosphere, and add metal to control the weld shape.
When an arc is struck using a coated electrode, the intense heat melts the top of the electrode. The drops of metal from the electrode enter the arc stream and are deposited on the base metal.
The equipment needed for electric arc welding is a power supply, electrode holder, ground clamp, protective shield, and welder's protective clothing.
Oxygen and Arc Cutting -- Metal cutting in welding is the severing or removal of metal by a flame or arc. The most common cutting processes are:
Oxygen Cutting: Metal is heated by a gas flame and an oxygen jet does the cutting.
Arc Cutting: The intense heat of the electric arc melts away the metal.
Personal Protective Equipment
Eye and Face Protection -- Proper eye and face protection vary depending on the particular task being performed. A helmet, hand shield, goggles, and safety glasses, or a combination of these, are acceptable protection in various applications. All filter lenses and plates must meet the test for the transmission of radiant energy prescribed in the ANSI standard Z87.1968, Practice for Occupational and Educational Eye and Face Protection.
According to OSHA 29 CFR 1910.252, "Helmets and hand shields shall protect the face, forehead, neck, and ears to a vertical line in back of the ears, from the arc direct radiant energy, and weld splatter."
Welding helmets with filter plates are intended to protect users from arc rays and from weld sparks and spatters that strike directly against the helmet. They are not intended to protect against slag chips, grinding fragments, wire wheel bristles, and similar hazards that can ricochet under the helmet. Spectacles, goggles, or other appropriate eye protection must also be worn to protect against these impact hazards.
Protective Clothing -- According to ANSI Z49.1.88-Welding and Cutting (4.3), appropriate protective clothing for any welding and cutting operation will vary with the size, nature, and location of the work to be performed. Clothing shall provide sufficient coverage and be made of suitable materials to minimize skin burns caused by sparks, spatter, or radiation. Covering all parts of the body is recommended to protect against ultraviolet and infrared ray flash burn.
Dark clothing works best to reduce reflection under the face shield. Heavier materials such as wool clothing, heavy cotton, or leather are preferred as they resist deterioration. Materials that can melt or can cause severe burns due to sparks that may lodge in rolled-up sleeves, pockets of clothing, or pant cuffs are not recommended.
The ANSI standard requires all welders and cutters to wear protective flame-resistant gloves, such as leather welder's gloves, which provide the heat resistance needed for welding. A gauntlet cuff offers additional arm protection, and insulated linings should be used to protect areas exposed to high radiant energy.
Other protective clothing would include durable, flame-resistant aprons made of leather or other suitable materials to provide protection to the front of the body when additional protection against sparks and radiant energy is needed.
Ventilation
Ventilation refers to changes of room air as often as necessary to prevent welders and other workers from breathing high levels of airborne contaminants. Ventilation is a means of providing adequate breathing air, and must be provided for all welding, cutting, brazing, and related operations. Adequate ventilation depends on the following factors:
Volume and configuration of the space where the welding operations occur
Number and type of operations that are generating contaminants
Natural airflow rate where operations are taking place
Locations of the welders' and other workers' breathing zones in relation to the contaminants or sources
Proper ventilation can be obtained either naturally or mechanically.
Natural Ventilation -- Natural ventilation is considered sufficient for welding and brazing operations if the present work area meets these requirements:
Space of more than 10,000 square feet is provided per welder;
A ceiling height of more than 16 feet
Welding is not done in a confined space
Welding space does not contain partitions, balconies, or structured barriers that obstruct cross ventilation
If your specific operation does not fall within these guidelines, mechanical ventilation will be required.
Mechanical Ventilation -- Mechanical ventilation options generally fall into two basic categories. The first is the low vacuum system, which takes large volumes of air at low velocities. These systems consist of hoods positioned at a distance from the work area. The hood and housing may have to be repositioned by the worker to get maximum benefit from this means of ventilation. Hoods generally remove the fumes and contaminated air through ducting and exhaust the contaminants to the outdoors. Hoods should be placed as near as practical to the work and should provide effective airflow with a velocity of 100 linear feet (30m) per minute at its most remote distance from the point of welding. Processes where low vacuum systems work best are arc air gouging, taking afterburner, and arc cutting.
Another category of mechanical ventilation is the high vacuum system. These are close-range extractors that are aimed at capturing and extracting fumes as near to the work as possible. Fume extractors often have an immediate area of welding. By removing a small volume of air at high velocity, the potentially hazardous materials are effectively removed before reaching the welder's breathing zone. These systems often are equipped with a fan that pulls the contaminants into a filtration system, with a HEPA (High Efficiency Particulate Absolute) filter or combination of HEPA filter and prefilter and then recirculated the clean air back into the work area. Advantages of high vacuum systems are greater flexibility for job adaptation, more efficient means of fume removal, and greater visibility to the welder due to reduced clouds of fumes and vapors being created.
Fumes and gases from welding and cutting cannot be easily classified. The quantity of fumes and gases is relative to the metal being worked and the processes and consumable material being used (such as coatings, like paint, galvanizing, and platings), along with contaminants in the atmosphere (such as halogenated hydrocarbon vapors from cleaning and degreasing activities).
Air sampling to verify the concentration levels of toxic fumes and gases is necessary, and respiratory protection is required along with mechanical ventilation in the cutting and/or welding of certain metals and compounds. For more information, see OSHA 29 CFR 1910.252 on welding regulations.
Hope the information helps. Keep on sharing and gaining.
From United States, Fpo
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Dear all,
Here I add a few questions related to welding. . .
Question 1:
What is a fume plume?
The fume plume is the clearly visible column of fume that rises directly from the spot of welding or cutting. Welders and cutters should take precautions to avoid breathing this area directly. Ventilation can direct the plume away from the face. (Fume removal is most effective when the airflow is directed across the face of the welder, rather than from behind.)
Question 2:
How do I know what hazardous materials I may be using?
Check the Material Safety Data Sheet (MSDS). The suppliers of welding materials must provide an MSDS or equivalent documentation that identifies the hazardous materials, if any, used in their welding and cutting products.
Question 3:
Where should oxygen not be used and why?
Oxygen should not be used as a substitute for compressed air. It should not be used in pneumatic tools, in oil preheating burners, to start internal combustion engines, to blow out pipelines, to dust clothing or work, or to create pressure for ventilation or similar applications. Oxygen should not be used as described due to the possibility of a raging oxygen-fed fire occurring. Oxygen is not flammable, but vigorously supports combustion. Oxygen can be absorbed by clothing. A slight spark can result in severe burns.
Question 4:
What is Mapp gas?
Mapp gas is a product that was developed as a fuel for welding, brazing, cutting, flame hardening, and metallizing operations. It has many of the physical properties of acetylene but lacks its shock sensitivity and therefore can be stored and shipped in lighter containers. Mapp gas is the result of rearranging the molecular structure of acetylene and propane. It also has a very distinct odor so any leakage can readily be detected.
Hope it helps. . .
Keep on sharing. . .
From United States, Fpo
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Here I add a few questions related to welding. . .
Question 1:
What is a fume plume?
The fume plume is the clearly visible column of fume that rises directly from the spot of welding or cutting. Welders and cutters should take precautions to avoid breathing this area directly. Ventilation can direct the plume away from the face. (Fume removal is most effective when the airflow is directed across the face of the welder, rather than from behind.)
Question 2:
How do I know what hazardous materials I may be using?
Check the Material Safety Data Sheet (MSDS). The suppliers of welding materials must provide an MSDS or equivalent documentation that identifies the hazardous materials, if any, used in their welding and cutting products.
Question 3:
Where should oxygen not be used and why?
Oxygen should not be used as a substitute for compressed air. It should not be used in pneumatic tools, in oil preheating burners, to start internal combustion engines, to blow out pipelines, to dust clothing or work, or to create pressure for ventilation or similar applications. Oxygen should not be used as described due to the possibility of a raging oxygen-fed fire occurring. Oxygen is not flammable, but vigorously supports combustion. Oxygen can be absorbed by clothing. A slight spark can result in severe burns.
Question 4:
What is Mapp gas?
Mapp gas is a product that was developed as a fuel for welding, brazing, cutting, flame hardening, and metallizing operations. It has many of the physical properties of acetylene but lacks its shock sensitivity and therefore can be stored and shipped in lighter containers. Mapp gas is the result of rearranging the molecular structure of acetylene and propane. It also has a very distinct odor so any leakage can readily be detected.
Hope it helps. . .
Keep on sharing. . .
From United States, Fpo
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[Hazards of Welding & Cutting With Oxygen-Fuel Gas]
When someone is using a blowtorch for welding, cutting, or brazing, what they're actually doing is burning a combination of a fuel gas (such as acetylene) that's been mixed with oxygen. A welding torch mixes gases from two separate cylinders and then ignites them to create a flame that's hot enough for the job at hand. However, welding with oxygen-fuel gas has a number of dangers that those who are doing the job should be aware of.
[Glare]
One of the dangers of welding and cutting with an oxygen and fuel gas mixture is the brightness of the flame. The burning of an oxygen and fuel gas mixture can burn extremely hot and bright, which can lead to problems with the welder's vision. Just staring at the flame for a short time may not be much of a problem, but welders are often welding and cutting metal with their torches for hours at a time, which can lead to their eyes becoming damaged by the bright light. This is why it's important that they wear safety goggles that are tinted, which will reduce the impact of the bright light on their eyes.
[Flashbacks]
One of the biggest dangers to welders that use oxygen and fuel gas mixtures in their work is a flashback. A flashback is when one or both of the gases that are being mixed begin to burn inside the blowtorch. The flame begins to burn down the hoses to the canisters, where it ignites the gases and causes an explosion that can cause a lot of damage. For this reason, it's important to carefully monitor your equipment when using an oxygen and fuel gas mixture, and it's equally important to install a gasket that will prevent a flashback from occurring.
[Fumes]
It's important that you focus the blowtorch very carefully and that you have the proper mixture of fuel gas and oxygen when using this method to weld or cut. Fumes from these gases that escape from the torch or from the canister could lead to fires or other damage to the user or their work area. Additionally, the fumes from the fuel gas are hazardous to breathe. So if the torch is left unlit but open, a small work area could be filled with the fumes from the canister. It's important to check all connections and the canister before lighting your torch for this reason.
From United States, Fpo
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When someone is using a blowtorch for welding, cutting, or brazing, what they're actually doing is burning a combination of a fuel gas (such as acetylene) that's been mixed with oxygen. A welding torch mixes gases from two separate cylinders and then ignites them to create a flame that's hot enough for the job at hand. However, welding with oxygen-fuel gas has a number of dangers that those who are doing the job should be aware of.
[Glare]
One of the dangers of welding and cutting with an oxygen and fuel gas mixture is the brightness of the flame. The burning of an oxygen and fuel gas mixture can burn extremely hot and bright, which can lead to problems with the welder's vision. Just staring at the flame for a short time may not be much of a problem, but welders are often welding and cutting metal with their torches for hours at a time, which can lead to their eyes becoming damaged by the bright light. This is why it's important that they wear safety goggles that are tinted, which will reduce the impact of the bright light on their eyes.
[Flashbacks]
One of the biggest dangers to welders that use oxygen and fuel gas mixtures in their work is a flashback. A flashback is when one or both of the gases that are being mixed begin to burn inside the blowtorch. The flame begins to burn down the hoses to the canisters, where it ignites the gases and causes an explosion that can cause a lot of damage. For this reason, it's important to carefully monitor your equipment when using an oxygen and fuel gas mixture, and it's equally important to install a gasket that will prevent a flashback from occurring.
[Fumes]
It's important that you focus the blowtorch very carefully and that you have the proper mixture of fuel gas and oxygen when using this method to weld or cut. Fumes from these gases that escape from the torch or from the canister could lead to fires or other damage to the user or their work area. Additionally, the fumes from the fuel gas are hazardous to breathe. So if the torch is left unlit but open, a small work area could be filled with the fumes from the canister. It's important to check all connections and the canister before lighting your torch for this reason.
From United States, Fpo
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How to Weld Fuel Tanks
Welding gas or diesel tanks is extremely hazardous. In addition to the risk of setting fuel vapors on fire, MIG or TIG welding inside fuel storage tanks can result in argon gas suffocation for the welder and anyone attempting a rescue.
"Disconnect the battery and remove or turn off ignition sources before draining the tank,". This reduces the chance that a spark might set off fuel residue.
Drain the fuel tank completely into an approved container for use with flammable liquids. "Do not drain gasoline tanks over or near inspection pits."
Remove the fuel tank (if for a vehicle). Open the access point if welding a storage tank. Take appropriate safety measures, including donning breathing apparatus and any necessary monitoring equipment. Arrange an observation, evaluation, rescue, and evacuation plan that will not endanger rescue crew members according to OSHA regulations for hot work/welding.
Rinse tanks thoroughly several times with warm, soapy water. Drain into approved containers for flammable liquids.
Evacuate fuel fumes from the tank with an air hose for a minimum of one hour or until the fuel smell from the filter is not detectable. Conduct chemical tests to determine whether all fuel fumes have been removed and whether the tank is now safe to weld.
Please follow all applicable laws, regulations, safety standards, and best welding practices. Allow the tank to cool to within 5 to 10 degrees of 70 degrees Fahrenheit.
Once the tank has cooled, put a small amount of fuel in the tank and test for leaks. If the tank does not leak, reinstall it according to the manufacturer's specifications.
From United States, Fpo
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Welding gas or diesel tanks is extremely hazardous. In addition to the risk of setting fuel vapors on fire, MIG or TIG welding inside fuel storage tanks can result in argon gas suffocation for the welder and anyone attempting a rescue.
"Disconnect the battery and remove or turn off ignition sources before draining the tank,". This reduces the chance that a spark might set off fuel residue.
Drain the fuel tank completely into an approved container for use with flammable liquids. "Do not drain gasoline tanks over or near inspection pits."
Remove the fuel tank (if for a vehicle). Open the access point if welding a storage tank. Take appropriate safety measures, including donning breathing apparatus and any necessary monitoring equipment. Arrange an observation, evaluation, rescue, and evacuation plan that will not endanger rescue crew members according to OSHA regulations for hot work/welding.
Rinse tanks thoroughly several times with warm, soapy water. Drain into approved containers for flammable liquids.
Evacuate fuel fumes from the tank with an air hose for a minimum of one hour or until the fuel smell from the filter is not detectable. Conduct chemical tests to determine whether all fuel fumes have been removed and whether the tank is now safe to weld.
Please follow all applicable laws, regulations, safety standards, and best welding practices. Allow the tank to cool to within 5 to 10 degrees of 70 degrees Fahrenheit.
Once the tank has cooled, put a small amount of fuel in the tank and test for leaks. If the tank does not leak, reinstall it according to the manufacturer's specifications.
From United States, Fpo
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Raghu,
You have indeed covered quite a bit in detail regarding welding and gas cutting. Good job. Keep it up.
The information you have provided should be shared with supervisors and those involved in welding as part of their induction before they begin any such work. If this information is not shared with the individuals involved, it becomes wasted. These toolbox talks should be conducted jointly by the HSE professional and the welding supervisor almost every day as a reminder until the knowledge and practices become habitual.
Regards,
Gopi
From Malaysia, Kuala Lumpur
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You have indeed covered quite a bit in detail regarding welding and gas cutting. Good job. Keep it up.
The information you have provided should be shared with supervisors and those involved in welding as part of their induction before they begin any such work. If this information is not shared with the individuals involved, it becomes wasted. These toolbox talks should be conducted jointly by the HSE professional and the welding supervisor almost every day as a reminder until the knowledge and practices become habitual.
Regards,
Gopi
From Malaysia, Kuala Lumpur
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Dear Sir,
I would like to thank you personally for your wonderful inputs on safety measures, especially in welding. Even though I am not in that particular profession, I am working as a coordinator in Skill Development initiatives, particularly with various welding training institutes in Tamil Nadu. It would help me a lot to relook at our activities from a safety point of view.
Thank you very much.
Raja Ganesh. M
From India, Madras
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I would like to thank you personally for your wonderful inputs on safety measures, especially in welding. Even though I am not in that particular profession, I am working as a coordinator in Skill Development initiatives, particularly with various welding training institutes in Tamil Nadu. It would help me a lot to relook at our activities from a safety point of view.
Thank you very much.
Raja Ganesh. M
From India, Madras
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Dear Gopi,
Yes, I agree with you. Same thing I am doing on my site daily, especially I conduct one meeting with our Fabricators (at least 15 minutes).
Dear Raja,
Nice to hear this. I am very happy, mate. Mr. Rajesh, as per your message, you're working as a coordinator for welding training institutes. Please share the message with our students/guys so it easily reaches them.
If you need anything regarding welding safety, please come forward, and we will help you.
Keep on sharing and gaining.
From United States, Fpo
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Yes, I agree with you. Same thing I am doing on my site daily, especially I conduct one meeting with our Fabricators (at least 15 minutes).
Dear Raja,
Nice to hear this. I am very happy, mate. Mr. Rajesh, as per your message, you're working as a coordinator for welding training institutes. Please share the message with our students/guys so it easily reaches them.
If you need anything regarding welding safety, please come forward, and we will help you.
Keep on sharing and gaining.
From United States, Fpo
Acknowledge(0)Amend(0)
How to Weld a Gas Tank
Welding gas tanks is particularly hazardous. The danger of gas tank welding does not necessarily come with the liquid fuel, but more specifically with gas fumes. Fuel vapors can be extremely flammable, and even a small spark can cause a massive explosion. Furthermore, argon gas buildup inside the fuel tank can cause suffocation for anyone welding. It is important to use extreme caution when working with gas tanks and flames.
Remove the battery from the vehicle if the tank is still strapped onto the vehicle. This will help prevent the possibility of a spark igniting the fuel or vapors. Detach the straps holding the fuel tank in place. Use a screwdriver to remove the screws in the strap. Avoid cutting the straps unless it is impossible to remove them otherwise. Move the tank away from the vehicle so the container may be drained.
Turn the tank over so the fuel drain hose or outlet drain is facing toward the ground. Place a breathing mask on for your safety so fumes from the fuel will not be inhaled. Empty the fuel from the tank into an approved fuel container. Ensure the tank is as empty as possible. Place sand over any fuel that might have spilled onto the ground.
Rinse the tank with warm water by pouring it into the gas tank as you would a gas pump. Apply a small amount of soap to the water. Empty the mixture into a small bucket after swishing the soap and water together. Repeat this process two or three times to clean the tank as best as possible.
Use an air hose to pull the remaining fuel fumes from the tank. This process should take anywhere from one to four hours depending on the size of the tank and the amount of fumes in the tank before it was emptied. Smell the inside of the tank by removing the breathing mask and waving your hand over the outlet hose. Do not directly sniff inside the tank drain as this might cause harmful fumes to enter your body.
Weld the tank using a welding torch and a welding mask. Conduct the welding in the desired manner and be sure to follow all safety protocols and fuel tank regulations, if applicable. Let the tank cool to about 75 degrees Fahrenheit. Use a small, handheld air thermometer to take the temperature reading. Fill the tank with a small amount of fuel to test for any leaking. Reattach the tank to the vehicle just as it was by tightening down the straps and inserting the screws.
From United States, Fpo
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Welding gas tanks is particularly hazardous. The danger of gas tank welding does not necessarily come with the liquid fuel, but more specifically with gas fumes. Fuel vapors can be extremely flammable, and even a small spark can cause a massive explosion. Furthermore, argon gas buildup inside the fuel tank can cause suffocation for anyone welding. It is important to use extreme caution when working with gas tanks and flames.
Remove the battery from the vehicle if the tank is still strapped onto the vehicle. This will help prevent the possibility of a spark igniting the fuel or vapors. Detach the straps holding the fuel tank in place. Use a screwdriver to remove the screws in the strap. Avoid cutting the straps unless it is impossible to remove them otherwise. Move the tank away from the vehicle so the container may be drained.
Turn the tank over so the fuel drain hose or outlet drain is facing toward the ground. Place a breathing mask on for your safety so fumes from the fuel will not be inhaled. Empty the fuel from the tank into an approved fuel container. Ensure the tank is as empty as possible. Place sand over any fuel that might have spilled onto the ground.
Rinse the tank with warm water by pouring it into the gas tank as you would a gas pump. Apply a small amount of soap to the water. Empty the mixture into a small bucket after swishing the soap and water together. Repeat this process two or three times to clean the tank as best as possible.
Use an air hose to pull the remaining fuel fumes from the tank. This process should take anywhere from one to four hours depending on the size of the tank and the amount of fumes in the tank before it was emptied. Smell the inside of the tank by removing the breathing mask and waving your hand over the outlet hose. Do not directly sniff inside the tank drain as this might cause harmful fumes to enter your body.
Weld the tank using a welding torch and a welding mask. Conduct the welding in the desired manner and be sure to follow all safety protocols and fuel tank regulations, if applicable. Let the tank cool to about 75 degrees Fahrenheit. Use a small, handheld air thermometer to take the temperature reading. Fill the tank with a small amount of fuel to test for any leaking. Reattach the tank to the vehicle just as it was by tightening down the straps and inserting the screws.
From United States, Fpo
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What are the OSHA Requirements for Oxygen-Fuel Storage?
Oxygen fuel is used in welding, cutting, and brazing. Oxygen fuel is prone to fire and explosions. The fire used for welding or cutting is very hot and dangerous. If an oxygen cylinder is leaking and the leak comes into contact with an ignition source, the cylinder can explode. Proper storage of oxygen fuel can help minimize the risk of fire and explosion. The Occupational Safety and Health Administration (OSHA) of the U.S. Department of Labor sets requirements for oxygen-fuel storage.
Mixing Gases
Mixing oxygen fuel with other flammable gases before use can cause the cylinder to explode. The mixture of oxygen fuel with other gases should only happen at the burner or in a standard torch.
Cylinders
Each cylinder must be marked with the name of the gas, either in chemical or trade name form. Any cylinder with a capacity of 30 lbs. or more must have a cap to provide protection for the valve or recess the valve so that it is not exposed should the cylinder tip over.
Storage of Cylinders
An oxygen cylinder must not be stored near highly combustible materials such as oil, grease, or acetylene. Oxygen cylinders must be separated from combustibles by 20 feet or by a barrier that is five feet high and noncombustible. If an oxygen cylinder is to be stored outside of a generator house, it must be separated from the generator by a gas-tight, noncombustible partition that will resist fire for at least one hour.
Cylinder Maintenance
An oxygen cylinder must be kept free of oil or grease and must not be handled with gloves that have oil or grease on them. Oxygen fuel must not touch oily or greasy objects. Cylinders must not strike one another or other objects violently, and all valves should be closed when not in use. Store cylinders away from the area where welding or cutting takes place so that sparks or slag cannot contact the cylinder. Oxygen cylinders must be kept away from open electrical currents.
Hope it helps. . .
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From United States, Fpo
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Oxygen fuel is used in welding, cutting, and brazing. Oxygen fuel is prone to fire and explosions. The fire used for welding or cutting is very hot and dangerous. If an oxygen cylinder is leaking and the leak comes into contact with an ignition source, the cylinder can explode. Proper storage of oxygen fuel can help minimize the risk of fire and explosion. The Occupational Safety and Health Administration (OSHA) of the U.S. Department of Labor sets requirements for oxygen-fuel storage.
Mixing Gases
Mixing oxygen fuel with other flammable gases before use can cause the cylinder to explode. The mixture of oxygen fuel with other gases should only happen at the burner or in a standard torch.
Cylinders
Each cylinder must be marked with the name of the gas, either in chemical or trade name form. Any cylinder with a capacity of 30 lbs. or more must have a cap to provide protection for the valve or recess the valve so that it is not exposed should the cylinder tip over.
Storage of Cylinders
An oxygen cylinder must not be stored near highly combustible materials such as oil, grease, or acetylene. Oxygen cylinders must be separated from combustibles by 20 feet or by a barrier that is five feet high and noncombustible. If an oxygen cylinder is to be stored outside of a generator house, it must be separated from the generator by a gas-tight, noncombustible partition that will resist fire for at least one hour.
Cylinder Maintenance
An oxygen cylinder must be kept free of oil or grease and must not be handled with gloves that have oil or grease on them. Oxygen fuel must not touch oily or greasy objects. Cylinders must not strike one another or other objects violently, and all valves should be closed when not in use. Store cylinders away from the area where welding or cutting takes place so that sparks or slag cannot contact the cylinder. Oxygen cylinders must be kept away from open electrical currents.
Hope it helps. . .
Keep on sharing and gaining. . .
From United States, Fpo
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Welding, Cutting, Brazing & Grinding
Welding and other hot work presents significant opportunity for fire and injury. Hot work is any temporary operation involving open flames or which produces heat/sparks. Typical operations include brazing, open flame soldering, grinding, arc welding/cutting, oxy-fuel gas welding, hot taps, and torch applied roofing. Because of the high temperatures involved and the potential for fire and serious injury, care must be taken to ensure that work is performed safely.
Hazard Avoidance
The hazards associated with hot work are:
Fires/Explosions (hot surfaces can be ignition sources)
Burns (both from welding equipment itself and hot surfaces)
Toxic fumes, particulates and smoke
Eye injuries (burn and particulates)
Electric shock
Noise
Fire/Explosion Precautions
Do not cut, weld, braze, or grind in the presence of combustible or flammable liquids or atmospheres (gases, vapors, dust).
Do not cut, weld, braze, or grind on drums, barrels, tanks, or other containers.
Inspect cracks and holes in floors, walls, and ceilings of the work area to ensure that no combustible materials, or personnel, will be exposed to sparks should they pass through a crack, hole, or penetration.
If the object to be worked cannot readily be moved to a routine welding area, move all combustible materials at least 35' from where the hot work will take place.
If any remaining combustibles cannot be moved, ,protect the combustibles with appropriate guards and covers.
Do not cut,, weld, braze, or grind inside a building if you have reason to suspect the sprinkler system (if present) is not working properly.
Do not mix aluminum grinding dust and iron or steel grinding dust. Such a mixture can, under special conditions, explode. Finely divided aluminum mixed with finely divided ferrous oxide forms thermite, a compound that burns greater than 3,000° C
Hot Work Safety
Burns and Personal Injury Precautions
Using welding curtains and shields.
Ensure adequate ventilation during the hot work process.
Materials such as lead, cadmium, and beryllium generate toxic gases when heated to their vaporization point.
Sanding, grinding, or similar activities can release dangerous respirable particles.
Protect workers from electrical shocks by maintaining electrical welding equipment in good condition. Repair damaged leads promptly.
Goggles and face shields that give maximum eye protection for each welding, flame cutting and soldering process shall be worn by personnel performing these operations and helpers assisting in the hot work.
It is not necessary to have a direct view of a welding arc to injure your eyes. Sufficient light can reflect from nearby surfaces to cause a "welders flash" - especially with prolonged exposure.
Flame resistant gloves and aprons shall be worn during welding, flame cutting and soldering processes.
Should protective hard hats be worn, they shall be made of a flame resistant material.
Safety shoes with protected tops should be worn to protect the operator from spark hazard.
Ensure worker protection from high noise levels produced by grinding or cutting activities.
Personal Awareness
Do not bring combustibles or flammables into an area where welding, cutting, brazing, or grinding occurs.
Ensure all compressed gas cylinders and fuels are stored and transported properly, and that any regulators, valves, hoses, and fittings are in good condition.
Thoroughly clean a grinding machine of all aluminum dust before grinding iron or steel.
Hope its helps. . .
From United States, Fpo
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Welding and other hot work presents significant opportunity for fire and injury. Hot work is any temporary operation involving open flames or which produces heat/sparks. Typical operations include brazing, open flame soldering, grinding, arc welding/cutting, oxy-fuel gas welding, hot taps, and torch applied roofing. Because of the high temperatures involved and the potential for fire and serious injury, care must be taken to ensure that work is performed safely.
Hazard Avoidance
The hazards associated with hot work are:
Fires/Explosions (hot surfaces can be ignition sources)
Burns (both from welding equipment itself and hot surfaces)
Toxic fumes, particulates and smoke
Eye injuries (burn and particulates)
Electric shock
Noise
Fire/Explosion Precautions
Do not cut, weld, braze, or grind in the presence of combustible or flammable liquids or atmospheres (gases, vapors, dust).
Do not cut, weld, braze, or grind on drums, barrels, tanks, or other containers.
Inspect cracks and holes in floors, walls, and ceilings of the work area to ensure that no combustible materials, or personnel, will be exposed to sparks should they pass through a crack, hole, or penetration.
If the object to be worked cannot readily be moved to a routine welding area, move all combustible materials at least 35' from where the hot work will take place.
If any remaining combustibles cannot be moved, ,protect the combustibles with appropriate guards and covers.
Do not cut,, weld, braze, or grind inside a building if you have reason to suspect the sprinkler system (if present) is not working properly.
Do not mix aluminum grinding dust and iron or steel grinding dust. Such a mixture can, under special conditions, explode. Finely divided aluminum mixed with finely divided ferrous oxide forms thermite, a compound that burns greater than 3,000° C
Hot Work Safety
Burns and Personal Injury Precautions
Using welding curtains and shields.
Ensure adequate ventilation during the hot work process.
Materials such as lead, cadmium, and beryllium generate toxic gases when heated to their vaporization point.
Sanding, grinding, or similar activities can release dangerous respirable particles.
Protect workers from electrical shocks by maintaining electrical welding equipment in good condition. Repair damaged leads promptly.
Goggles and face shields that give maximum eye protection for each welding, flame cutting and soldering process shall be worn by personnel performing these operations and helpers assisting in the hot work.
It is not necessary to have a direct view of a welding arc to injure your eyes. Sufficient light can reflect from nearby surfaces to cause a "welders flash" - especially with prolonged exposure.
Flame resistant gloves and aprons shall be worn during welding, flame cutting and soldering processes.
Should protective hard hats be worn, they shall be made of a flame resistant material.
Safety shoes with protected tops should be worn to protect the operator from spark hazard.
Ensure worker protection from high noise levels produced by grinding or cutting activities.
Personal Awareness
Do not bring combustibles or flammables into an area where welding, cutting, brazing, or grinding occurs.
Ensure all compressed gas cylinders and fuels are stored and transported properly, and that any regulators, valves, hoses, and fittings are in good condition.
Thoroughly clean a grinding machine of all aluminum dust before grinding iron or steel.
Hope its helps. . .
From United States, Fpo
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"Hot work" can cause catastrophic workplace accidents.
There are many causes of industrial/construction workplace accidents, but perhaps one of the most deadly, yet easily preventable, occurrences is an explosion caused by "hot work".
The Health and Safety Executive describes "hot work" as "any process that generates a source of ignition (e.g., naked flames, heat, sparks) arising from working methods such as welding, flame cutting, grinding and using disc cutters".
Where hot work is carried out on drums, containers, or any receptacle which contains, or previously contained, flammable or combustible liquids, then a serious risk of explosion can occur. Drums or containers used to store waste thinners, new or used engine oil, antifreeze, solvents, petrol or diesel fuel should be handled with extreme care, and an alternative to hot work should be found if they need to be repaired or altered in any way.
The use of flammable materials is a significant factor in many industries across the UK and the types of containers used to transport and store them are numerous. If a container is reused after being emptied, especially if labeling is removed or becomes unreadable, there may be a danger that a worker could unwittingly begin hot work on it, or carry out hot work near to an old flammable liquid container, which may, in turn, cause an explosion.
Even when a container appears to be empty, seams, creases, and folds in its surface material may still hold sufficient liquid residue to provide an explosive vapor which could provide perfect fuel for an explosion should hot work be carried out on the vessel.
The HSE reports that it has investigated a number of serious accidents involving hot work and, following two deaths in North East Scotland, occurring in separate incidences but within a short period of time, a Safety Alert was issued to warn employers and duty holders of the inherent risks involved in performing hot work on containers and drums.
Key advice to prevent personal injury from a workplace accident involving "hot work":
The hazards associated with performing hot work on tanks and drums are great, so alternatives should always be considered. These could include using cold cutting or cold repair techniques; or container replacement rather than repair.
If the work is considered to be unavoidable and absolutely necessary, a specialist company should be employed, or the risks reduced by using methods such as gas-freeing, cleaning, or "inerting" before hot work commences.
The HSE advises that no one should repair or cut up tanks or drums unless they have received full training and are aware of all the risks involved.
Hope it helps. . .
From United States, Fpo
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There are many causes of industrial/construction workplace accidents, but perhaps one of the most deadly, yet easily preventable, occurrences is an explosion caused by "hot work".
The Health and Safety Executive describes "hot work" as "any process that generates a source of ignition (e.g., naked flames, heat, sparks) arising from working methods such as welding, flame cutting, grinding and using disc cutters".
Where hot work is carried out on drums, containers, or any receptacle which contains, or previously contained, flammable or combustible liquids, then a serious risk of explosion can occur. Drums or containers used to store waste thinners, new or used engine oil, antifreeze, solvents, petrol or diesel fuel should be handled with extreme care, and an alternative to hot work should be found if they need to be repaired or altered in any way.
The use of flammable materials is a significant factor in many industries across the UK and the types of containers used to transport and store them are numerous. If a container is reused after being emptied, especially if labeling is removed or becomes unreadable, there may be a danger that a worker could unwittingly begin hot work on it, or carry out hot work near to an old flammable liquid container, which may, in turn, cause an explosion.
Even when a container appears to be empty, seams, creases, and folds in its surface material may still hold sufficient liquid residue to provide an explosive vapor which could provide perfect fuel for an explosion should hot work be carried out on the vessel.
The HSE reports that it has investigated a number of serious accidents involving hot work and, following two deaths in North East Scotland, occurring in separate incidences but within a short period of time, a Safety Alert was issued to warn employers and duty holders of the inherent risks involved in performing hot work on containers and drums.
Key advice to prevent personal injury from a workplace accident involving "hot work":
The hazards associated with performing hot work on tanks and drums are great, so alternatives should always be considered. These could include using cold cutting or cold repair techniques; or container replacement rather than repair.
If the work is considered to be unavoidable and absolutely necessary, a specialist company should be employed, or the risks reduced by using methods such as gas-freeing, cleaning, or "inerting" before hot work commences.
The HSE advises that no one should repair or cut up tanks or drums unless they have received full training and are aware of all the risks involved.
Hope it helps. . .
From United States, Fpo
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Dear all, Please find the attached "16 Steps to Fire Safety on Timber Frame Construction Sites" file. . . Hope its helps. . .
From United States, Fpo
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From United States, Fpo
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Dear all, Please see the attached safety alert "Hot Work Leads to Fire". . . Source: Internet
From United States, Fpo
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From United States, Fpo
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Dear All,
Just have a look into the ANSI standard on Welding and Gas Cutting. It's downloaded from the internet only. A great reference about the topic. Hope this will shed some more light on this thread.
Dear Raghu: Great sharing. Keep on posting and keep up the pace.
Thanks a lot to all other participants. Keep on sharing.
From India
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Just have a look into the ANSI standard on Welding and Gas Cutting. It's downloaded from the internet only. A great reference about the topic. Hope this will shed some more light on this thread.
Dear Raghu: Great sharing. Keep on posting and keep up the pace.
Thanks a lot to all other participants. Keep on sharing.
From India
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Hi Members, It is nice contribution by all of you. Keep on posting. This will help to resuce industrial accident to some extend. Avinash Kanoray, Nashik
From India, Pune
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From India, Pune
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Hot Work Requirements
What is a Hot Work Permit?
Hot work is defined as cutting and welding operations for construction/demolition activities that involve the use of portable gas or arc welding equipment. The use of these types of equipment for cutting and welding introduces significant fire hazards into our buildings/sites.
The hot work permit system is intended to educate the parties involved in construction of these hazards and to implement control measures to help mitigate them.
A hot work permit is the means by which the departments of Planning Design & Construction and Risk Management and Safety can stay aware and keep track of construction activities that involve hot work. The hot work permit also provides a step-by-step check list for hot work fire safety and serves as a reminder to contractors of their fire prevention responsibilities before, during, and after any hot work is conducted.
How Does the Hot Work Permit System Work?
Before a contractor can perform hot work for a construction project they need to get a hot work permit. To get a permit, the contractor must to go to the Department of safety. After completing a sign-out form, the permit is issued to the contractor for a specified time period for the building/sites where the work will be performed. The contractor may then perform the hot work, following the precautions outlined on the permit. After the hot work is completed, the contractor turns the permit over to their Department of safety.
When is a Hot Work Permit Necessary?
Hot work permits are needed for all cutting or welding activities that are conducted with portable gas or arc equipment on buildings/sites/construction projects.
Where is a Hot Work Permit Necessary?
Hot work permits are needed for each building where hot work will be performed (utility tunnels are considered to be separate buildings). For example, if one contractor is performing work at several different buildings for one project, a permit is necessary for each building.
Who Needs Hot Work Permits?
Hot work permits are needed for each and every contractor or sub-contractor/trade performing hot work for a project. For example, if there are three different sub-contractors/trades performing hot work on one project, each sub-contractor/trade is responsible for obtaining a permit for their own work.
How Long is a Hot Work Permit Valid?
The duration of a hot work permit depends upon the type of project (new or existing construction) and the character of the hot work. The following are guidelines used to determine how long a permit is good for. These are guidelines. If there are conditions unique to the project or activities a contractor will be performing, exceptions can be made.
New construction is defined as new buildings, additions to existing buildings, new tunnels (including vaults), and new exterior improvement work. The following are the types of work anticipated for new construction;
Structural hot work - cutting/welding reinforcing steel and structural steel for all of the project's structural work (tunnels construction, building super-structure, site work).
Mechanical hot work - tunnel services connections, building system installations, HVAC equipment installations.
General activities hot work - all other cutting/welding for equipment/building component installations (handrails, guardrails, specialties, and ornamental metal).
Renovations and remodels are defined as new work that takes place in an existing building. The following are the types of hot work anticipated for renovations/remodels;
Demolition hot work - dismantling built-in equipment, removal of discontinued/abandoned equipment.
Mechanical hot work - removal of discontinued/abandoned services, new services tie-ins, building system installations/modifications.
General activities hot work - all other cutting/welding for equipment/building component installations (handrails, guardrails, specialties, and ornamental metal).
Where Should the Hot Work Permit be Posted?
Hot work permits should be posted at the job site in an accessible and conspicuous location. Job site trailers are an acceptable location.
Who Checks To See If the Hot Work Requirements Are Met?
The contractor or sub-contractor/trade performing hot work is ultimately responsible for conducting their hot work activities in a sound, fire-safe manner and following the precautions outlined on the hot work permit. The responsible contractor or sub-contractor/trade supervisor or foreman shall review the work area and sign the card daily.
The Construction Project Manager/ Safety may periodically check the work and job site to verify that the contractor is carrying out the requirements of the hot work permit.
After the Hot Work Permit is Filled or The Hot Work is Complete…Then What?
Once a hot work permit has been filled or when the hot work has been completed, the contractor shall return the completed hot work permit to the Department of safety for the project records. Once the project has been closed-out, the hot work permits may either be disposed or retained.
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What is a Hot Work Permit?
Hot work is defined as cutting and welding operations for construction/demolition activities that involve the use of portable gas or arc welding equipment. The use of these types of equipment for cutting and welding introduces significant fire hazards into our buildings/sites.
The hot work permit system is intended to educate the parties involved in construction of these hazards and to implement control measures to help mitigate them.
A hot work permit is the means by which the departments of Planning Design & Construction and Risk Management and Safety can stay aware and keep track of construction activities that involve hot work. The hot work permit also provides a step-by-step check list for hot work fire safety and serves as a reminder to contractors of their fire prevention responsibilities before, during, and after any hot work is conducted.
How Does the Hot Work Permit System Work?
Before a contractor can perform hot work for a construction project they need to get a hot work permit. To get a permit, the contractor must to go to the Department of safety. After completing a sign-out form, the permit is issued to the contractor for a specified time period for the building/sites where the work will be performed. The contractor may then perform the hot work, following the precautions outlined on the permit. After the hot work is completed, the contractor turns the permit over to their Department of safety.
When is a Hot Work Permit Necessary?
Hot work permits are needed for all cutting or welding activities that are conducted with portable gas or arc equipment on buildings/sites/construction projects.
Where is a Hot Work Permit Necessary?
Hot work permits are needed for each building where hot work will be performed (utility tunnels are considered to be separate buildings). For example, if one contractor is performing work at several different buildings for one project, a permit is necessary for each building.
Who Needs Hot Work Permits?
Hot work permits are needed for each and every contractor or sub-contractor/trade performing hot work for a project. For example, if there are three different sub-contractors/trades performing hot work on one project, each sub-contractor/trade is responsible for obtaining a permit for their own work.
How Long is a Hot Work Permit Valid?
The duration of a hot work permit depends upon the type of project (new or existing construction) and the character of the hot work. The following are guidelines used to determine how long a permit is good for. These are guidelines. If there are conditions unique to the project or activities a contractor will be performing, exceptions can be made.
New construction is defined as new buildings, additions to existing buildings, new tunnels (including vaults), and new exterior improvement work. The following are the types of work anticipated for new construction;
Structural hot work - cutting/welding reinforcing steel and structural steel for all of the project's structural work (tunnels construction, building super-structure, site work).
Mechanical hot work - tunnel services connections, building system installations, HVAC equipment installations.
General activities hot work - all other cutting/welding for equipment/building component installations (handrails, guardrails, specialties, and ornamental metal).
Renovations and remodels are defined as new work that takes place in an existing building. The following are the types of hot work anticipated for renovations/remodels;
Demolition hot work - dismantling built-in equipment, removal of discontinued/abandoned equipment.
Mechanical hot work - removal of discontinued/abandoned services, new services tie-ins, building system installations/modifications.
General activities hot work - all other cutting/welding for equipment/building component installations (handrails, guardrails, specialties, and ornamental metal).
Where Should the Hot Work Permit be Posted?
Hot work permits should be posted at the job site in an accessible and conspicuous location. Job site trailers are an acceptable location.
Who Checks To See If the Hot Work Requirements Are Met?
The contractor or sub-contractor/trade performing hot work is ultimately responsible for conducting their hot work activities in a sound, fire-safe manner and following the precautions outlined on the hot work permit. The responsible contractor or sub-contractor/trade supervisor or foreman shall review the work area and sign the card daily.
The Construction Project Manager/ Safety may periodically check the work and job site to verify that the contractor is carrying out the requirements of the hot work permit.
After the Hot Work Permit is Filled or The Hot Work is Complete…Then What?
Once a hot work permit has been filled or when the hot work has been completed, the contractor shall return the completed hot work permit to the Department of safety for the project records. Once the project has been closed-out, the hot work permits may either be disposed or retained.
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Controlling Hot Work Fire Hazards
It's highly advisable to use a hot work permit system for all hot work operations outside the designated area
Hot work continues to be a leading cause of industrial fires, consistently in the top five across all industries, and it has been responsible for many of industry's most severe fire losses. Hot work is often synonymous with welding and cutting but also includes any work activity with potential to produce ignition sources or excess heat, such as burning, brazing, grinding, soldering, thermal resistance heating, or torch applied roofing.
Sparks and molten material from hot work can be scattered more than 35 feet during welding, cutting, and grinding. These sparks and slag are typically at a temperature above 1,000 degrees F when thrown from the hot work operations—a temperature which can easily ignite paper, wood, flammable liquids, vapors, and many other combustibles if they are allowed to come into contact. While designated hot work areas should have a 35-foot clear radius of combustibles typically maintained, there are very few areas in the average facility that are always clear of combustible material 35 feet in all directions from a given point. If combustibles are not relocated, wet down, or protected with welding curtains or blankets, the hot sparks and slag from welding can easily lead to ignition.
Additional fire hazards from hot work include:
Sparks can fall through cracks and other floor openings, thus starting fires in hidden locations.
Ducts and conveyor systems can carry sparks to distant combustibles.
Hot work done near a partition, wall, ceiling, or roof that has a combustible covering or insulation, or on walls or partitions of combustible sandwich-type panel construction, can lead to ignition.
Hot work on one side of a wall can ignite combustibles on the other side.
Hot work on pipes or other metal that is in contact with combustible walls, partitions, ceilings, roofs, or other combustibles can lead to ignition through conductive heating.
With containers and piping, there is the possibility of explosions, fires, and the release of toxic vapors or fumes.
Before Beginning
Evaluate the decision to perform hot work. The first step of the hot work management process is to determine whether the hazard can be avoided or minimized. Where practical:
Avoid hot work if possible.
Relocate the object requiring hot work outdoors or to specially designated areas that have been designed and constructed to minimize fire risk.Good housekeeping should be maintained and the area routinely audited to ensure it remains safe for hot work.
Schedule hot work during shutdowns if it cannot be avoided or relocated.
If it is determined that hot work is necessary and the object cannot be relocated to a designated hot work area, the persons requesting and those who will be performing the hot work should contact a Hot Work Permit issuing supervisor and begin the permit process.
Utilizing a Permit System
While many standards, including NFPA 51B, Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, require a permit only under certain conditions, such as being unable to secure a 35- foot radius clear of combustibles, it is a best practice and highly advisable to use a hot work permit system for all hot work operations outside the designated area.
Like any other safety program, the first and most critical step in implementing a hot work permit program is a comprehensive written policy and firm management support. Employees and contractors must fully understand that before undertaking any welding outside designate areas, a permit must be obtained from an authorized supervisor and violation of the hot work policy is not acceptable. Even if a facility does not have welding equipment or trained welders and hot work would be a very seldom occurrence performed by outside contractors, a hot work policy and permit system should be in place and included in the contractor management program.
Permit Issuing Supervisors
The permit issuing supervisor's role in completing the permit is to ensure the area or equipment is properly prepared for hot work and the operation is conducted safely. Any supervisor selected to issue permits should be trained in the hazards of hot work and the site-specific hazards, such as flammable liquids, hazardous processes, and storage areas. They must understand the situations that can prevent hot work from being performed and how to interpret atmospheric monitoring results.
One of the most common errors in hot work management programs is the issuance of hot work permits from an office or other production area.To properly issue a permit, the supervisor should tour the proposed hot work area and visually verify that all permissive conditions of the permit are met. Once the permits are properly completed, there should be a copy of the permit kept with those performing the hot work— such as affixed to the welding equipment— and a copy should remain in the supervisor's office or possession during the hot work operations.
Permit Components
Permits should contain a section, preferably highlighted or otherwise set apart from the other items, saying that if any of the situations within exist, hot work cannot be performed and no permit can be issued. The permit also should include a checklist section for confirmation of general conditions. In addition to the hazards checklist portion, permits should contain a section that describes the location, nature, and time of the work and those responsible for the hot work, fire watch, and supervision. The sample hot work permit in Figure 1 provides an example of the items for the conditions checklist section:
Vessel, Container, and Piping Precautions
The heat from the hot work can release hazardous and potentially flammable fumes from materials hidden in cracks and crevices, even in containers appearing empty. Even containers and piping containing water should be considered hazardous until verified otherwise because byproducts of corrosion can result in hydrogen accumulation and potentially explosive atmospheres. Due to the potential for personnel injury, company guidelines always should be consulted for further guidance before conducting hot work on or within any vessel, container, or piping. At a minimum for property conservation, prior to applying heat to or welding on any vessels, containers, or piping, the following precautions should be included on the permit and taken when applicable:
Do not perform hot work on any equipment, drums, tanks, or other containers that have previously contained materials that could develop explosive atmospheres until they have been sufficiently purged, cleaned, and verified as non-hazardous by a qualified person.
For enclosed vessels and confined spaces , a qualified person should check the atmosphere for:
Suitable oxygen content (maximum alloable range of 19.5 to 23.5 percent)
Combustibles or reactive gases
Toxic gases
When working on piping, where feasible, isolate lines by capping or double-blockand- bleed valving and venting.
During and After Hot Work
Once the hot work has been approved, often the only two employees or contractors in the area are the hot work operator and the fire watch. There is no set guideline for the supervisor to remain in the area or to routinely audit areas while hot work is being performed, but it is a good practice to make periodic rounds as time permits to ensure conditions remain safe.
During hot work, the operator and fire watch must ensure the ongoing safety of the hot work operation throughout the process. If unsafe conditions develop, the operator should immediately stop the hot work operation and notify management, the area supervisor, or the permitissuing supervisor for reassessment of the situation.
Fire Watch
The fire watch, just as the hot work issuing supervisor, should be trained to understand the inherent hazards of the work site and of the hot work and ensure safe conditions are maintained during hot work operations. The fire watch should have adequate fire extinguishers and/or small hose lines available and be trained in their use. The fire watch has two principal duties during hot work operations and during the minimum 30-minute post-hot work fire watch period:
Watch for fires in all exposed areas and try to extinguish them as long as they are in the incipient stage. If the fire watch determines the fire is not within the capacity of the equipment, the fire watch and operator should leave the area and sound the fire alarm immediately.
Watch for and stop the hot work operations if unsafe conditions develop. During the post-hot work period, the fire watch may be allowed to perform additional tasks as long as they do not distract him or her from their primary duty of fire watch responsibility. When the fire watch period is completed, the fire watch should make a final check of the area, sign the permit in the appropriate location, and return the completed permit to the supervisor.
Managing Hot Work with Diligence
Ensuring proper safety in a hot work program should be done with the same diligence as an electrical and equipment lockout/tagout program. One would never open electrical switchgear or climb inside equipment capable of moving without absolute verification that it is not live and is properly locked out to prevent activation during work.
Aside from being trained on the potential serious personal injuries that can occur from not following the lockout/tagout procedures, at most facilities employees and contractors are keenly aware that violating the facility's lockout/tagout policy has serious consequences—including dismissal from the facility, in many cases. Property damage and personnel injury from hot work can be greatly reduced by managing the hot work program with the same diligence and philosophy.
Potential hot work areas should be assumed unsafe until they have been rendered safe and verified by a qualified person and/or hot work supervisor, including:
All containers, including fixed tanks and mobile containers.
All piping, regardless of type of fluid normally present.
All areas within the general facility outside the designated welding area.
Virtually all severe fires and explosions caused by hot work can be avoided with proper management of the process. All parties must understand the mutual responsibility for prevention of hot work fires and explosions and proper use of a hot work permit system, taking ownership of their individual responsibilities, which include management support, supervisors' proper use of the permit and procedures, and welders and fire watches to ensure safe practices are followed before, throughout, and after the welding process.
From United States, Fpo
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It's highly advisable to use a hot work permit system for all hot work operations outside the designated area
Hot work continues to be a leading cause of industrial fires, consistently in the top five across all industries, and it has been responsible for many of industry's most severe fire losses. Hot work is often synonymous with welding and cutting but also includes any work activity with potential to produce ignition sources or excess heat, such as burning, brazing, grinding, soldering, thermal resistance heating, or torch applied roofing.
Sparks and molten material from hot work can be scattered more than 35 feet during welding, cutting, and grinding. These sparks and slag are typically at a temperature above 1,000 degrees F when thrown from the hot work operations—a temperature which can easily ignite paper, wood, flammable liquids, vapors, and many other combustibles if they are allowed to come into contact. While designated hot work areas should have a 35-foot clear radius of combustibles typically maintained, there are very few areas in the average facility that are always clear of combustible material 35 feet in all directions from a given point. If combustibles are not relocated, wet down, or protected with welding curtains or blankets, the hot sparks and slag from welding can easily lead to ignition.
Additional fire hazards from hot work include:
Sparks can fall through cracks and other floor openings, thus starting fires in hidden locations.
Ducts and conveyor systems can carry sparks to distant combustibles.
Hot work done near a partition, wall, ceiling, or roof that has a combustible covering or insulation, or on walls or partitions of combustible sandwich-type panel construction, can lead to ignition.
Hot work on one side of a wall can ignite combustibles on the other side.
Hot work on pipes or other metal that is in contact with combustible walls, partitions, ceilings, roofs, or other combustibles can lead to ignition through conductive heating.
With containers and piping, there is the possibility of explosions, fires, and the release of toxic vapors or fumes.
Before Beginning
Evaluate the decision to perform hot work. The first step of the hot work management process is to determine whether the hazard can be avoided or minimized. Where practical:
Avoid hot work if possible.
Relocate the object requiring hot work outdoors or to specially designated areas that have been designed and constructed to minimize fire risk.Good housekeeping should be maintained and the area routinely audited to ensure it remains safe for hot work.
Schedule hot work during shutdowns if it cannot be avoided or relocated.
If it is determined that hot work is necessary and the object cannot be relocated to a designated hot work area, the persons requesting and those who will be performing the hot work should contact a Hot Work Permit issuing supervisor and begin the permit process.
Utilizing a Permit System
While many standards, including NFPA 51B, Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, require a permit only under certain conditions, such as being unable to secure a 35- foot radius clear of combustibles, it is a best practice and highly advisable to use a hot work permit system for all hot work operations outside the designated area.
Like any other safety program, the first and most critical step in implementing a hot work permit program is a comprehensive written policy and firm management support. Employees and contractors must fully understand that before undertaking any welding outside designate areas, a permit must be obtained from an authorized supervisor and violation of the hot work policy is not acceptable. Even if a facility does not have welding equipment or trained welders and hot work would be a very seldom occurrence performed by outside contractors, a hot work policy and permit system should be in place and included in the contractor management program.
Permit Issuing Supervisors
The permit issuing supervisor's role in completing the permit is to ensure the area or equipment is properly prepared for hot work and the operation is conducted safely. Any supervisor selected to issue permits should be trained in the hazards of hot work and the site-specific hazards, such as flammable liquids, hazardous processes, and storage areas. They must understand the situations that can prevent hot work from being performed and how to interpret atmospheric monitoring results.
One of the most common errors in hot work management programs is the issuance of hot work permits from an office or other production area.To properly issue a permit, the supervisor should tour the proposed hot work area and visually verify that all permissive conditions of the permit are met. Once the permits are properly completed, there should be a copy of the permit kept with those performing the hot work— such as affixed to the welding equipment— and a copy should remain in the supervisor's office or possession during the hot work operations.
Permit Components
Permits should contain a section, preferably highlighted or otherwise set apart from the other items, saying that if any of the situations within exist, hot work cannot be performed and no permit can be issued. The permit also should include a checklist section for confirmation of general conditions. In addition to the hazards checklist portion, permits should contain a section that describes the location, nature, and time of the work and those responsible for the hot work, fire watch, and supervision. The sample hot work permit in Figure 1 provides an example of the items for the conditions checklist section:
Vessel, Container, and Piping Precautions
The heat from the hot work can release hazardous and potentially flammable fumes from materials hidden in cracks and crevices, even in containers appearing empty. Even containers and piping containing water should be considered hazardous until verified otherwise because byproducts of corrosion can result in hydrogen accumulation and potentially explosive atmospheres. Due to the potential for personnel injury, company guidelines always should be consulted for further guidance before conducting hot work on or within any vessel, container, or piping. At a minimum for property conservation, prior to applying heat to or welding on any vessels, containers, or piping, the following precautions should be included on the permit and taken when applicable:
Do not perform hot work on any equipment, drums, tanks, or other containers that have previously contained materials that could develop explosive atmospheres until they have been sufficiently purged, cleaned, and verified as non-hazardous by a qualified person.
For enclosed vessels and confined spaces , a qualified person should check the atmosphere for:
Suitable oxygen content (maximum alloable range of 19.5 to 23.5 percent)
Combustibles or reactive gases
Toxic gases
When working on piping, where feasible, isolate lines by capping or double-blockand- bleed valving and venting.
During and After Hot Work
Once the hot work has been approved, often the only two employees or contractors in the area are the hot work operator and the fire watch. There is no set guideline for the supervisor to remain in the area or to routinely audit areas while hot work is being performed, but it is a good practice to make periodic rounds as time permits to ensure conditions remain safe.
During hot work, the operator and fire watch must ensure the ongoing safety of the hot work operation throughout the process. If unsafe conditions develop, the operator should immediately stop the hot work operation and notify management, the area supervisor, or the permitissuing supervisor for reassessment of the situation.
Fire Watch
The fire watch, just as the hot work issuing supervisor, should be trained to understand the inherent hazards of the work site and of the hot work and ensure safe conditions are maintained during hot work operations. The fire watch should have adequate fire extinguishers and/or small hose lines available and be trained in their use. The fire watch has two principal duties during hot work operations and during the minimum 30-minute post-hot work fire watch period:
Watch for fires in all exposed areas and try to extinguish them as long as they are in the incipient stage. If the fire watch determines the fire is not within the capacity of the equipment, the fire watch and operator should leave the area and sound the fire alarm immediately.
Watch for and stop the hot work operations if unsafe conditions develop. During the post-hot work period, the fire watch may be allowed to perform additional tasks as long as they do not distract him or her from their primary duty of fire watch responsibility. When the fire watch period is completed, the fire watch should make a final check of the area, sign the permit in the appropriate location, and return the completed permit to the supervisor.
Managing Hot Work with Diligence
Ensuring proper safety in a hot work program should be done with the same diligence as an electrical and equipment lockout/tagout program. One would never open electrical switchgear or climb inside equipment capable of moving without absolute verification that it is not live and is properly locked out to prevent activation during work.
Aside from being trained on the potential serious personal injuries that can occur from not following the lockout/tagout procedures, at most facilities employees and contractors are keenly aware that violating the facility's lockout/tagout policy has serious consequences—including dismissal from the facility, in many cases. Property damage and personnel injury from hot work can be greatly reduced by managing the hot work program with the same diligence and philosophy.
Potential hot work areas should be assumed unsafe until they have been rendered safe and verified by a qualified person and/or hot work supervisor, including:
All containers, including fixed tanks and mobile containers.
All piping, regardless of type of fluid normally present.
All areas within the general facility outside the designated welding area.
Virtually all severe fires and explosions caused by hot work can be avoided with proper management of the process. All parties must understand the mutual responsibility for prevention of hot work fires and explosions and proper use of a hot work permit system, taking ownership of their individual responsibilities, which include management support, supervisors' proper use of the permit and procedures, and welders and fire watches to ensure safe practices are followed before, throughout, and after the welding process.
From United States, Fpo
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Dear all, Please see the attached Safety practice in welding. . . Hope its helps. . .
From United States, Fpo
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From United States, Fpo
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Dear All,
I have a few simple questions on welding that I am bringing up for discussion in the hope of getting answers. It may seem very simple, but I don't know the exact explanations, which is why I am asking.
1. What should be the minimum and maximum distance from the power source to the welding machine (Power Cable Length)? Why? I have read in one safety tip that it should be between 3 to 5. However, I am not able to understand the logic behind this.
2. What should be the minimum and maximum distance (Length of welding and earth return cable) between the welding machine and the piece to be welded?
3. How many earthing points should be provided in the welding machine? How should it be done and why?
4. Is there any point in insisting on the use of a Welding Rectifier instead of a welding transformer? Are there any safety considerations, or is it only for better quality?
I request all of you to share your views on the above questions.
From India
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I have a few simple questions on welding that I am bringing up for discussion in the hope of getting answers. It may seem very simple, but I don't know the exact explanations, which is why I am asking.
1. What should be the minimum and maximum distance from the power source to the welding machine (Power Cable Length)? Why? I have read in one safety tip that it should be between 3 to 5. However, I am not able to understand the logic behind this.
2. What should be the minimum and maximum distance (Length of welding and earth return cable) between the welding machine and the piece to be welded?
3. How many earthing points should be provided in the welding machine? How should it be done and why?
4. Is there any point in insisting on the use of a Welding Rectifier instead of a welding transformer? Are there any safety considerations, or is it only for better quality?
I request all of you to share your views on the above questions.
From India
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Dear All Sharing one fatal accident report related to Welding Machine... Ensure to take pro-active actions to prevent from occuring such accidents in your area of work...
From India
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From India
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Dear Hansa Something on hindi related to Welding... May be helpful to you... Keep on sharing and keep up the pace...
From India
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From India
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Dear all, Please see the attached Welding Accident investigation report PPT for our view. . . prevention is better than cure. . .
From United States, Fpo
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From United States, Fpo
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Dear all, Please see the attached ARC WELDING PRE-TEST PPT . . . . Easily you know/find out the result about of our training. . . Hope its helps. . . Keep on sharing. . .
From United States, Fpo
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From United States, Fpo
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Dear all, good articles on welding are being shared. a small clipping to share from my end regards nandish
From United Arab Emirates, Dubai
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From United Arab Emirates, Dubai
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Hi,
A very good post on safety aspects. HR personnel have to promote safety consciousness amongst staff and workers. Exchange of literature, presentations, etc., helps HR in providing new and fresh inputs on safety down the line. Just displaying safety posters is not sufficient. Revisiting the same topics with fresh inputs is highly effective. Keep up the exchange and focus on safety.
Daljit Singh
From Saudi Arabia, Riyadh
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A very good post on safety aspects. HR personnel have to promote safety consciousness amongst staff and workers. Exchange of literature, presentations, etc., helps HR in providing new and fresh inputs on safety down the line. Just displaying safety posters is not sufficient. Revisiting the same topics with fresh inputs is highly effective. Keep up the exchange and focus on safety.
Daljit Singh
From Saudi Arabia, Riyadh
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@Daljit Singh
Dear Sir,
It's really nice to see comments from seniors like you on our small initiative. With the guidance and support of seniors like you, we hope to make this journey a never-ending one.
Thanks a lot and keep on sharing your expertise with us.
From India
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Dear Sir,
It's really nice to see comments from seniors like you on our small initiative. With the guidance and support of seniors like you, we hope to make this journey a never-ending one.
Thanks a lot and keep on sharing your expertise with us.
From India
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Dear All,
Going through my archives, I found a file comprising various extracts on welding safety. It covers most of what has been discussed in this forum but may still be useful since the sources are varied.
Gopi
From Malaysia, Kuala Lumpur
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Going through my archives, I found a file comprising various extracts on welding safety. It covers most of what has been discussed in this forum but may still be useful since the sources are varied.
Gopi
From Malaysia, Kuala Lumpur
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Another leaflet from HSE in UK. Hope it is useful. Gopi
From Malaysia, Kuala Lumpur
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From Malaysia, Kuala Lumpur
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@ Gopinathan Pillai
Thanks a lot for your input, sir.
@ Dear All
Once again, I am requesting everyone to come forward if you know the answers to the following questions:
1. What should be the minimum and maximum distance from the power source to the welding machine (Power Cable Length)? Why? I have seen in one safety tip that it should be between 3 to 5, but I am not able to understand the logic.
2. What should be the minimum and maximum distance (Length of welding and earth return cable) between the welding machine and the piece to be welded?
3. Is there any significance in insisting on the use of a Welding Rectifier instead of a welding transformer? Are there any safety points to consider, or is it solely for better quality outcomes?
Thanks in advance.
From India
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Thanks a lot for your input, sir.
@ Dear All
Once again, I am requesting everyone to come forward if you know the answers to the following questions:
1. What should be the minimum and maximum distance from the power source to the welding machine (Power Cable Length)? Why? I have seen in one safety tip that it should be between 3 to 5, but I am not able to understand the logic.
2. What should be the minimum and maximum distance (Length of welding and earth return cable) between the welding machine and the piece to be welded?
3. Is there any significance in insisting on the use of a Welding Rectifier instead of a welding transformer? Are there any safety points to consider, or is it solely for better quality outcomes?
Thanks in advance.
From India
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Silly Canadian guys, they want people to stop and read from their huge libraries. Welder safety in a pinch before an injury or incident.
- [Welding-helmet, safe practices, and welding precautions](http://www.welding-advisers.com/Welding-helmet.html)
- [AWS Safety & Health Fact Sheets](http://www.aws.org/technical/facts/)
- [Welding Fumes: Tips to Minimize Your Risk](http://www.welding-rod-dangers.com/exposure/exposure_safety.htm)
- [MIG Welding Stainless Steel, Safety Issues](http://www.weldreality.com/Safety%20stainless%20issues.htm)
- [Health, safety, and environment - Job Knowledge](http://www.twi.co.uk/content/prof_jobknow.html#defects)
From Canada, Calgary
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- [Welding-helmet, safe practices, and welding precautions](http://www.welding-advisers.com/Welding-helmet.html)
- [AWS Safety & Health Fact Sheets](http://www.aws.org/technical/facts/)
- [Welding Fumes: Tips to Minimize Your Risk](http://www.welding-rod-dangers.com/exposure/exposure_safety.htm)
- [MIG Welding Stainless Steel, Safety Issues](http://www.weldreality.com/Safety%20stainless%20issues.htm)
- [Health, safety, and environment - Job Knowledge](http://www.twi.co.uk/content/prof_jobknow.html#defects)
From Canada, Calgary
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Dear Dipil,
First of all, sorry for the late reply. Based on my knowledge and experience, here are my answers:
1. The power supply cable length is determined by engineering values. Cables may be interlinked in series until the impedance or resistance becomes too high. The first sign of an issue will be the degradation of the arc and weld, and heating of the cable, especially at the couplings. However, generally, the power supply cable should be one length (whatever the distance) with lugged connections.
2. The same principle applies to the weld cable connected to the piece to be welded, as mentioned in point 1. The rule of thumb states that you should not interconnect more than five cable lengths (typically one length is 16m).
3. The weld machine must have an internal ground to earth, both for quality and safety reasons. This is addressed in the US by OSHA under assured equipment ground (not to be confused with grounding requirements for portable tools and extension cords).
4. A rectifier converts alternating current to direct current (or vice versa) and adjusts phase, whereas a transformer only converts one voltage to another. Rectifiers generally offer better control of the arc and heat, resulting in higher quality welds. From a safety standpoint, anything that provides better control reduces risks.
One important point to remember is that the best quality and safety practice is to connect the welding ground clamp to the piece within 0.5m of the area to be welded. This results in the lowest weld resistance and controls the current path to the ground. This is especially crucial when welding on mechanical or electrical equipment, as a remote connection to the ground may allow the current path to arc across bearings, camshafts, drive shafts, gears, circuit boards, etc. Some building fires have also been known to occur due to arcing from structural components (or pipes) that inadvertently became the path to ground for the welding current.
Hope this helps.
Please let me know.
From United States, Fpo
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First of all, sorry for the late reply. Based on my knowledge and experience, here are my answers:
1. The power supply cable length is determined by engineering values. Cables may be interlinked in series until the impedance or resistance becomes too high. The first sign of an issue will be the degradation of the arc and weld, and heating of the cable, especially at the couplings. However, generally, the power supply cable should be one length (whatever the distance) with lugged connections.
2. The same principle applies to the weld cable connected to the piece to be welded, as mentioned in point 1. The rule of thumb states that you should not interconnect more than five cable lengths (typically one length is 16m).
3. The weld machine must have an internal ground to earth, both for quality and safety reasons. This is addressed in the US by OSHA under assured equipment ground (not to be confused with grounding requirements for portable tools and extension cords).
4. A rectifier converts alternating current to direct current (or vice versa) and adjusts phase, whereas a transformer only converts one voltage to another. Rectifiers generally offer better control of the arc and heat, resulting in higher quality welds. From a safety standpoint, anything that provides better control reduces risks.
One important point to remember is that the best quality and safety practice is to connect the welding ground clamp to the piece within 0.5m of the area to be welded. This results in the lowest weld resistance and controls the current path to the ground. This is especially crucial when welding on mechanical or electrical equipment, as a remote connection to the ground may allow the current path to arc across bearings, camshafts, drive shafts, gears, circuit boards, etc. Some building fires have also been known to occur due to arcing from structural components (or pipes) that inadvertently became the path to ground for the welding current.
Hope this helps.
Please let me know.
From United States, Fpo
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Uppercase share and endeavor... I am trusty a lot member in the marketplace get benefited from this rib... Fastidious instrument ups and presentations... Thanks for sharing...Now retributive distribution a record correlated to welding as my contribution to the draw...
In order to handle welding equipment, make sure you are trained properly. Additionally, do not allow just anyone to use your welding or cutting equipment. Ensure that your equipment is stored safely at all times when not in use. Unauthorized individuals should never be permitted to use your welding equipment.
Thanks for sharing...
From India, Ahmadabad
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In order to handle welding equipment, make sure you are trained properly. Additionally, do not allow just anyone to use your welding or cutting equipment. Ensure that your equipment is stored safely at all times when not in use. Unauthorized individuals should never be permitted to use your welding equipment.
Thanks for sharing...
From India, Ahmadabad
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Dear Dipil,
I discussed with my electrical engineering friend. Combining his point of view and my analysis, I can state as below, with the assumption that this information is needed to educate the end user as a toolbox talk or training without using any jargon.
1. Your question on cable length pertains to power rather than welding cable: What should be the minimum and maximum distance from the power source and welding machine (Power Cable Length)? Why? I have written in one safety tip it is between 3 to 5 meters, but I am not able to understand the logic.
Ideally, there is no limit to the length of the power source. In factories, we connect the machine through a bus bar. That means if you can dress the cable properly protecting it from damage, any length can be used. If the cable is free and prone to damage as it may lie all over the ground/shop floor, it is better to restrict the length.
Moreover, if the cable length is more and the machine is far away from the source, the welder may not be able to see the source and control in case of any mishap or accident. A long cable when used cannot be maintained due to pulling and shifting continuously, which may damage the insulation, resulting in the risk of accidents.
In short, if the welding machine is moved frequently, it is better to keep a manageable length of 3 to 5 meters.
2. Second Question - What should be the minimum and maximum distance (Length of welding and earth return cable) between the welding machine and the piece to be welded?
It is always advisable to use a longer power cable than welding cable. Welding cables are costlier (due to copper) when compared to power cable. Also, there will be a drop in voltage as the length of the welding cable increases.
Generally, the earth cable is connected to the welding machine when the weld piece is nearby. Otherwise, they are grounded through the nearest structure (in factory buildings or workshops). Many times we may not be sure that the connected structure is adequately protected, and there may be a ground failure.
It may also affect the quality, as the welder may set one voltage and complete the job if the machine is far away rather than changing the setting wherever required.
3. Third one - Is there any point in insisting on the use of a Welding Rectifier instead of a welding transformer? Is any safety point included, or is it only in view of better quality?
As mentioned by our friends, a rectifier converts AC to DC, whereas a transformer is on AC only. In transformers, we can get a fixed output for an input. It is like a step transfer. For seamless transition, a rectifier can be used wherein you can have more control from 0 to full. Again, take the example of some fan regulators or light intensity regulators wherein it is not a step transition.
Regarding quality, AC current (transformers) can be used best for metals like mild steel, iron, etc., and DC current rectifiers for thin metals or where the weld needs better quality control.
I hope I addressed your questions.
Regards,
Nandish
From United Arab Emirates, Dubai
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I discussed with my electrical engineering friend. Combining his point of view and my analysis, I can state as below, with the assumption that this information is needed to educate the end user as a toolbox talk or training without using any jargon.
1. Your question on cable length pertains to power rather than welding cable: What should be the minimum and maximum distance from the power source and welding machine (Power Cable Length)? Why? I have written in one safety tip it is between 3 to 5 meters, but I am not able to understand the logic.
Ideally, there is no limit to the length of the power source. In factories, we connect the machine through a bus bar. That means if you can dress the cable properly protecting it from damage, any length can be used. If the cable is free and prone to damage as it may lie all over the ground/shop floor, it is better to restrict the length.
Moreover, if the cable length is more and the machine is far away from the source, the welder may not be able to see the source and control in case of any mishap or accident. A long cable when used cannot be maintained due to pulling and shifting continuously, which may damage the insulation, resulting in the risk of accidents.
In short, if the welding machine is moved frequently, it is better to keep a manageable length of 3 to 5 meters.
2. Second Question - What should be the minimum and maximum distance (Length of welding and earth return cable) between the welding machine and the piece to be welded?
It is always advisable to use a longer power cable than welding cable. Welding cables are costlier (due to copper) when compared to power cable. Also, there will be a drop in voltage as the length of the welding cable increases.
Generally, the earth cable is connected to the welding machine when the weld piece is nearby. Otherwise, they are grounded through the nearest structure (in factory buildings or workshops). Many times we may not be sure that the connected structure is adequately protected, and there may be a ground failure.
It may also affect the quality, as the welder may set one voltage and complete the job if the machine is far away rather than changing the setting wherever required.
3. Third one - Is there any point in insisting on the use of a Welding Rectifier instead of a welding transformer? Is any safety point included, or is it only in view of better quality?
As mentioned by our friends, a rectifier converts AC to DC, whereas a transformer is on AC only. In transformers, we can get a fixed output for an input. It is like a step transfer. For seamless transition, a rectifier can be used wherein you can have more control from 0 to full. Again, take the example of some fan regulators or light intensity regulators wherein it is not a step transition.
Regarding quality, AC current (transformers) can be used best for metals like mild steel, iron, etc., and DC current rectifiers for thin metals or where the weld needs better quality control.
I hope I addressed your questions.
Regards,
Nandish
From United Arab Emirates, Dubai
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Dear Mr. Nandish,
I am really happy to see your inputs. Members like you showing this much interest in discussions related to safety and contributing in such a great way is not only helpful but also motivating for me. Thanks a lot.
Your answers were very useful. With yours and earlier Mr. Raghu's contributions, I can come to a good conclusion. Thanks a lot.
Keep on participating and share your expertise with us.
From India
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I am really happy to see your inputs. Members like you showing this much interest in discussions related to safety and contributing in such a great way is not only helpful but also motivating for me. Thanks a lot.
Your answers were very useful. With yours and earlier Mr. Raghu's contributions, I can come to a good conclusion. Thanks a lot.
Keep on participating and share your expertise with us.
From India
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Truck age oxygen and ethane cylinders in your neb. A short urination here,,, a little disclosure there… a unchanging spark…boom!! Your Ass is killed! This goes for motor truck tool boxes also. Throwing a set of crib bottles in your truck means box can grow into a assail and…you guessed it …………can Kill your Ass! There are umpteen causes of dumpy point retentiveness loss and it varies from person to mortal. Following are many of the joint causes.
From India, Ahmadabad
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From India, Ahmadabad
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Dear all, Please find the attached ARC welding safety Pre-Test Presentation.Hope its helps. . . Keep on sharing. . .
From United States, Fpo
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From United States, Fpo
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I read your post; it's very informative and offers useful tips. However, safety in welding is of utmost importance. For more tips on welding safety, you can visit [Welding Safety Welding Safety Tips](http://www.weldingtipsandtricks.com/welding-safety.html). Thanks for...
From India, Ahmadabad
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From India, Ahmadabad
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Dear all, Very useful information.Kindly advise what is the ratio of LPG and oxygen used for cutting metals of various thickness. Thank you, Balagopal.R
From India, Mumbai
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From India, Mumbai
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Team, I am attaching a document that gives full details of Cutting Equipment as a pdf file. Hope its helps.
From United States, Fpo
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From United States, Fpo
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Team, Take a look on attached "ELECTRIC AND MAGNETIC FIELDS may be dangerous". Hope its helps.
From United States, Fpo
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From United States, Fpo
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Team, Please find the attached document of Welding & hazard control as a pdf file. keep on sharing.
From United States, Fpo
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From United States, Fpo
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Team, Attached the Under Water welding file for your info & use. Keep on sharing. . .
From United States, Fpo
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From United States, Fpo
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Dear All, Please send me the gangways measurement as per Factory act 1948 for industy Regards, Jenny
From India, Pune
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From India, Pune
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safety tips for sray paint - What are safety precuations to be taken for spray paint by using paint booth. Regards, SHRINIVASA JENNI
From India, Pune
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From India, Pune
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Dear Raghu,
Thank you for sending the file on Underwater welding. Some time ago, I was discussing this topic with my son. Interestingly, in Vadodara, there is a two-year full-time PG course specializing in special weldings. I have forwarded your attachment to my son.
Thanks again.
Regards,
Sudhir
From India, Vadodara
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Thank you for sending the file on Underwater welding. Some time ago, I was discussing this topic with my son. Interestingly, in Vadodara, there is a two-year full-time PG course specializing in special weldings. I have forwarded your attachment to my son.
Thanks again.
Regards,
Sudhir
From India, Vadodara
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