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Welding

Module 10

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DISCLAIMERThis material was produced under grant

number SH-22248-1 from the Occupational Safety and Health Administration, U.S.

Department of Labor. It does not necessarily reflect the views or policies of

the U.S. Department of Labor, nor does mention of trade names, commercial

products, or organizations imply endorsement by the U.S. Government.

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Objectives• After this module you should be able to– identify the most common welding hazards– take the necessary steps to avoid those

hazards

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Welding Hazards• Fire• Explosion• Health• Burns• Slag and splatter• Radiant light• Ambient temperatures• Electric shock• Cylinders

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Before Welding• Authorization must be given by management,

preferably in the form of a written permit• All fire hazards must be moved at least 35’ away

from welding area or a suitable barrier should be built

• Ensure that a fire extinguisher is readily available

• Inspect all welding equipment to ensure that it is in working order and not damaged

• Wear the appropriate PPE• Set up barriers to protect other workers in the

area

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welding and cutting requires certain PPE; these workers are not wearing face shields

Corrective Action: these operations require hand, arm, eye, face, and sometimes respiratory protection, even for others involved in the operation

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After Welding• At least a 30-minute fire watch must be

established after a welding operation• Store compressed gas cylinders in well-

protected, ventilated, dry location away from any sources of heat

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these oxygen and fuel gas cylinders are stored too close together

Corrective Action: store oxygen at least 20’ from fuel gas and other combustibles or separate them by a 5’ high, 30-minute fire-rated wall

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cylinders must be stored upright with hand-tightened valve caps in place

Corrective Action: while there are valve caps in place, these cylinders need to be stored upright and secured

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Compressed Gas Cylinders• Before connecting a regulator to a cylinder,

open the valve slightly then close immediately• Always stand to one side when opening the

valve of a cylinder• Never crack open a cylinder valve near other

welding work or any other source of ignition• Open an acetylene cylinder valve no more than

1.5 turns, preferably just ¾ of a turn• Under no condition should acetylene be used at

a pressure greater than 15 psig• Empty cylinders should have their valves closed

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Moving Cylinders• Unless cylinders are secured on a special truck

like the one pictured, regulators shall be removed and valve caps in place

• Never lay them down horizontallyand roll them to another location

• Never use the valve cap to pick upa cylinder

• When transported by crane– use a cradle or suitable platform– never use slings or electric magnets– valve caps should always be in place

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cylinders must be kept upright and secure while in transport

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never store or transport cylinders with regulators attached

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Arc Welding• Ensure equipment is installed properly• Ensure equipment is serviceable• Always wear suitable protective clothing• Avoid breathing air in the fume plume• Keep the work area free of fire hazards• Consider hazards associated with wet areas• Safely dispose of electrode stubs• Shield others from light rays

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Applicable Standards• 1910 Subpart Q Welding, Cutting, and

Brazing• 1926 Subpart J Welding and Cutting• API RP 54 Section 20 Hotwork, Welding,

and Flame Cutting Operations

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Your Employer Is Responsible For

• Providing the appropriate PPE• Authorizing welding work to begin• Designating proper storage areas and

ensuring their use• Providing the necessary welding

equipment and fire extinguishers

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You Are Responsible For• Wearing the appropriate PPE• Ensuring that your welding operations do not

cause a fire or explosion• Using, moving, and storing compressed gas

cylinders properly• Inspecting all welding equipment before each

use

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Always Remember• Protect yourself from the radiation, heat,

and slag of welding and cutting operations by wearing PPE

• Properly use, move, and store compressed gas cylinders

• Inspect welding equipment before each use; remove defective equipment from service

• Ensure that all fire hazards are eliminated during operations and watch for fire for at least 30 minutes after operations

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Memory Check1. Unless a suitable barrier is built,

combustibles must be kept how many feet away from the welding operation?

a. 15b. 25c. 35d. 50

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Memory Check2. The fire watch at the end of the welding

operation must last at least how long?a. 30 minutesb. 1 hourc. 2 hoursd. 3 hours

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Memory Check3. Acetylene must not be used above what

pressure (psig)?a. 1b. 2c. 10d. 15