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Get the PointEmployee Safety Training Series

Get the Point

Training Series

by

TechneTrain, Inc.140 Wooster Pike

Milford OH 45150

Copyright © 2010 TechneTrain, Inc.

Welding, Cutting

& Brazing

29 CFR 1910 Subpart Q

Welding, cutting and brazing can be exceptionally dangerous.

Compressed gases are typically used to create an extremely hot flame.

Various welding techniques create fumes, radiation and other hazards.

Extremely Hazardous Work

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The purpose of this

program is not to teach

you how to weld, cut or

braze, but to train you on

OSHA’s safety

regulations for this work.

1.OSHA Welding, Cutting &

Brazing Standard

2.Personal Protective Equipment

3.Oxygen-Fuel Gas Welding and

Cutting

4.Arc Welding and Cutting

5.Resistance Welding

Objectives

Objectives

1.OSHA Welding, Cutting & Brazing Standard

2.Personal Protective Equipment

3.Oxygen-Fuel Gas Welding and Cutting

4.Arc Welding and Cutting

5.Resistance Welding

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OSHA’s Welding Cutting

& Brazing Standard

Safe operating procedures

Safe equipment maintenance

Safe storage of gases and supplies

Fire protection

Personal Protective

Equipment (PPE)

Health protection

and ventilation

Key Areas

Fire Prevention

Establish a safe area for hot

work

Check the work area and move

or guard any hazards.

If these requirements cannot be met,

welding and cutting are prohibited!

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Managing your location and

surroundings are not enough.

You must also:

Have proper extinguishing

equipment available.

Maintain a fire watch if

needed.

Fire Watch

The fire watch is maintained by a

designated attendant in hot work

locations where:

A fire could develop

Combustible materials are within 35’

Combustible materials are > 35’, but

could be easily ignited by sparks

Hot Work in a Confined Space

A confined space is a restricted work area such as a tank, tunnel or pit.

Hot Work in confined spaces requires even more precautions.

Must also have a designated attendant

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Confined Space Hot Work

Precautions

Ventilation

Gas cylinders and welding machines

must remain outside the space

Emergency procedure for removal of

workers

Attendant must be present at all times

When Suspending Work

Remove electrodes from holders

Disconnect machine from power

source

Close torch valves

Shut off torch gas supply

outside the confined space

Where practical, remove torch

and hose from space

Areas not authorized by management

Buildings with impaired sprinkler systems

Explosive atmospheres

Unclean tanks

Accumulation of combustible dusts

Locations where explosive atmospheres

can develop

Forbidden Areas

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Engineering and Work

Practice Controls

The first step to protecting employees

are these engineering and safe work

practice controls.

Additionally, your employer must

provide you with PPE.

Objectives

1.OSHA Welding, Cutting & Brazing

Standard2.Personal Protective Equipment3.Oxygen-Fuel Gas Welding and Cutting

4.Arc Welding and Cutting

5.Resistance Welding

Hazards Requiring Protection

Ultraviolet and infrared

radiation

Metal fumes and welding gases

Electrical current

Hot metal and sharp edges

Noise

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Personal Protective

Equipment

Eye Protection

Helmet

Hand shields

Booths or

Screens

Protective Clothing

Safety Shoes

Gauntlet Gloves

Fall Protection

Respirators

Goggles

Must be used to protect the eyes from UV

and IR light.

A face shield may be needed.

Proper lens shade number for the operation.

Welding Hood with Dark Glass

Must be used with appropriately dark

glass viewing ports while carbon

arcing to protect from UV and IR light.

Proper lens shade number for the

operation.

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Welding Curtains or Booths

Welders should be enclosed in an

individual booth or work behind a

non-combustible screen.

Screens are coated with a low

reflecting finish, such as zinc oxide

and lamp black.

Booths and screens must permit

free circulation of air.

Hand Protection

Long-cuffed leather gloves required while arc welding.

Leather or similar gloves required for other hot work.

Protective Clothing

Wear fire retardant garments such as

aprons, leggings, capes, sleeves.

Remove combustible items from pockets

or clothing.

Prevent sparks or slag from catching in

clothing.

Wear cotton or wool clothing to protect

from UV and IR light.

When hoods are used, they must be fire-

retardant.

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Foot Protection

Wear high-top boots or safety shoes

with spats.

Wear pant legs outside the shoes to

prevent slag from entering.

Boots should be fully laced or zipped.

Hearing Protection

When noise is above

acceptable limits, you must

wear ear muffs or ear plugs

to protect your hearing.

Fall Protection

Railings

Safety Lifelines

Other Safeguards

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Respirators

Respirators may be required for hot

work on some materials or in certain

environments.

If you wear a respirator, you must be

included in a respirator safety

program.

Other workers exposed to the same

atmosphere must also be protected.

Flourine

Zinc

Lead

Chrome

compounds

Beryllium

Cadmium

Mercury

Ventilation Required

Along With PPE

Confined or Enclosed Spaces

Hot work in confined space consumes

oxygen and requires ventilation or

supplied air respirators.

Air-line respirators supply air to the

welders through a hose.

Air-line respirators may not be enough

and an SCBA may be required.

Don’t allow ventilation to block access.

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Air-line Respirators

Air-line respirators are always required

in addition to ventilation if surfaces:

Contain lead, cadmium, or mercury.

Are covered with toxic preservatives.

Contain beryllium.

Hot Work in Open Air

Air-purifying respirators required when:

Surface contains lead, cadmium, or mercury.

Surface contains beryllium.

You need a filter type respirator when doing hot work on surfaces covered with toxic preservatives.

You may need a respirator if you work on stainless steel or surfaces containing chrome.

While PPE is required for all

types of hot work, OSHA has

additional requirements for:

• Oxygen-fuel gas welding/cutting

• Arc welding and cutting

• Resistance welding

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Objectives

1.OSHA Welding, Cutting & Brazing

Standard

2.Personal Protective Equipment3.Oxygen-Fuel Gas Welding and

Cutting4.Arc Welding and Cutting

5.Resistance Welding

One of the most

serious issues with

fuel gas welding is

the handling and

storage of gas

cylinders.

Compressed Gas

High pressure cylinders

can be dangerous.

Can be highly flammable.

Can asphyxiate.

Can increase fire hazards.

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Cylinder Safety

Cylinder marking

Safe storage

Safe operating

procedures

Cylinder Marking

Must be legibly marked

Chemical or trade name

Marking must be done by

Stenciling

Stamping

Labeling

Should be located on the

shoulder

Cylinder Storage

Must be stored in protected, ventilated

locations

Away from sources of heat

At least 20’ away from highly

combustible materials

Away from elevators, stairs or

gangways

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Cylinders must be chained to prevent damage due to falling.

Empty cylinders must have valves closed.

Valve protection caps must always be in place.

Valve Outlet

Valve protection caps protect

the valve on the cylinder from

oil, grease and damage.

Valve protection caps should

never be used for lifting

cylinders.

If the valve outlet becomes

clogged with ice, thaw with

warm water.

Regulators must be removed before

cylinders are moved.

Regulators must be compatible with

gas and pressure needs.

Use only clean regulators and filters.

“Crack” the valve before attaching.

Close valve and release gas before

removing regulator.

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Cylinders, valves, couplings,

regulators, hose and

apparatus must be kept

free from oily or greasy

substances.

Oxygen

Acetylene

Anhydrous ammonia

Liquefied petroleum gases

Hydrogen

Nitrous oxide

SpecialRegulations

Oxygen- Acetylene

Welding & Cutting

Acetylene Safety

Pressure Limits

Cylinder Usage and Handling

Storage of Fuel Gas and Oxygen

Regulators

Service Pipe System

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Acetylene

Acetylene at gage pressures over 15 psig is hazardous.

Acetylene is potentially unstable at higher pressure and can decompose explosively.

Acetylene is stored as a gas in liquid solution in special cylinders.

Cylinders must be stored upright.

Cylinder Manifolding

All manifolds must be used

only for the gases for which

they are approved.

Manifold systems must meet

the requirements of

ANSI/NFPA.

Combine (manifold) gases.

Manifolds and service piping

must be located outside.

Acetylene piping must be

steel or wrought iron.

Clearly mark all cylinder

connection points.

Service Pipe Systems

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Objectives

1.OSHA Welding, Cutting & Brazing

Standard

2.Personal Protective Equipment

3.Oxygen-Fuel Gas Welding and Cutting4.Arc Welding and Cutting5.Resistance Welding

Electric arc produces intense heat capable of melting metal.

Arc welding is used on carbon or alloy steels and nonferrous metals.

Arc cutting primarily used for rough cuts or scrapping.

Arc Welding and Cutting

Processes

Shielded Metal-Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Gas Tungsten Arc Welding (GTAW)

Flux Cored Arc Welding (FCAW)

Plasma Arc Cutting (PAC)

Air Carbon-Arc Cutting (AAC)

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Electric Current

100 Volts100 VoltsAutomatic

100 Volts80 VoltsManual

Direct

Current (DC)

Limit

Alternating

Current (AC)

Limit

AC Welding

It is easy to receive an electric shock

when AC equipment is not handled

properly.

When AC welding under wet

conditions or where perspiration is a

factor, use reliable automatic controls

for reducing no-load voltage.

Equipment Installation

Arc welding requires proper

installation.

The case of the welding machine

must be grounded.

All connections must be checked

each time the equipment is used.

Coiled welding cable must be

spread out.

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Cables

Do not use cables with splices within 10’ of the electrode holder.

Do not coil or loop cables around body parts.

Replace damaged insulation or conductors.

Use the right connectors.

Shielding

Preserves the integrity of the

weld joint

Provided by:

Decomposition of the electrode

covering, known as flux

Gas or a gas mixture

Objectives

1.OSHA Welding, Cutting & Brazing

Standard

2.Personal Protective Equipment

3.Oxygen-Fuel Gas Welding and Cutting

4.Arc Welding and Cutting5.Resistance Welding

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Utilizes pressure and heat

that is generated in the

pieces to be welded by

resistance to an electric

current.

Resistance Welding

Must be installed by qualified electrician.

Circuits must be low voltage.

Doors and access panels must be locked to prevent access by unauthorized persons.

Equipment

Foot switches must be guarded to prevent accidental operation.

All equipment suspended from overhead structures must be equipped with safety cables.

Effective guards must be used if there is a possibility of the operator’s fingers being under the point of operation.

Guarding

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Shield guards made of safety glass or suitable fire-resistant plastic must be installed at the point of operation and as needed to protect from flying sparks.

Flying Sparks

Inspections

Periodic inspections must be made by

qualified maintenance personnel and a

certification record maintained.

Operator must report any equipment

defects to his supervisor.

Use of equipment must be discontinued

until safety repairs are completed.

Be mindful of fire hazards.

Remember the specific hazards for

the type of hot work that you do.

Compressed gases

Electrical

Ultraviolet and infrared radiation

Noise

Always wear the required PPE.

Key Points for Safety

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Great Job!!

You still need training on:The specific hazards at your job.How your employer protects you

with engineering controls and safe work practices.

The PPE that you are required to wear.

Stay Safe!

Get the PointTechneTrain, Inc. has no control over the use of this

material. This product is meant to be only an overview of the subject matter. Any specific use or application of this

product is beyond the scope of responsibility of TechneTrain, Inc.

TechneTrain, Inc. makes no warranties, either expressed or implied, and assumes no responsibility for the use of

this product. Some states may have more stringent regulations than the Federal OSHA Standard. This product is solely intended to address Federal OSHA

regulations.

No part of this presentation may be copied or reproduced without the express written consent of TechneTrain, Inc.

Copyright © 2010 TechneTrain, Inc.