Welding Safety

Cummins Southern Plains, Ltd.

Welding SafetyHealth HazardsElectrical HazardsFire & Explosion HazardsTrips and FallsCompressed Gas Hazards Identifying HazardsReducing HazardsBasic Safety Rules

Health Hazards Gases and Fumes… Welding “Smoke” is a mixture of very fine particles

called fumes and gases Welding “Smoke” contains fumes and gases including…

Chromium, nickel, arsenic, asbestos, manganese, silica, beryllium, cadmium, nitrogen oxides, phosgene, acrolein, flourine compounds, carbon monoxide, cobalt, copper, lead, ozone, selenium, and zinc

Health Hazards…Gases & Fumes Generally, gases and fumes come from…

Base material & filler materialCoatings & paintsShielding gases & chemical reactionsProcess & consumables usedContaminants in the air

Health Hazards It is difficult to list all the health effects of welding

exposures because the fumes may contain so many different substances that are known to be harmful

The individual components of welding “smoke” can affect just about any part of the body, including the lungs, heart, kidneys, & central nervous system

Health Hazards Exposure to welding “smoke” may have… Short-term effects…

Effects happen at or very soon after exposure Long-term effects

Effects may happen after repeated overexposures or an extended time after the exposure

Short-term exposures Exposure to zinc, magnesium, copper and

copper oxide can cause metal fume fever Symptoms of metal fume fever may occur 4 to

12 hours after exposure Symptoms include…

Chills, thirst, fever, muscle ache, chest soreness, coughing, wheezing, fatigue, nausea, and metallic taste in mouth

Short-term exposures Welding “smoke” can irritate

the eyes, nose, chest and respiratory tract

Welding “smoke” can cause coughing, wheezing, shortness of breath, bronchitis, pulmonary edema, and pneumonitis

Welding “smoke” can cause nausea, loss of appetite, vomiting, cramps, and slow digestion

                                                                                                      

Long-term exposures Studies of welders, flame cutters, and burners

have shown that welders have an increased risk of lung cancer…

and…possibly cancer of the larnyx and urinary tract

Remember… welding “smoke” can include cancer causing agents such as…cadmium, nickel, beryllium, chromium, and arsenic

Other Health Risks… Heat exposure…

Heat stress, heat stroke Burns, eye injuries from hot slag, metal chips, sparks,

and hot electrodes Shirts

keep collar and sleeves buttoned to keep out sparks and remove pockets or tape them shut

Pantsno cuffs and come over shoe tops

Other Health Risks… Visible light, and ultraviolet and infrared radiation Intense light can cause damage to retina Infrared radiation may damage the cornea and

result in cataracts Invisible UV light can cause “arc eye” or

“welders’ flash”May include sandy or gritty eye, blurred vision, intense pain, tearing, burning and headache

DANGERDO NOTWATCH

ARC

Other Health Risks… Permanent eye damage Skin burns Skin cancer Noise

Can result in stress, increased blood pressure, may contribute to heart disease, tiredness, nervousness, and irratability

Electrical Hazards Even though welding generally uses low voltage,

there is still a danger of electric shock Wet work areas, Cramped work spaces Falls, fractures and other accidents can result

from electrical exposure Even small shock can cause brain damage Death can occur from large shocks

Electrical Hazards Always use dry gloves Always wear rubber soled shoes Always use insulating layers Protect yourself from surfaces that conduct electricity When working on electrically powered machinery, make sure

the frame is grounded Keep insulation on all welding equipment and components

dry and in good condition Don’t change electrodes with bare hands, wet gloves or

while standing on wet or ungrounded surfaces

Fire and Explosion Hazards

Intense heat and sparks can cause fires or explosions if in the vicinity of combustible or flammable materials

Welding and cutting should only be performed in areas free of combustible materials such as trash, wood, paper, textiles, plastics, chemicals, and flammable dusts, liquids and gases

Cutting torch temperatures can exceed 5000 degrees F

Suitable fire extinguishers shall be maintained in a state of readiness

Fire Watchers are required whenever welding and cutting is performed in locations where other than a minor fire might develop

Fire Prevention and Protection

Fire Watchers are also required when:Appreciable combustible materials, in building construction or contents, are closer than 35 feet to the point of operationAppreciable combustible materials more than 35 feet away but are easily ignited by sparksA fire watch shall be maintained for at least one half hour after the completion of welding or cutting operations

Fire Prevention and Protection

Fire and Explosion Hazards

Never weld or cut on containers that have held a flammable or combustible material unless the container is thoroughly cleaned or filled with an inert gas

A fire inspection should be performed prior to leaving a work area and for at least 30 minutes after the operation is completed

Fire extinguishers should be nearby, of proper size, type and number for the hazards involved

Case StudyArc welder dies in explosion while using an old barrel as a

worktable A 38-year-old male arc welder died as a result of an

explosion at a construction company.The victim was arc welding some brackets on the back of the truck. He was apparently welding with a wire welder and used a metal 55-gal barrel as a worktable while welding. Apparently the heat or sparks from the welding ignited residual vapors and/or material in the barrel, causing it to explode. The explosion knocked the victim down, and started a fire in the immediate area.

Case StudyRecommendations Ensure welders are suitably trained in

safe operation of equipment and process.

Ensure that welding should not be performed on or near used drums, until they have been thoroughly cleaned.

Develop, implement, and enforce a written safety program, including HOT WORK.

Designate a competent person to conduct frequent and regular site safety inspections.

Trips and Falls To prevent trips and falls…

Keep work areas clear of equipment, machines, cables, and hosesAlways properly maintain and use handrailsAlways use and maintain safety lines, harnesses and lanyardsAlways make sure that scaffolds are properly assembled and used

Compressed Gas Hazards Gas welding and cutting use a

fuel gas and oxygen which are stored in high pressure cylinders

Most fuel gases are explosive Pure oxygen will increase the

flammability of any combustible/flammable material

Identifying Hazards Identify hazards and potential hazards prior to

beginning hot work Read the MSDS sheet to identify the hazardous

material used in welding and cutting products, and the fumes that may be generated

Make sure that you know what you are welding before beginning

Reducing Hazards After a specific hazard(s) has been identified…

You can implement appropriate control method(s)You can use appropriate PPE

PPE

CONTROL

Engineering Controls and Work Practices

UV shields between the worker and other operations can protect against exposures

Use work area barriers to protect others working in the same general area

Barriers can also reduce noise

Filter Lens Shade Numbers Soldering = #2 Torch Brazing = #3 or #4 Light cutting up to 1 inch = #3 or #4 Medium cutting 1 inch to 6 inches = #4 or #5 Heavy cutting over 6 inches = #4 or #6 Light gas welding up to 1/8” = #4 or #5 Medium gas welding 1/8” to ½ “ = #5 or #6 Heavy Gas Welding over ½ “ = #6 or #8

Protective Clothing Fire resistant gauntlet gloves Headcap High top hard toed shoes Leather apron Faceshield Flame retardant clothing Safety Glasses Safety helmet

Hearing Protectors Ear plugs and/or muffs should be worn during

noisy operations such as air arcing or grinding Most welding operations are noisy

Respirators Must be specific to the hazard Must be fitted, cleaned, stored and maintained in

accordance to regulation and manufacturers specs

NIOSH recommends respirators whenever a carcinogen is present

Basic Safety Rules 1. Before you start make sure personal safety is followed. 2. Make sure you have had instruction 3. Release adjusting screw on regulators before opening valves 4. Stand on the opposite side of the regulator when opening a

valve 5. Open cylinder valve slowly, oxygen first all the way open

acetylene just a quarter of a turn 6. Do not use or compress acetylene at pressure higher than 15

psi.

Basic Safety Rules 7. Set working pressures as desired. 8. Light acetylene first, shut it off first 9. Never use oil on regulators or any equipment 10. Do not use oxygen as a substitute for compressed air 11. Keep heat, flames and sparks away from

combustibles. 12. Keep hoses out of sparks or spatter to prevent leaks