Work Safety in Cutting Welding
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Work Safety in
CuttingWelding
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What is?????
Welding: Joining two pieces of metal by the
use of heat, pressure, or both
Cutting: Metal cutting by heating the metalwith a flame and directing a stream of pureoxygen along the line to be cut
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Welding
Arc Welding
Shielded Metal Arc Welding (SMAW)
Metal Inert Gas (MIG) Tungsten Inert Gas (TIG)
Plasma Arc Welding (PAW)
Submerged Arc Welding (SAW)
And Many More..more than 80 in all
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Arc Welding
A fusion process for
joining metals. Through
the application of
intense heat, the metalsat the joint intermix
(often with a filler
material) to create a
metallurgical bond asstrong as the original
two metals.
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Applications and Environment
Arc welding is performed whenever an
extremely strong metal bond is needed:
± Construction
± Maintenance
± Manufacturing
Arc welding is performed in all
environments:
± Indoors / Outdoors
± Extreme Heights
± Confined Spaces
± Underwater
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Arc Welding Components
Arc Welding requires
five main pieces of
equipment:
± Electrode
± Electrode Holder
± Electrode Cable
± Welding Machine (AC or
DC)
± Work Cable
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Dangers of Welding
Most fatalities that
occur while welding fall
into below categories:
± Electrocution
± Fire / Explosions
± ± Fumes and gasesFumes and gases
± ± Confined spacesConfined spaces
± ± Radiation exposureRadiation exposure
± Falls
Welding and cutting are hazardous activities ... The
risk from fatal injuries alone is more than four deaths
per 1,000 workers over a working lifetime.
- OSHA Safety and Health Topics
http://www.osha.gov/SLTC/weldingcuttingbrazing/index.html
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Electric shockElectric shockTwo kinds of electric shock: primary voltageTwo kinds of electric shock: primary voltage
shock and secondary voltageshock and secondary voltage shockshock
Primary voltage shock involves 230 or 460 voltsPrimary voltage shock involves 230 or 460 volts
and is caused by touching both the lead insideand is caused by touching both the lead inside
the welding equipment and the weldingthe welding equipment and the welding
equipment case or other grounded metal whileequipment case or other grounded metal while
the equipment is powered ONthe equipment is powered ON
Secondary voltage shock involves 60 to 100Secondary voltage shock involves 60 to 100
watts and is caused by touching a part of thewatts and is caused by touching a part of the
electrode circuit and the side of the weldingelectrode circuit and the side of the welding
circuit.circuit.
Types of Welding HazardsTypes of Welding Hazards
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Fires and explosionsFires and explosions
The welding process can produce extremeThe welding process can produce extreme heat.heat.
HoweverHowever, fire hazards are not caused by the heat but by, fire hazards are not caused by the heat but by
the effect of the heat on thethe effect of the heat on the work piecework piece, such as sparks, such as sparksand moltenand molten metal.metal.
Keep the work area and all surrounding areas free of Keep the work area and all surrounding areas free of
combustible items.combustible items.
Be cautious when working in dusty areas where sparks
and dust particles can easily oxidize without warning,
which can result in a flash fire or an
explosion.
Types of Welding Hazards (continued)Types of Welding Hazards (continued)
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How to avoid FiresHow to avoid Fires andand explosions..explosions..
Do the following to protect from fire and
explosions:
Always know where the fire exits and fire
extinguishers are located.
If welding within 35 feet of a combustible object,
utilize a fire watcher, who can watch for landingsparks.
Types of Welding Hazards (continued)Types of Welding Hazards (continued)
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Fumes and gasesFumes and gases
Fumes contain particles from base metal and baseFumes contain particles from base metal and base
metal coatingmetal coating
Effects from fumes are normally temporaryEffects from fumes are normally temporarySymptoms caused by shortSymptoms caused by short--term exposure to fumes canterm exposure to fumes can
include burning eyes, burning skin, dizziness, nausea, andinclude burning eyes, burning skin, dizziness, nausea, and
fever.fever.
LongLong--term exposure to fumes can causeterm exposure to fumes can cause siderosissiderosis
(which are iron deposits in the lungs) and can affect(which are iron deposits in the lungs) and can affect
pulmonary function.pulmonary function.
Types of Welding Hazards (continued)Types of Welding Hazards (continued)
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Types of Welding Hazards (continued)Types of Welding Hazards (continued)
Zinc fumes can cause metal fume fever, which is aZinc fumes can cause metal fume fever, which is a
temporary illness similar to the flu.temporary illness similar to the flu.
CadmiumCadmium fumes can cause symptoms similar to metalfumes can cause symptoms similar to metalfumefume fever. Howeverfever. However, it can be fatal, even under brief , it can be fatal, even under brief
exposure.exposure.
When shielding gases are released into the air, they canWhen shielding gases are released into the air, they can
cause dizziness, unconsciousness, and even death if cleancause dizziness, unconsciousness, and even death if clean
oxygen is withheld for a long enough period.oxygen is withheld for a long enough period.UV radiation forms gases when it hits the air, which canUV radiation forms gases when it hits the air, which can
cause headaches, chest pains, eyecause headaches, chest pains, eye irritation,andirritation,and itchinessitchiness
in the nose and throat.in the nose and throat.
Fumes and gasesFumes and gases (continued)(continued)
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Do the following to protect from fume and gas exposureDo the following to protect from fume and gas exposure::
Ensure adequate ventilation in the work area.Ensure adequate ventilation in the work area.
Wear appropriate personal protectiveWear appropriate personal protective equipmentequipment,, suchsuch asas
aa respirator.respirator.
Read material safety data sheets beforeRead material safety data sheets before beginning workbeginning work toto
learnlearn what fumes can bewhat fumes can be potentially releasedpotentially released..
Familiarize yourself with the metals that areFamiliarize yourself with the metals that are being usedbeing used
toto determine if a paint or coating candetermine if a paint or coating can causecause toxictoxic fumesfumesoror gases.gases.
If symptoms of dizziness, headache, or nausea occur, turnIf symptoms of dizziness, headache, or nausea occur, turn
off the welding equipment, notify supervisors andoff the welding equipment, notify supervisors and
coworkers, and get fresh air immediately.coworkers, and get fresh air immediately.
Types of Welding Hazards (continued)Types of Welding Hazards (continued)
How to avoid FumesHow to avoid Fumes andand gasesgases
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Confined spacesConfined spaces
Examples of confined spaces include a boiler, tank, orExamples of confined spaces include a boiler, tank, or
hold of a ship where all the welding hazards are amplified,hold of a ship where all the welding hazards are amplified,such as insufficient ventilation, fume and gas exposure, andsuch as insufficient ventilation, fume and gas exposure, and
chances of fire or explosion.chances of fire or explosion.
Types of Welding Hazards (continued)Types of Welding Hazards (continued)
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Safety for working in Confined spacesSafety for working in Confined spaces
Types of Welding Hazards (continued)Types of Welding Hazards (continued)
Do the following to protect yourself when working inDo the following to protect yourself when working in
confined spacesconfined spaces::
Follow all the safety requirements for Entry in to theFollow all the safety requirements for Entry in to theconfined spaces.confined spaces.
MakeMake sure your body is insulated from thesure your body is insulated from the work piecework piece
and ground.and ground.
WearWear dry gloves.dry gloves.
UseUse only a wellonly a well--insulated electrode holder.insulated electrode holder.
VerifyVerify that there is sufficient ventilation.that there is sufficient ventilation.
AlwaysAlways make sure there is a trained person outsidemake sure there is a trained person outside thethe
confined space at all times to disconnect power andconfined space at all times to disconnect power and pullpull
the welder out if a dangerous situation occurs.the welder out if a dangerous situation occurs.
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Types of Welding Hazards (continued)Types of Welding Hazards (continued)
FallsFalls
Examine the workspace
prior to commencing any
work to identify possible
hazards
Always properly tie-off
when welding from heights
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Safe components for Safe Welding
Manual Electrode Holders:
Only use electrode holders specifically designed
to safely handle the maximum rated current
required
Make sure all current carrying parts are well
insulated
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Welding Cables and Connectors:
± All welding cables should be well insulated
± Repairs or splices must be at least 10ft from the
electrode. Splices made closer must have the
same insulating quality as the cable.
10 Min.
Repair or splice
Safe components for Safe Welding
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Use substantial insulating material at splices or connectors
Cables in need of repair can
not be used
Splice
Safe components for Safe Welding
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Ground Returns and Machine Grounding:
Ground cables must be able to carry the specified
maximum current capacity
Do not use pipes carrying flammable gases, flammable
liquids, or electric wires as a ground
Ground Wire
Flammable Gases / Liquids
Electrical Wiring
Safe components for Safe Welding
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Frame of welding machine must also be grounded
Ground must be able to break fuse
Ground connections must be strong and adequate
Must Also be Grounded
Safe components for Safe Welding
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Operating Procedures:
When left unattended, remove electrodes and place away
from conductive materials
Never place hot electrode holders in water
Hot
ElectrodeHolder
Safe Procedures for Safe Welding
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Turn off welding machine when left unattended or when
moving
Use shielding screens if possible
Safe Procedures for Safe Welding
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Personal Protective Equipment
Wear the appropriate PPE
for the job:
Eye Protection
Burn Protection
Inhalation Protection
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Cutting
The most common cutting processes are:
Oxygen Cutting
Arc Cutting
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Oxygen (Gas) Cutting
Metal is heated by gas flame and an oxygen jet
does the cutting.
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Applications and Environment
Gas Cutting is performed
whenever a metal has tobe cut as needed:
Construction
Maintenance
Manufacturing
Gas Cutting is performed
both indoor as well as
out door environments
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Gas Cutting Components
Gas Cutting requires
following main pieces
of equipment:
Oxygen/ Fuel CuttingRig
Oxygen/ Fuel Regulator
Oxygen/ Fuel Hose
Cutting Torch
Spark Lighter
Suitable nozzle/ tip
Flash back arrestors
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Oxygen/ Acetylene Cutting Torch
Safety Hazards Most incidents that occur
while Cutting fall into below
categories:
Working Pressure GaugeFailure
Cracked Acetylene Hose
Improper storage of Oxygen/
Acetylene Cutting Torch Improper use/ storage of Improper use/ storage of
cylinderscylinders
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Dos& Donts of Oxygen (Gas) Cutting
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Dos& Donts of Oxygen (Gas) Cutting
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Safe procedures for safe Oxygen (Gas)
Cutting
Make sure regulators are tight.
Never use oily rags around cylinders and
regulators.
Check hoses for leaks before lighting the torch.
Make sure regulators are at proper settings.
15 psi max. acetylene 40 psi max. oxygen
Be sure to completely shut down the cutting
torch when the job is completed.
Ventilate work areas adequately.
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Safe procedures for safe Oxygen (Gas)
Cutting
Personnel Safety
Wear flame resistant clothing,
protective gloves, sleeves, aprons
and safety shoes to protect skinand clothing from sparks and slag.
Keep collars, sleeves and pockets
buttoned.
DO NOT
roll up sleeves or cuff pants.
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Please Remember