MODULE 2

Potential hazards the welding inspector may face include: electric shock, falling,
radiation, eye hazards such as UV light, particulate matter in the air, smoke and
fumes and falling objects.
The recommended safety precautions are available on ANSI Z49.1, safety in
welding, cutting and allied processes.
The most important component of an effective safety and health program is
leadership support and direction. Management must clearly state objectives and
show commitment to safety and health by consistent support of safe practices.
Management Support is evidenced by:

Stating clear safety objectives

Showing commitment to safety
Designating safe work areas
Developing safety procedures
Providing safe equipment
Implementing safety training Management must be certain that only
approved welding, cutting and allied equipment are used.

Adequate supervision must be provided to assure a equipment is properly used

and maintained.
Adequate safety training is mandated under the provisions of the U.S.
Occupational safety and Health Act (OSHA).
Workers are trained on how to keep their heads away from fume plume.
Fume plume is a smoke like cloud containing minute solid particles arising
directly from the area of the melting metal.
Before work begins users must read and understand the MSDS. Manufacturers of
welding consumables should furnish MSDS. MSDS provides information on OSHA
permissible exposure limits called threshold limit value TLV. The MSDS gives
composition of fumes generated and other hazards that may be caused during
use.
Under the OSHA hazard communication standard, 29 CFR 1910, 1200, employers
are responsible for employees hazardous material training in workplace. Welding
consumable in this standard are defined under hazardous materials.

Safety Training

Mandated by local occupational safety regulations (e.g., OSHA

29CFR1910.1200)
A key aspect of safety
Fosters continuous improvement

Aids accident prevention

All accidents can be prevented!

Occupational Safety Training Topics

Hazardous materials
Equipment operation
Equipment maintenance
Recognition of hazards
Safety rules

Housekeeping:
Housekeeping is the safety key to reducing:

Tripping hazards
Fire hazards
Blocked escape routes
Improper materials storage

Fire Prevention:

There should be designated welding/cutting areas

Work areas are free of combustibles
Workers should have good Knowledge of equipment
Fire watch if needed
Hot work permit should be in place

Hot Work Permit

Hot work permit contains

Date
Time
Location
Nature of job
Flammability checks
Fire extinguishers
Instructions
Supervision signature

Personnel next to welding and cutting must be protected from radiant energy
and hot spatter by using flame resistance screen or shield.

Areas where arc welding or cutting is performed regularly, painted walls near it
should be of paint of low reflectivity such as titanium dioxide or zinc oxide
pigment formulated paint.
When a hot work permit is issued, the welding inspector must be aware of and
adhere to all its requirements.
EYE AND FACE PROTECTION:
Welding helmets and handshields containing appropriate filter plates must be
worn.
The standard for welding helmets, handshield, face shield, goggles and
spectacles are given in ANSI publication Z87.1 practice for occupational and
educational eye and face protection.
Number 2 filter plates are recommended for general purpose protection.
When doing arc welding you should wear arc welding helmet.
When doing oxyfuel gas welding and submerged arc welding, you should wear
tinted safety glass.
When doing Torch bracing and soldering safety spectacles with side shields and
appropriate filters should be worn.
PROTECTIVE CLOTHING:
Woollen clothes are preferred to cotton because its not readily ignited.
FUMES AND GASES:
Fumes are usually a greater concern in arc welding than oxyfuel gas welding,
cutting and brazing.
The exposure factors to fumes include the position of the head, ventilation, work
area, background fume level, design of welding helmet, base metal and surface
condition.
Ventilation might be local or general.
Local ventilation: in local ventilation, fumes are extracted near the point of
welding.
General ventilation: in this case the shop air is changed or filtered.
The appropriate type of ventilation will depend on the type welding process, the
material being welded and other shop conditions.
Background fume level: this depends upon the number and type of weld stations
and the duty cycle for each power source.
Sources of ventilation:

Natural
General area ventilation
Overhead exhaust hoods
Portable local exhaust devices
Downdraft tables
Crossdraft table
Extractors built in welding machines
Air ventilated helmets.

CONFINED SPACE:
Positive pressure self-contained breathing apparatus must be used when welding
or cutting related processes are done in confined space where ventilation cannot
be provided. It must have an emergency air supply of at least 5 minutes in case
the main source fails.
HANDLING OF COMPRESSED GASES:
In the U.S. only cylinders designed and maintained by U.S. Department of
transportation DOT specifications may be used. Use of other cylinders may be
dangerous and illegal. Cylinders requiring periodic test may not be filled except
retest is current.
Welding must not be performed on cylinders. Cylinders must be allowed to be
used as part of an electrical circuit because arcing may result from this. Cylinders
containing shielding gases used in conjunction with arc welding must not be
grounded.

Cylinders should be kept in areas free of impact of other objects. Cylinders

should not be kept at Temperatures below -20F and above 130F. Cylinders
should not be hoisted using slings or chains. Electromagnets should not be used
to handle cylinders.
Acetylene cylinders must be kept upright. The content of the cylinder should be
labelled thereon. Color, banding or shape of cylinder should not be used for
identification.
An acetylene cylinder valve shall not be opened more than approximately one
and one-half turns and preferably no more than three-fourths of a turn, unless
otherwise specified by the manufacturer.
Maximum Acetylene Pressure:
Acetylene shall not be utilized at a pressure in excess of 15 psig (103kPa) or 30
psia (206 kPa). This requirement shall not apply to storage of acetylene dissolved
in a suitable solvent in cylinders manufactured and maintained according to
Department of Transportation requirements, or to acetylene for chemical use.

The valve safety cap should always be in place except the cylinder is being used.
If high pressure cylinders are filled in excess of 2000 PSI, and approved pressure
reducing regulator must be used to withdraw gas from the cylinder or manifold.
Needle valves should never be used. Pressure relief valve or safety valve rated to
function at less than maximum allowable pressure of the welding equipment
should also be employed.
Before connecting a gas cylinder to a regulator or manifold, the valve outlet
should be cleaned to be free from dirt, moisture and other foreign matter. The
valve should be then opened and closed momentarily. This process of opening
momentarily and closing immediately is called cracking the cylinder valve. This
action, generally termed cracking, is intended to clear the valve of dust or dirt
that otherwise might enter the regulator.
Use of adapters to change the cylinder connection thread is not recommended to
avoid contamination or incorrect regulator.
Manifolds:
Pipings and fittings for acetylene and methyacetelene-propadiene MPS manifolds
must not be dealloyed coppers or alloys containing 70% copper or more. These
fuel gas react with copper to form unstable copper acetylide which can detonate
under shock or heat. Manifolds shall contain appropriate relief valve. Each fuel
gas branch line should incorporate a backflow check valve and flash arrester.
In cryogenic piping systems, relief devices should be located in every section of
the system where liquefied gas may be trapped.
In case of fuel fire, an effective means of controlling the fire is to shut off the fuel
valve.