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  1. Module 10 Welding

  2. DISCLAIMER This 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.

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

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

  5. 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

  6. 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

  7. 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

  8. 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

  9. 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

  10. 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

  11. 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 horizontally and roll them to another location • Never use the valve cap to pick up a cylinder • When transported by crane • use a cradle or suitable platform • never use slings or electric magnets • valve caps should always be in place

  12. cylinders must be kept upright and secure while in transport

  13. never store or transport cylinders with regulators attached

  14. 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

  15. 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

  16. 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

  17. 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

  18. 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

  19. Memory Check • Unless a suitable barrier is built, combustibles must be kept how many feet away from the welding operation? • 15 • 25 • 35 • 50

  20. Memory Check • The fire watch at the end of the welding operation must last at least how long? • 30 minutes • 1 hour • 2 hours • 3 hours

  21. Memory Check • Acetylene must not be used above what pressure (psig)? • 1 • 2 • 10 • 15