WELCOME

1. WELDING SAFETY OSHA TRAINING OSHA 29 CFR 1910.251 - 255 WELCOME

2. COURSE OBJECTIVES DISCUSS THE FOLLOWING: • TRAINING REQUIREMENTS • PERSONAL PROTECTIVE EQUIPMENT • CONTRACTOR SAFETY REQUIREMENTS • THE RELEVANT REGULATORY STANDARDS • VENTILATION REQUIREMENTS FOR WELDING • ELECTRIC WELDING SAFETY REQUIREMENTS • THE BASICS OF CONFINED SPACE OPERATIONS • FIRE EVACUATION, PREVENTION AND PROTECTION • THE GENERAL HAZARDS INVOLVED WITH WELDING • OXYGEN-FUEL GAS WELDING SAFETY REQUIREMENTS

3. BASIS FOR THIS COURSE • HUNDREDS OF WELDERS CRITICALLY INJURED ANNUALLY • WELDERS ARE EXPOSED TO NUMEROUS TOXIC FUMES AND GASES • WELDERS ARE EXPOSED TO NUMEROUS PHYSICAL HAZARDS • OSHA WELDING SAFETY STANDARDS REQUIRE: • ESTABLISHMENT OF A “WORKER SAFETY” PROGRAM • TRAINING BE CONDUCTED • WRITTEN “HOTWORK” PERMITS • USE OF MATERIAL SAFETY DATA SHEETS • USE OF LABELS AND OTHER WARNINGS • THAT HAZARDS AND PRECAUTIONS BE EXPLAINED

4. BASIS FOR THIS COURSE THE BOTTOM LINE TRAINING YOU TO BE KNOWLEDGEABLE OF HOW TO LOWER YOUR LIFETIME WORKPLACE EXPOSURE TO THE WELDING HAZARDS YOU ARE POTENTIALLY EXPOSED TO IN YOUR DAILY WORKING LIFE!

5. REGULATORY STANDARD THE GENERAL DUTY CLAUSE FEDERAL - 29 CFR 1903.1 EMPLOYERS MUST: Furnish a place of employment free of recognized hazards that are causing or are likely to cause death or serious physical harm to employees. Employers must comply with occupational safety and health standards promulgated under the Williams-Steiger Occupational Safety and Health Act of 1970.

6. DANGER HOTWORK IN PROGRESS OSHA REGULATORY STANDARDS 29CFR - SAFETY AND HEALTH STANDARDS 1910 - GENERAL INDUSTRY 252 - GENERAL REQUIREMENTS 253 - OXYGEN WELDING 254 - ARC WELDING 255 - RESISTANCE WELDING

7. NFPA - 51B FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES ANSI - Z49.1 SAFETY IN WELDING AND CUTTING REGULATORY STANDARD NFPA and ANSI WELDING CRITERIA

8. THE SAFETY PROGRAM GENERAL PROGRAM REQUIREMENTS ALL EMPLOYERS MUST: • REVIEW FIRE HAZARDS • INSTITUTE SAFE WORK PRACTICES • PROVIDE COMPLETE HAZARD INFORMATION • PROVIDE HEALTH SCREENING WHERE NEEDED • PROVIDE TRAINING TO ALL REQUIRED EMPLOYEES • INSTALL ENGINEERING CONTROLS WHERE POSSIBLE

9. WELDING SAFETY TRAINING REQUIREMENTS • THE EMPLOYER MUST: • MAINTAIN A WELDING SAFETY PROGRAM. • DISCUSS EMPLOYEE PROTECTIVE MEASURES. • REVIEW THE PROGRAM ON AN ANNUAL BASIS. • TRAIN ALL EMPLOYEES PRIOR TO JOB ASSIGNMENT. • DISCUSS PERIPHERALS SUCH AS LOCKOUT AND CONFINED • SPACES.

10. WELDING SAFETY RETRAINING REQUIREMENTS • REQUIRED WHEN THERE IS A: • CLOSE-CALL EVENT • CHANGE IN JOB ASSIGNMENT • NEW HAZARDS OR EQUIPMENT • NEW HAZARD CONTROL METHODS • FAILURE IN THE SAFETY PROCEDURES • REASON TO DOUBT EMPLOYEE PROFICIENCY

11. PROGRAM MANAGEMENT FORMS COMMONLY USED PROGRAM MANAGEMENT FORMS • NON-ROUTINE TASK - • PROTECTIVE MEASURES DETERMINATION FORM: • USED BY SUPERVISORS TO ASSESS JOBS THAT ARE NOT • PERFORMED ON A ROUTINE BASIS, BUT WHERE THE • POSSIBILITY OF INJURY TO AN EMPLOYEE EXISTS.

12. NON-ROUTINE TASKS • DEFINITION: A TASK THAT IS REQUIRED ONLY ON OCCASION AND • WHERE EMPLOYEES ARE NOT COMPLETELY FAMILIAR • WITH ALL ASPECTS OF THE JOB. • PROBLEM: THIS LACK OF FAMILIARITY CONTRIBUTES GREATLY TO A HIGHER PROBABILITY OF INJURY. • EXAMPLE: THE ANNUAL (OR INFREQUENT) CLEANING OF REACTOR • VESSELS IN PROCESSES. • SUPERVISORS MUST: IDENTIFY NONROUTINE TASKS AND ASSESS • THEIR DEGREE OF RISK TO EMPLOYEES.

13. DANGER FIRE HAZARD HOTWORK PERMIT REQUIRED PROGRAM MANAGEMENT FORMS COMMONLY USED PROGRAM MANAGEMENT FORMS • HOTWORK PERMIT: • PRE-WORK SAFETY EVALUATION • ISSUED BY COMPETENT AUTHORITY • LOWERS RISK OF ACCIDENTS AND FIRES • STANDARDIZES WORK ACCOMPLISHMENT • ESTABLISHES TIMEFRAMES WHEN HOTWORK CAN OCCUR • GENERALLY NOT NEEDED FOR DESIGNATED FIRE-SAFE AREAS

14. DANGER HOTWORK IN PROGRESS GENERAL WELDING HAZARDS • ARC RADIATION. • EXPLOSIVE DUSTS. • ELECTRICAL SHOCK. • WELDING CLEANING. • AIR CONTAMINATION. • FIRE AND EXPLOSION. • CONFINED SPACE OPERATIONS. • CONTROL OF HAZARDOUS ENERGY. • COMPRESSED GAS HANDLING AND USE HAZARDS. • OTHER HAZARDS RELATED TO SPECIFIC PROCESSES OR • OCCUPATIONS.

15. SPECIFIC TYPES OF HAZARDS • AIR CONTAMINANTS • GASES. GENERALLY USED IN A COMPRESSED FORM. • CAN EFFECT ALL ROUTES OF ENTRY. • VAPORS. FORMED BY EVAPORATION OF LIQUIDS OR • SOLIDS. AMOUNT USUALLY DEPENDS UPON EXPOSED • SURFACE AREA, TEMPERATURE, AND VAPOR PRESSURE • OF SUBSTANCE. CAN BE DEADLY.

16. SPECIFIC TYPES OF HAZARDS • AIR CONTAMINANTS • FUMES. USUALLY METALLIC AND FORMED BY WELDING, • CUTTING, OR BRAZING OPERATIONS. • EXTREMELY HAZARDOUS TO INHALE. • PARTICULATES. COMPOSED OF SOLID OR LIQUID • PARTICLES THAT ARE SUSPENDED OR DISPERSED IN AIR. • SUCH AS DUST, MISTS, OR SMOKES. CAN BE EXPLOSIVE • AND HAZARDOUS TO BREATH.

17. SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS • - INHALATION: • MOST COMMON ROUTE OF ENTRY. • SMALLER PARTICULATES ARE TRAPPED IN LUNGS • AND ABSORBED.

18. SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS • - INGESTION: • EATING, DRINKING, OR SMOKING WITHOUT WASHING HANDS • FIRST. • EATING, DRINKING, OR SMOKING CONTAMINATED • CONSUMABLES.

19. SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS • - ABSORPTION. • CAN OCCUR THROUGH UNBROKEN SKIN OR MUCOUS • MEMBRANES. • ABSORPTION GENERALLY LEAST HAZARDOUS ROUTE • OF ENTRY.

20. SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS • - INJECTION. • USUALLY CAUSED BY PUNCTURE WOUNDS INVOLVING • METALS. • COMPRESSED AIR CAN ALSO CAUSE INJECTION OF • METALS.

21. SPECIFIC TYPES OF HAZARDS • - METAL PARTICULATES: • COME FROM SAND BLASTING, DEBURRING, AND LIKE • OPERATIONS. • METALS CAN TAKE THE FORM OF AIRBORNE DUSTS. • ENGINEERING CONTROLS ARE USUALLY REQUIRED. • RESPIRATORY PROTECTION IS NEEDED WHERE DUSTS • CANNOT BE ADEQUATELY CONTROLLED WITH ENGINEERING • CONTROLS.

22. SPECIFIC TYPES OF HAZARDS • - FUMES: • COMMON TO ALL WELDING OPERATIONS • FUMES ARE MADE UP OF VERY TINY SOLID METAL PARTICLES. • PARTICLES ARE THE CONDENSATES OF VAPORIZED METAL. • EFFECTS ON THE HUMAN BODY CAN BE DISASTROUS IF PROPER • VENTILATION IS NOT USED. • THINK OF THE DIFFERENT TYPES OF METALS AND BONDING • MATERIALS USED USED IN A WELDING OPERATION.

23. SPECIFIC TYPES OF HAZARDS SPECIFIC METALS • - CADMIUM. • HIGHLY TOXIC, INHALATION MOST COMMON ROUTE OF ENTRY. • SMALLER PARTICULATES ARE TRAPPED IN LUNGS AND • ABSORBED. • DANGEROUS DOSES CAN BE ASYMPTOMATIC FOR HOURS. • KNOWN HUMAN CARCINOGEN. • TARGET ORGANS INCLUDE, KIDNEYS, RESPIRATORY SYSTEM.

24. SPECIFIC TYPES OF HAZARDS SPECIFIC METALS • - COPPER AND ZINC. • HIGHLY TOXIC, INHALATION MOST COMMON ROUTE OF ENTRY. • CAN CAUSE “METAL FUME FEVER” RESULTING IN • (SEVERE FLU-LIKE SYMPTOMS). • TARGET ORGANS INCLUDE, KIDNEYS, RESPIRATORY SYSTEM.

25. SPECIFIC TYPES OF HAZARDS SPECIFIC METALS • - NICKEL. • CAN BE ABSORBED THROUGH SKIN, OR LUNGS. • ABSORPTION GENERALLY LEAST HAZARDOUS ROUTE OF ENTRY. • TARGET ORGANS INCLUDE; CNS, RESPIRATORY SYSTEM.

26. SPECIFIC TYPES OF HAZARDS METALS - GENERAL PRECAUTIONS • IF YOU’RE NOT FAMILIAR WITH THE METAL, FIND OUT! • READ THE MATERIAL SAFETY DATA SHEET! • READ THE LABELS ON CONTAINERS. • OBSERVE WRITTEN WARNINGS! • DON’T EAT, DRINK, OR SMOKE AROUND METAL DUSTS. • CHANGE YOUR CLOTHS! DON’T TAKE IT HOME!

27. SPECIFIC TYPES OF HAZARDS METALS - GENERAL PRECAUTIONS (CONTINUED) • ENSURE WORK AREA IS VENTILATED. • WEAR APPROPRIATE PROTECTIVE EQUIPMENT. • SPILLS OF METALS MUST BE CONTAINED, NOT RAISED! • FOR LARGE SPILLS, CONTACT SAFETY OFFICER. • STORE ACIDS FROM BASES TO PREVENT REACTIONS. • MAGNESIUM IS WATER REACTIVE, USE DRY SAND TO • EXTINGUISH MAGNESIUM FIRES.

28. PERSONAL PROTECTIVE EQUIPMENT • EYE PROTECTION: • FOLLOW LOCAL JOB PROCEDURES • SEE ANSI STANDARD Z87.1 FOR SHADING CRITERIA • SEE CHART IN 29CFR 1910.252 FOR SHADING CRITERIA • REVIEW THE JOB HAZARD ANALYSIS ASSESSMENT • IF A NEW JHA IS NEEDED REQUEST IT • IF YOU HAVE QUESTIONS CONSULT YOUR SUPERVISOR

29. PERSONAL PROTECTIVE EQUIPMENT GUIDE FOR SELECTION OF SHADE NUMBERS: WELDING OPERATION SHADE # Soldering 2 Torch Brazing 3 or 4 Light Cutting, up to 1 Inch 3 or 4 Medium Cutting, 1 to 6 Inches 4 or 5 Heavy Cutting, 6 Inches and Over 5 or 6 Gas Welding (Light) Up to 1/8 Inch 4 or 5 Gas Welding (Medium) 1/8 to 1/2 Inch 5 or 6 Gas Welding (Heavy) 1/2 Inch and Over 6 or 8

30. PERSONAL PROTECTIVE EQUIPMENT GUIDE FOR SELECTION OF SHADE NUMBERS: WELDING OPERATION SHADE # Shielded Metal-Arc Welding 1/16, 3/32, 1/8, 5/32 Inch Electrodes 10 Gas-Shielded Arc Welding (nonferrous) 1/16, 3/32, 1/8, 5/32 Inch Electrodes 11 Gas-Shielded Arc Welding (ferrous) 1/16, 3/32, 1/8, 5/32 Inch Electrodes 12 Shielded Metal Arc Welding 3/16, 7/32, 1/4 Inch Electrodes 12 Shielded Metal Arc Welding 5/16, 3/8 , Inch Electrodes 14 Atomic Hydrogen welding 10-14 Carbon Arc Welding 14

31. PERSONAL PROTECTIVE EQUIPMENT • SHADE NUMBER SELECTION: • AS A RULE OF THUMB, START WITH A SHADE THAT IS • TOO DARK TO SEE THE WORK ZONE. THEN GO TO A • LIGHTER SHADE WHICH GIVES SUFFICIENT VISIBILITY • OF THE WORK ZONE WITHOUT EXERTING A STRAIN ON • YOUR EYES. • DO NOT ALLOW OBSERVERS TO REMAIN IN THE AREA • WITHOUT PROPER PROTECTION.

32. PERSONAL PROTECTIVE EQUIPMENT • SKIN PROTECTION: • FOLLOW LOCAL JOB PROCEDURES • USE ONLY APPROVED WELDING SAFETY EQUIPMENT • ENSURE FULL SKIN PROTECTION IS PROVIDED • SEE ANSI STANDARD Z49.1 FOR SPECIFIC CRITERIA • SEE 29CFR 1910.132 AND 252 FOR GENERAL CRITERIA • REVIEW THE JOB HAZARD ANALYSIS ASSESSMENT • IF YOU HAVE QUESTIONS CONSULT YOUR SUPERVISOR

33. PERSONAL PROTECTIVE EQUIPMENT • FIRE RESISTANT PROTECTIVE CLOTHING: • WEAR CLOTHING WITHOUT POCKETS OR CUFFS • SLEEVES SHOULD BE ROLLED DOWN AND BUTTONED • COLLARS SHOULD BE BUTTONED • WEAR A LEATHER CAP OR HARD HAT • REMEMBER TO WEAR PROPER SHOES FOR THE JOB • ENSURE CLOTHING IS FREE OF IGNITABLE STAINS • CONSIDER SCARFS, GAUNTLETS AND LEGGINGS

34. PERSONAL PROTECTIVE EQUIPMENT • HEAD PROTECTION: • FOLLOW LOCAL JOB PROCEDURES • USE ONLY APPROVED WELDING SAFETY EQUIPMENT • REQUIRED FOR ALL ARC WELDING OR ARC CUTTING • HELMETS MUST BE INSULATED AND HEAT RESISTANT • HELMETS MUST PROTECT FACE, NECK, HAIR AND EARS • HELMETS MUST BE MADE OF NONFLAMMABLE MATERIAL • HELMETS MUST BE CAPABLE OF BEING STERILIZED

35. PERSONAL PROTECTIVE EQUIPMENT • RESPIRATORY PROTECTION: • FOLLOW LOCAL JOB VENTILATION PROCEDURES • ADEQUATE VENTILATION IS MANDATORY • USE APPROVED RESPIRATORY PROTECTION EQUIPMENT • NEVER BREATH METALLIC FUMES • ALWAYS ASSUME WORST-CASE SCENARIO WHEN • SELECTING RESPIRATORY PROTECTION MEASURES

36. PERSONAL PROTECTIVE EQUIPMENT • OBSERVERS/CO-WORKER PROTECTION: • NEED THE SAME PROTECTION AS THE WORKER • DESIGNATE SAFE AREAS TO ALLOW FOR SMOOTH • OPERATIONS IN THE LOCAL WORKING AREA • ALWAYS ASSUME WORST-CASE SCENARIO WHEN • SELECTING PROTECTIVE MEASURES

37. FIRE EVACUATION • BASIC CONSIDERATIONS: • KNOW TWO MEANS OF ESCAPE FROM AREA • KNOW THE WRITTEN POLICY • KNOW THE PREFERRED MEANS OF ALERTING OTHERS • KNOW WHERE THE EVACUATION RELOCATION POINT IS • YOU WON’T HAVE TIME TO LEARN SHOULD YOU HAVE • TO EVACUATE!

38. FIRE PREVENTION AND PROTECTION • BASIC PRECAUTIONS: • NFPA STANDARD 51B HAS DETAILED REQUIREMENTS • ADEQUATE VENTILATION IS MANDATORY • SITE ASSESSMENT FOR HOT-WORK MUST BE MADE • SITE PRECAUTIONS VARY FROM SITE TO SITE • MOVABLE FIRE HAZARDS MUST BE MOVED • NON-MOVEABLE FIRE HAZARDS MUST BE GUARDED • HOT-WORK PERMITS ESSENTIAL IN NON FIRE-SAFE AREAS

39. FIRE PREVENTION AND PROTECTION • WELDING SURFACES: • FLOOR OPENINGS AND CRACKS MUST BE PROTECTED • WET SURFACES MUST BE PROTECTED • CONSIDER EFFECT ON LOWER LEVEL SURFACES • CONSIDER HOLES IN WALLS, DOORWAYS, AND WINDOWS • CONSIDER DUCTING OR VENTS THAT CAN CARRY SPARKS • CONSIDER EFFECTS OF HIGH WIND AREAS • CONSIDER EFFECT RAIN COULD HAVE ON THE JOB

40. DANGER NO SMOKING, MATCHES OR OPEN FLAME FIRE PREVENTION AND PROTECTION • FIRE EXTINGUISHING EQUIPMENT: • PORTABLE EXTINGUISHERS • PAILS OF WATER • PAILS OF SAND • MUST BE MAINTAINED FOR INSTANT USE • IS THE METHOD APPROPRIATE FOR THE HAZARD? • ARE PERSONNEL TRAINED IN PROPER USE? • WHAT IF THE EXTINGUISHING EQUIPMENT ISN’T ENOUGH? • WHO WILL CONTACT THE LOCAL FIRE DEPARTMENT?

41. FIRE PREVENTION AND PROTECTION FIRE WATCHERS ARE: 1. OBSERVERS WHO ARE SPECIFICALLY TRAINED TO WATCH OVER AREAS WHERE HOT-WORK IS BEING PERFORMED. 2. REQUIRED WHENEVER WELDING OR CUTTING IS PERFORMED IN LOCATIONS WHERE OTHER THAN A MINOR FIRE MIGHT DEVELOP, OR IF ANY OF THE CONDITIONS NOTED ON THE FOLLOWING SLIDE EXIST.

42. FIRE PREVENTION AND PROTECTION • FIRE WATCH IS REQUIRED WHEN: • COMBUSTIBLES ARE CLOSER THAN 35 FEET • COMBUSTIBLES ARE EASILY IGNITED BY SPARKS • COMBUSTIBLES ARE ADJACENT TO METAL PARTITIONS • COMBUSTIBLES CAN BE IGNITED BY CONDUCTION • COMBUSTIBLES CAN BE IGNITED BY RADIATION • WALLS, CEILINGS OR FLOOR HOLES CONTAIN • COMBUSTIBLES • WHENEVER SPECIAL HAZARDS WARRANT FIRE WATCH

43. FIRE PREVENTION AND PROTECTION • FIREWATCHERS MUST: • BE EQUIPPED WITH PROPER EXTINGUISHING EQUIPMENT • BE TRAINED TO RECOGNIZE OUT-OF-CONTROL FIRES • BE FAMILIAR WITH LOCAL FIRE ALARM PROCEDURES • BE TRAINED TO KNOW THEIR LEVEL OF CAPABILITY • OBSERVE HOT AREAS FOR 1/2 HR AFTER COMPLETION • BE FAMILIAR WITH THE HOT-WORK PERMITTING SYSTEM

44. PROHIBITED WELDING SITUATIONS • WELDING OR CUTTING IS PROHIBITED: • IN AREAS NOT AUTHORIZED BY MANAGEMENT • IN SPRINKLER IMPAIRED BUILDINGS • IN THE PRESENCE OF EXPLOSIVE ATMOSPHERES • WHERE EXPLOSIVE ATMOSPHERES CAN DEVELOP • NEAR EXPOSED READILY IGNITABLE MATERIALS • ON UNPREPARED DRUMS, BARRELS, TANKS ETC. • ON UNPREPARED PIPE LINES, VALVES ECT.

45. VENTILATION FOR GENERAL WELDING • MECHANICAL VENTILATION IS PROVIDED WHEN: • THE WORK AREA IS LESS THAN 10,000 CF PER WELDER • CEILINGS HEIGHTS OF LESS THAN 16FT ARE PRESENT • NATURAL VENTILATION IS OBSTRUCTED • MINIMUM RATE: • 2000CFM PER WELDER MUST BE MAINTAINED

46. CONFINED SPACE OPERATIONS IMPORTANT! CONFINED SPACE OPERATIONS ARE BEYOND THE SCOPE OF THIS CLASS. IN DEPTH TRAINING MUST BE PROVIDED FOR SAFE ENTRY. NEVER ATTEMPT TO WELD IN A CONFINED SPACE WITHOUT PROPER TRAINING AND RESCUE SUPPORT! DON’T CREATE ANOTHER OSHA STATISTIC!

47. CONFINED SPACE OPERATIONS CONTINUED • THE FOLLOWING CONSTITUTE A CONFINED SPACE: • ITS SIZE AND SHAPE ALLOW A PERSON TO ENTER IT • HAS LIMITED ENTRY AND EGRESS • IS NOT DESIGNED FOR CONTINUOUS OCCUPANCY

48. CONFINED SPACE OPERATIONS CONTINUED • THE FOLLOWING CONSTITUTE A PERMIT REQUIRED • CONFINED SPACE: • CONTAINS OR HAS A POTENTIAL TO CONTAIN A • HAZARDOUS ATMOSPHERE OR; • CONTAINS A MATERIAL THAT HAS THE POTENTIAL TO • ENGULF AN ENTRANT OR; • HAS AN INTERNAL CONFIGURATION IN WHICH AN • ENTRANT COULD BE TRAPPED OR ASPHYXIATED BY • INWARDLY CONVERGING WALLS OR BY A FLOOR • WHICH SLOPES DOWNWARD AND TAPERS TO A • SMALLER CROSS-SECTION OR;

49. CONFINED SPACE OPERATIONS CONTINUED • CONTAINS ANY OTHER RECOGNIZED SERIOUS SAFETY • OR HEALTH HAZARD

50. DANGER CONFINED SPACE ENTRY PERMIT REQUIRED CONFINED SPACE OPERATIONS CONTINUED • EXAMPLES OF CONFINED SPACES INCLUDE: • SILOS • TANKS • SEWERS • BOILERS • FLOOR PITS • CRAWL SPACES • REACTORS VESSELS