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Welding
Safety
John Newquist
First Incident
• Byron Nuclear
• 1983
• Hundreds of
construction workers
• Welding at several
levels so fire tarps
everywh...
1926.350 (a)(1)
Valve protection caps shall
be in place and secured.
1926.350 (a)(5)
Valve protection caps shall not be
us...
1926.350(a)(4) Transporting of cylinders
When cylinders are transported by powered vehicles, they shall be secured
in a ve...
1926.350(a)(7)
A suitable cylinder truck, chain,
or other steadying device shall
be used to keep cylinders from
being knoc...
1926.350(a)(8)
Cylinder valve
When work is finished,
when cylinders are empty,
or when cylinders are
moved at any time, th...
1926.350(a)(10)
Oxygen cylinders in storage shall
be separated from fuel-gas cylinders
or combustible materials(especially...
1926.350 (d)(1)
Before a regulator to a
cylinder valve is
connected, the valve
shall be opened slightly
and closed immedia...
1926.(d)(4)
Removal of regulator
Before a regulator is
removed from a cylinder
valve, the cylinder valve
shall always be c...
1926.350 (f)(1)
Hose colors
Fuel gas hose and oxygen
hose shall be easily
distinguishable from each
other.
Oxygen and fuel...
1926.350 (f)(2)
Taped sections
When parallel sections of
oxygen and fuel gas hose
are taped together, not more
than 4 inch...
1926.350 (f)(3)
Inspections
All hose in use, carrying
acetylene, oxygen, natural
or manufactured fuel gas,
or any gas or s...
1926.350 (f)(5)
Hose couplings
shall be of the type that
cannot be unlocked or
disconnected by means of a
straight pull wi...
1926.350 (g)(1) - Torches.
Clogged torch tip openings
shall be cleaned with suitable
cleaning wires, drills, or other
devi...
1926.351(b)(2)
• Only cable free from
repair or splices for a
minimum distance of 10
feet from the cable end to
which the ...
1926.351(e)
• Shielding.
• Whenever practicable, all arc
welding and cutting operations
shall be shielded by
noncombustibl...
Subpart J - Welding & Cutting
(1926.350 -354)
33
30
18
9
9
350(a)(9)
350(a)(10)
351(b)(4)
351(b)(2)
351 e
Standard-1926.
C...
Compressed Gas Cylinder Safety
Cylinders are not protected from falling. Note
that the Chain is not secured across.
Is the...
Compressed Gas Cylinder Safety
1. Cylinder not secured 2. Cylinder should be stored
3. Subject to damage. 4. Electrical co...
Compressed Gas Cylinder Safety
Cylinder is damaged. Should be taken out of service immediately!
Electrical arc
damage
Compressed Gas Cylinder Safety
Cylinder should be in storage protected from damage and not
laying on the ground regardless...
Compressed Gas Cylinder Safety
1. Inadequate housekeeping
2. Valve caps should be installed.
Compressed Gas Cylinder Safety
1. Unsecured acetylene cylinder 2. Exposed to damage
Compressed Gas Cylinder Safety
Unsecured cylinders
Compressed Gas Cylinder Safety
Regulator left pressurized after use
Compressed Gas Cylinder Safety
Improper Storage
Oxygen Acetylene 2013
Fatalities
• On December
13, 2011, Employee #1
and two coworkers were
welding from a properly
erected scaffold system
insi...
Burn Incident
• On February 2, 2011,
Employee #1 was welding
overhead.
• A piece of molten slag from the
weld arc went dow...
Fatalities
• September 2003 -
The employees were
arc welding the
guardrail system of a
solid waste storage
tank (40' above...
Fatalities
• February 2003 - An
employee was tig
welding on an open pipe
and a combustible liquid
oil flushed from the pip...
Fatalities
• July 2003 - the victim was
arc welding to install metal
sub- flooring on a balcony.
The welding cables of the...
Fatalities
• November 2002 - Employee
#1 had cut a hole in the bottom
cone of silo #341 with an
Oxygen and Acetylene torch...
Fatalities
• January 2001 -
Welder was Tungsten
Inert Gas Welding in
a confined space at a
refinery and suffered
Argon asp...
Fatalities
• June – 2000
Employee was
welding Underneath A
Back Hoe and It Ran
Over Him.
• What would you have
done differ...
Fatalities
• 1987 – Wheaton
• Oxy-acetylene hose
caught on fire when
cut by welder. Tanks
exploded as welder
went to shut ...
Fires
• 1992 – Food Plant
under construction.
Welder has sparks
ignite area between
walls causing $12M
loss.
What precauti...
Setup Accident
• August 2003 – going to
weld a 7 foot long 20 inch
pipe through a wall.
When they moved the
pipe, it fell ...
Fall Hazard
• Falls through roof
holes and fall off roofs
are most common
hazards.
• What should be done
for this fall haz...
Wet Condition
• Avoid working in wet
conditions
• Water conducts electricity
• Insulate yourself from the work
and the gro...
Personal Protective Equipment
• Most common
problem is the welder
has protection and
the helper does not.
Lead
Cutting or welding
painted surfaces that
contain lead can
result in lead
overexposure in 5
minutes.
Hex Chrome
• A major source of
worker exposure to
Cr(VI) occurs
during "hot work"
such as welding on
stainless steel and
o...
What is in welding fume?
• Metals such as..
• Aluminum, Antimony,
Arsenic, Beryllium,
Cadmium, Chromium,
Cobalt, Copper, I...
Heat
• 2013 Year of
Dehydration
• Heat Fatal in
Chicago in June
2013 on first day of
work
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Welding Safety 2014

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Transcript of "Welding Safety 2014"

  1. 1. Welding Safety John Newquist
  2. 2. First Incident • Byron Nuclear • 1983 • Hundreds of construction workers • Welding at several levels so fire tarps everywhere. • What danger is there with tarps and floor openings?
  3. 3. 1926.350 (a)(1) Valve protection caps shall be in place and secured. 1926.350 (a)(5) Valve protection caps shall not be used for lifting cylinders from one vertical position to another. Valve cap protection 1926.350(a)(6) Unless cylinders are firmly secured on a special carrier intended for this purpose, regulators shall be removed and valve protection caps put in place before cylinders are moved. Valve cap
  4. 4. 1926.350(a)(4) Transporting of cylinders When cylinders are transported by powered vehicles, they shall be secured in a vertical position.
  5. 5. 1926.350(a)(7) A suitable cylinder truck, chain, or other steadying device shall be used to keep cylinders from being knocked over while in use.
  6. 6. 1926.350(a)(8) Cylinder valve When work is finished, when cylinders are empty, or when cylinders are moved at any time, the cylinder valve shall be closed. 1926.350(a)(9) Upright position Compressed gas cylinders shall be secured in an upright position at all times except, if necessary, for short periods of time while cylinders are actually being hoisted or carried. Valve
  7. 7. 1926.350(a)(10) Oxygen cylinders in storage shall be separated from fuel-gas cylinders or combustible materials(especially oil or grease), a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet (1.5 m) high having a fire-resistance rating of at least one-half hour. 1926.350(a)(11) Inside of buildings, cylinders shall be stored in a well-protected, well- ventilated, dry location, at least 20 feet (6.1 m) from highly combustible materials such as oil or excelsior.
  8. 8. 1926.350 (d)(1) Before a regulator to a cylinder valve is connected, the valve shall be opened slightly and closed immediately. (This action is generally termed "cracking" and is intended to clear the valve of dust or dirt that might otherwise enter the regulator.) The person cracking the valve shall stand to one side of the outlet, not in front of it.
  9. 9. 1926.(d)(4) Removal of regulator Before a regulator is removed from a cylinder valve, the cylinder valve shall always be closed and the gas released from the regulator.
  10. 10. 1926.350 (f)(1) Hose colors Fuel gas hose and oxygen hose shall be easily distinguishable from each other. Oxygen and fuel gas hoses shall not be interchangeable.
  11. 11. 1926.350 (f)(2) Taped sections When parallel sections of oxygen and fuel gas hose are taped together, not more than 4 inches out of 12 inches shall be covered by tape. 4” 12”
  12. 12. 1926.350 (f)(3) Inspections All hose in use, carrying acetylene, oxygen, natural or manufactured fuel gas, or any gas or substance which may ignite or enter into combustion, or be in any way harmful to employees, shall be inspected at the beginning of each working shift. Defective hose shall be removed from service. cracking
  13. 13. 1926.350 (f)(5) Hose couplings shall be of the type that cannot be unlocked or disconnected by means of a straight pull without rotary motion.
  14. 14. 1926.350 (g)(1) - Torches. Clogged torch tip openings shall be cleaned with suitable cleaning wires, drills, or other devices designed for such purpose. 1926.350(g)(2) Torches in use shall be inspected at the beginning of each working shift for leaking shutoff valves, hose couplings, and tip connections. Defective torches shall not be used. 1926.350 (g)(3) - Lighters Torches shall be lighted by friction lighters or other approved devices, and not by matches or from hot work. Striker
  15. 15. 1926.351(b)(2) • Only cable free from repair or splices for a minimum distance of 10 feet from the cable end to which the electrode holder is connected shall be used…
  16. 16. 1926.351(e) • Shielding. • Whenever practicable, all arc welding and cutting operations shall be shielded by noncombustible or flameproof screens which will protect employees and other persons working in the vicinity from the direct rays of the arc.
  17. 17. Subpart J - Welding & Cutting (1926.350 -354) 33 30 18 9 9 350(a)(9) 350(a)(10) 351(b)(4) 351(b)(2) 351 e Standard-1926. Cylinders secured upright No Shielding from welding operations Oxygen cylinder storage Cables needing repair Splices within 10 feet of holder
  18. 18. Compressed Gas Cylinder Safety Cylinders are not protected from falling. Note that the Chain is not secured across. Is the carrier safe? Chain
  19. 19. Compressed Gas Cylinder Safety 1. Cylinder not secured 2. Cylinder should be stored 3. Subject to damage. 4. Electrical cord draped over. Electrical Cord
  20. 20. Compressed Gas Cylinder Safety Cylinder is damaged. Should be taken out of service immediately! Electrical arc damage
  21. 21. Compressed Gas Cylinder Safety Cylinder should be in storage protected from damage and not laying on the ground regardless if it is full or empty
  22. 22. Compressed Gas Cylinder Safety 1. Inadequate housekeeping 2. Valve caps should be installed.
  23. 23. Compressed Gas Cylinder Safety 1. Unsecured acetylene cylinder 2. Exposed to damage
  24. 24. Compressed Gas Cylinder Safety Unsecured cylinders
  25. 25. Compressed Gas Cylinder Safety Regulator left pressurized after use
  26. 26. Compressed Gas Cylinder Safety Improper Storage
  27. 27. Oxygen Acetylene 2013
  28. 28. Fatalities • On December 13, 2011, Employee #1 and two coworkers were welding from a properly erected scaffold system inside a one million gallon steel storage tank. • For some reason, Employee #1 removed his harness and fell 55 ft through the scaffold railings to the base of the steel tank. • Employee #1 was killed.
  29. 29. Burn Incident • On February 2, 2011, Employee #1 was welding overhead. • A piece of molten slag from the weld arc went down in- between the four layers of clothing he was wearing and ignited the inner clothing layers. • Employee #1 suffered burns over approximately eighteen percent of total body surface area and was off work for at least four months.
  30. 30. Fatalities • September 2003 - The employees were arc welding the guardrail system of a solid waste storage tank (40' above the ground) when an explosion occurred. • What precautions should be taken?
  31. 31. Fatalities • February 2003 - An employee was tig welding on an open pipe and a combustible liquid oil flushed from the pipe and covered his body. The oil was ignited by the welder and the employee suffered burns to approximately 95% of his body. • What Precautions here? Pipes in a chemical plant.
  32. 32. Fatalities • July 2003 - the victim was arc welding to install metal sub- flooring on a balcony. The welding cables of the arc welder had frayed cables and improper repairs within 10 feet of the electrode end holders. The victim came into contact with the exposed wires on the welding cables and was electrocuted. • What could have been done differently?
  33. 33. Fatalities • November 2002 - Employee #1 had cut a hole in the bottom cone of silo #341 with an Oxygen and Acetylene torch and MIG welded the bottom half of a side chute onto the opening. The employee stopped welding in order to torch cut a notch out of the top of the newly attached side chute when residual dust from inside the silo ignited causing a flash fire. • What should have done? Cone Silo on its side.
  34. 34. Fatalities • January 2001 - Welder was Tungsten Inert Gas Welding in a confined space at a refinery and suffered Argon asphyxiation. • Several Argon deaths due to heavy nature of gas. Argon welding
  35. 35. Fatalities • June – 2000 Employee was welding Underneath A Back Hoe and It Ran Over Him. • What would you have done differently? Backhoe on incline.
  36. 36. Fatalities • 1987 – Wheaton • Oxy-acetylene hose caught on fire when cut by welder. Tanks exploded as welder went to shut off flow. • What would you do if these hose got on fire?
  37. 37. Fires • 1992 – Food Plant under construction. Welder has sparks ignite area between walls causing $12M loss. What precautions would be required for sparks?
  38. 38. Setup Accident • August 2003 – going to weld a 7 foot long 20 inch pipe through a wall. When they moved the pipe, it fell off the roller stand and the welder's finger got caught between the outer surface of the pipe and the edge of the concrete wall penetration. • Load must be secured. Typical Roller Stand
  39. 39. Fall Hazard • Falls through roof holes and fall off roofs are most common hazards. • What should be done for this fall hazard? List two methods.
  40. 40. Wet Condition • Avoid working in wet conditions • Water conducts electricity • Insulate yourself from the work and the ground by standing on a dry rubber mat or similar non-flammable material. • Ground Welder • Build shelter for welder
  41. 41. Personal Protective Equipment • Most common problem is the welder has protection and the helper does not.
  42. 42. Lead Cutting or welding painted surfaces that contain lead can result in lead overexposure in 5 minutes.
  43. 43. Hex Chrome • A major source of worker exposure to Cr(VI) occurs during "hot work" such as welding on stainless steel and other alloy steels containing chromium metal. Cancers targets the respiratory system, kidneys, liver, skin and eyes
  44. 44. What is in welding fume? • Metals such as.. • Aluminum, Antimony, Arsenic, Beryllium, Cadmium, Chromium, Cobalt, Copper, Iron, Lead, Manganese, Molybdenum, Nickel, Silver, Tin, Titanium, Vanadium, Zinc. Position fume hoods so to not pass through your breathing zone
  45. 45. Heat • 2013 Year of Dehydration • Heat Fatal in Chicago in June 2013 on first day of work
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