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Welding and Cutting Safety.ppt & hot work
- 1. Welding, Cutting and Welding,Cutting and Brazing Safety Brazing Safety Understanding the Safety Requirements for Welding, Cutting and Brazing 29 CFR 1910.251-255 Welding, Cutting and Brazing
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- 3. Fire Prevention andProtection Part I
- 4. Prohibited Areas forWelding and Prohibited Areas for Welding and Cutting Cutting Welding and cutting is not allowed in: ◦ Areas not authorized by management. ◦ In buildings with sprinklers where the sprinkler system is not operating. ◦ In explosive or potentially explosive atmospheres. ◦ Areas near the storage of large quantities of exposed, ignitable material.
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- 6. Guarding Fire Hazards GuardingFire Hazards If there are floor openings or cracks that could allow sparks to fall to a lower level, then combustible materials must be removed from that level. The same precaution applies to windows, doorways, or other openings. Sparks can shoot long distances! Be very cautious and remove all combustible materials in the area.
- 7. Fire Extinguishers Fire Extinguishers A proper fire extinguisher must be ready for immediate use. Type of extinguisher depends on the type and quantity of the combustible material. This includes pails of water, buckets of sand, or typical extinguishers. Make sure you have the proper type of extinguisher!
- 8. Fire Watch Fire Watch A fire watch must be posted when: 1. In a location where more than a minor fire would develop. 2. Large amounts of combustible materials are within 35 feet, or greater than 35 feet but are easily ignited by sparks. 3. Wall or floor openings within 35 feet expose combustible material in adjacent areas. 4. Combustible materials are next to the opposite side of an object where the work is and are likely to ignite due to heat conduction or radiation. Be aware of objects that conduct heat. They may transfer enough heat to start a fire.
- 9. Requirements for FireWatch Requirements for Fire Watch Must have fire extinguisher ready and be trained in its use. Must know how to sound the alarm in the case of a fire. Must be maintained for at least ½ hour after welding or cutting is completed. Fires can smolder undetected. It is important to be alert even after the welding is completed.
- 10. Fire Watch Responsibilities FireWatch Responsibilities Fire watch must be the sole responsibility. Cannot perform work or be distracted. Should only put out a fire if it is within the capacity of the equipment available. If the fire cannot be extinguished immediately, sound the alarm. It is easy to get distracted as a fire watch. Don’t lose focus – lives depend on you!
- 11. Authorizing Work Authorizing Work Before cutting or welding is allowed, it must be authorized by the company. The authorizing supervisor must inspect the area for hazards and ensure that all flammable materials have been removed or guarded. Work will be authorized using a written permit.
- 12. Preparing An Areafor Welding Preparing An Area for Welding Move all combustibles at least 35 feet from the work site. If the materials cannot be relocated, protect them with flameproof covers, or shield them with metal or asbestos guards or curtains. Easy thumb rule for clearing combustible materials. “When in doubt, get it out!”
- 13. Preparing An Areafor Welding Preparing An Area for Welding Ducts and conveyor systems that could carry sparks to distant combustibles must be protected or shut down. Air ducts can suck up sparks and send them to other parts of the building. Make sure they are shut down.
- 14. Preparing an Areafor Welding Preparing an Area for Welding When cutting or welding is done near walls, partitions, ceilings, or other combustible constructions, fire- resistant shields or guards must be used to prevent ignition.
- 15. Preparing an Areafor Welding Preparing an Area for Welding
- 16. Preparing an Areafor Welding Preparing an Area for Welding Welding or cutting on pipes or other metal objects may not be undertaken if they are close enough to combustible objects to cause a fire by heat conduction.
- 17. Management Responsibilities Management Responsibilities Management is responsible for the safe usage of cutting and welding equipment on its property. Designate an individual who is responsible for authorizing welding and cutting that occurs outside of areas designated for that process. Designate areas for welding and cutting, and procedures for welding and cutting outside of those areas. Ensure all operators are trained on their equipment. Advise all contractors of flammable materials or hazardous conditions that they are not aware of.
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- 19. Supervisor Responsibilities –Eliminate Fire Hazards Supervisor Responsibilities – Eliminate Fire Hazards
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- 21. Supervisor Responsibilities –Fire Watch Supervisor Responsibilities – Fire Watch
- 22. Welding and CuttingContainers Welding and Cutting Containers No welding or cutting can be performed on used containers unless they have been thoroughly cleaned so that it is certain they do not have flammable materials or could emit toxic fumes when heated. All hollow spaces must be vented to allow toxic and flammable gasses to escape. Even small amounts of contaminants can make used containers dangerous.
- 23. Fire Prevention inConfined Spaces Fire Prevention in Confined Spaces
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- 25. Welding at Heights Weldingat Heights When working at heights employees must be protected against falling. If possible, eliminate the fall hazard by using railings, or doing the work on the ground. Safety belts, life lines, or other effective means can be used.
- 26. Eye Protection Requirements EyeProtection Requirements What eye protection equipment is available for employees?
- 27. Eye Protection Requirements EyeProtection Requirements Helmets must be made from materials that insulate heat and electricity. Helmets, shields, and goggles cannot be readily flammable. Helmets and hand shields must be arranged to protect the face, neck, and ears from direct radiant energy.
- 28. Eye Protection Requirements EyeProtection Requirements Helmet filter and cover plates must be easily removed. Protection must not color or corrode the skin. Goggles must be ventilated to prevent fogging.
- 29. Lenses and Shading Lensesand Shading All lens glass must be tempered, smooth, and parallel. They must have a permanent mark to identify the source and shade. All filter lenses and plates must meet the ANSI Z87.1-1968 test standards. Shading requirements for welding operations can be found in OSHA 29 CFR 1910.252(b)2(ii)(H).
- 30. Protective Clothing Protective Clothing Appropriate protective clothing will vary depending on the nature and location of the work. The employer must conduct a job hazard analysis for each work process, and provide PPE to protect from the hazard. Materials should be non- flammable, and flame and heat resistant. Every environment has unique PPE requirements. OSHA Standard 1910.132 helps employers identify proper PPE.
- 31. Protection in ConfinedSpaces Protection in Confined Spaces All confined spaces must be properly ventilated. Gas cylinders and welding machines must be left outside a confined space. Wheel mounted equipment must be blocked to prevent accidental movement. Unsafe atmospheres are the top cause of fatalities in confined spaces. Make sure that you are following the company Confined Space program.
- 32. Lifelines in ConfinedSpaces Lifelines in Confined Spaces When a welder enters a confined space through a manhole or small opening, they must be attached to a lifeline. They must be attached in a way that prevents the body getting jammed in a small opening. There must be a rescue plan, and an attendant in place at all times who can perform a rescue. The attendant must monitor the work for signs of distress. The welder and attendant must be trained on the company Confined Space Entry Program.
- 33. Ventilation and Protectionof Employee Health Part III
- 34. Welding Screens Welding Screens When welding in an area with screens on all sides, they should be arranged so that no serious restriction in ventilation exists. Screens should be mounted about 2 feet above the floor. If welding near the floor, screens can be moved lower to protect nearby workers.
- 35. Maximum Allowable Concentrations MaximumAllowable Concentrations Exhaust and ventilation systems must keep the amount of toxic gasses, fumes and dusts below maximum allowable concentrations. These concentrations can be found in OSHA 29 CFR 1910.1000. 1910.100 has a long list of requirements. It is a good idea to consult an industrial hygienist when measuring contaminants and verifying proper ventilation.
- 36. Precautionary Labels Precautionary Labels Hazardous materials from fluxes, coatings, coverings, and filler metals are released into the air while welding or cutting. Different materials have different labeling requirements. These warnings should be in the form of tags, on boxes or other containers, so that welders are informed of the hazards. This bundle of welding material should be tagged with the appropriate warnings.
- 37. Precautionary Precautionary Labels Labels All filler metals andfusible granular materials must be labeled with this warning.
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- 39. Precautionary Precautionary Labels Labels Brazing and gas weldingfluxes that have fluorine compounds must have a warning that they include fluorine compounds.
- 40. General Ventilation Requirements GeneralVentilation Requirements
- 41. Minimum Ventilation Flow MinimumVentilation Flow Ventilation flow rate must be at least 2,000 ft3 /min per welder. Flow hoods and airline respirators can also be used. Fixed enclosures and movable hoods can be used provided they provide a 100 linear feet per minute of suction.
- 42. Ventilation in ConfinedSpaces Ventilation in Confined Spaces All welding and cutting done in confined spaces must be ventilated to prevent accumulation of toxic materials or oxygen deficiency. Never use oxygen for ventilation! If proper ventilation cannot be achieved, NIOSH airline respirators or hose masks can be used. In spaces immediately hazardous to life, NIOSH approved self-contained units may be used. Always have a safety attendant when working in confined spaces!
- 43. Special Requirements Special Requirements FluorineZinc Requires local exhaust or airline respirators if the fluorides exceed their maximum allowable concentration. When working with zinc indoors, local exhaust hoods or booths must be used.
- 44. Special Requirements Special Requirements LeadBeryllium Welding indoors must be done with local exhaust hoods or booths. When welding outdoors, employees must use a respirator designed for lead protection. When welding with beryllium, local exhaust and airline respirators must be used.
- 45. Special Requirements Special Requirements CadmiumMercury In confined spaces or indoors, must be ventilated using exhaust ventilation or airline respirators. Outdoors, welders should use a NIOSH approved respirator. In confined spaces or indoors, must be ventilated using exhaust ventilation or airline respirators. Outdoors welders should use a NIOSH approved respirator.
- 46. Cleaning Compounds Cleaning Compounds Cleaning agents can be toxic and flammable. Review and comply with manufacturers hazard warnings. Vapors from degreasers or cleaners should never be allowed into the area near welding operations. Simple cleaners can be very dangerous when exposed to heat or flame.
- 47. Gas Welding andCutting Part IV
- 48. Special Requirements forGas Welding Special Requirements for Gas Welding and Cutting and Cutting
- 49. Equipment Responsibility Equipment Responsibility Employees in charge of oxygen or fuel gas supply equipment must be trained and judged competent by the employer before being placed in charge of it. The employer must make rules for operation and maintenance of this equipment available. A good set of Operations & Maintenance Manuals will make the workplace much safer.
- 50. Cylinder Markings Cylinder Markings Compressed gas cylinders must be labeled with the chemical name. The marking must not be easily removable. If possible, the marking should be located on the shoulder of the cylinder. Proper labeling is essential for employee safety. Missing labels is a very common citation on OSHA inspections.
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- 52. Oxygen Cylinders Oxygen Cylinders Oxygen cylinders shall not be stored near combustible material, such as oil and grease. Carbide, acetylene, and other gasses can cause dangerous fires if mixed. Oxygen cylinders must be stored at least 20 feet from fuel-gas cylinders.
- 53. General Safe WorkPractices General Safe Work Practices Keep cylinders and associated equipment free from dirt, grease, and oil. Do not handle with oily hands or gloves. Never mix fuels or gasses. Don’t use tools to open stuck cylinder valves. If it cannot be opened by hand, contact the supplier. Close cylinder valves when work is finished.
- 54. General Safe WorkPractices General Safe Work Practices Safety devices should never be tampered with or disabled. Keep cylinders away from hot work. Close valves before moving cylinders. Cylinders must be transported in suitable containers or devices. Never drop a cylinder or allow it to be struck. Do not place cylinders where they may become part of an electric circuit or circuit grounding.
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- 56. Arc Welding andCutting Part V
- 57. Special Requirements forArc Welding Special Requirements for Arc Welding and Cutting and Cutting
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- 59. Equipment Requirements Equipment Requirements When arc welding must be done in unusual conditions, such as in areas with flammable gasses, the equipment must be specifically designed for that purpose. Maximum Allowable Voltages: 1. A/C Manual – 80 Volts Automatic – 100 volts 2. D/C Manual – 100 Volts Automatic – 100 Volts
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- 61. Special Requirements forResistance Special Requirements for Resistance Welding Welding OSHA Standard 1910.255 has special requirements for Resistance Welding. Most of these requirements are specific to system configurations. We will discuss key requirements for employees in this section. Facilities managers should pay special attention to 1910.255 .
- 62. Worker Requirements Worker Requirements Workers using resistance welding must be trained and judged competent to operate the equipment. Workers must be familiar with all the safety features of the equipment. If any equipment is found damaged or defective, it must be tagged out of service and reported immediately.
- 63. Resistance Welding Equipment ResistanceWelding Equipment Must be installed by a qualified electrician. Ignition tubes must have thermal protection switches. Should only be worked on by qualified repairmen. Maintenance and repair of equipment should only be done by the vendor or qualified individuals.
- 64. Required Safety Devices RequiredSafety Devices Guards to prevent accidental startup of equipment. Interlocks to prevent access to live parts of the equipment by unauthorized persons. Shielding to prevent sparks from contacting flammable materials and injuring employees. Emergency stop buttons or switches. Guards to prevent employee body parts, such as fingers, from entering hazardous parts of the equipment. E-Stops allow employees to de- energize equipment quickly and safely.
- 65. Welding and CuttingSummary Welding and Cutting Summary Welding should be performed in designated welding areas. If not possible, welding may be performed at the location provided all hazards are managed and the supervisor approves. Fire watches should be posted when there is a potential for a large fire. Adequate space or ventilation must be verified before welding can commence. PPE must be made available by the company to protect employees from hazards.
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Editor's Notes
- #1 Note: Some slides contain copyright images. These slides have been “flattened” for that reason. Feel free to alter these slides by adding images over them, or copying the information on a new slide and adding your own images or text to replace them.
- #4 Discussion Point: What areas in your company are not safe for welding and cutting?
- #7 Note: There are different types of extinguishers for different types of hazards. Discussion Points: What fire extinguishers are used at your company? Where are they located? Who is in charge of inspecting and maintaining them? Are they the correct type for the hazards presented?
- #8 Discussion Point: What areas in your facility would require a fire watch when work is performed?
- #10 Note: Companies have a tendency to assign fire watch to new and inexperienced employees. While the job may be tedious, it is important to have an experienced individual on fire watch, in case something goes wrong. Discussion Points: Who would make a good fire watch? Should brand new employees be assigned fire watch duties? Why or why not?
- #11 Discussion Point: Distribute a copy of your permits. Discuss how they are used.
- #12 Discussion Point: What items at your company should be removed from a welding area?
- #13 Discussion Point: What ventilation systems does this apply to?
- #14 Discussion Points: What shielding or guards are available for use? Where should they be used?
- #17 Discussion Point: What are some other key management responsibilities?
- #19 Discussion Point: What other things can supervisors do to eliminate fire hazards?
- #22 Note: Welding and cutting used containers should be avoided if possible. Discussion Point: What are the hazards of welding and cutting on used containers?
- #23 Note: Welding in confined spaces should only be performed in accordance with the company Confined Space plan.
- #25 Discussion Point: What techniques and equipment does the company have to protect workers at heights? Note: Work should always be performed on the ground if it is possible to do so.
- #26 Discussion Point: What eye protection is available for employees to use?
- #30 Discussion Points: What protective clothing is used at your company? What applications are they used for?
- #34 Note: When setting up screens and barriers, be mindful of how they affect ventilation.
- #37 Discussion Points: Do you have any of these materials? Are they properly tagged?
- #38 Discussion Points: Do you have any of these materials? Are they properly tagged?
- #39 Discussion Points: Do you have any of these materials? Are they properly tagged?
- #40 Discussion Points: What areas do you have that would require ventilation while welding? What ventilation do you have available?
- #43 Discussion Points: Do your employees work with these materials? What equipment is available to mitigate the hazard?
- #44 Discussion Points: Do your employees work with these materials? What equipment is available to mitigate the hazard?
- #45 Discussion Points: Do your employees work with these materials? What equipment is available to mitigate the hazard?
- #46 Discussion Points: What cleaning compounds are commonly used at your facility? Should they be allowed in welding areas?
- #49 Discussion Points: Who is in charge of your equipment? Where are the rules and procedures for this equipment?
- #54 Discussion Point: What other safe work practices should be used at your facility?
- #64 Discussion Point: What safety devices are installed on your equipment?