This document discusses welding safety hazards and regulations. It begins by describing past welding incidents that resulted in injuries or fatalities. Some key risks mentioned include falls, electrical hazards, fires, confined space hazards, and exposure to toxic fumes and gases. The document then outlines OSHA regulations on compressed gas cylinder safety, personal protective equipment, and controlling hazards like lead, hexavalent chromium, and heat exposure during welding operations. Protecting workers from these risks requires following safety protocols for cylinder handling and storage, electrical safety, housekeeping, ventilation, and use of proper protective equipment.

1. Welding
Safety
John Newquist

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. 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. 1926.350(a)(4) Transporting of cylinders
When cylinders are transported by powered vehicles, they shall be secured
in a vertical position.

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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Compressed Gas Cylinder Safety
Cylinders are not protected from falling. Note
that the Chain is not secured across.
Is the carrier safe?
Chain

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. Compressed Gas Cylinder Safety
Cylinder is damaged. Should be taken out of service immediately!
Electrical arc
damage

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. Compressed Gas Cylinder Safety
1. Inadequate housekeeping
2. Valve caps should be installed.

23. Compressed Gas Cylinder Safety
1. Unsecured acetylene cylinder 2. Exposed to damage

24. Compressed Gas Cylinder Safety
Unsecured cylinders

25. Compressed Gas Cylinder Safety
Regulator left pressurized after use

26. Compressed Gas Cylinder Safety
Improper Storage

27. Oxygen Acetylene 2013

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. 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. 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. 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. 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. 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. 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. 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. 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. Fires
• 1992 – Food Plant
under construction.
Welder has sparks
ignite area between
walls causing $12M
loss.
What precautions would be required
for sparks?

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. 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. 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. Personal Protective Equipment
• Most common
problem is the welder
has protection and
the helper does not.

42. Lead
Cutting or welding
painted surfaces that
contain lead can
result in lead
overexposure in 5
minutes.

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. 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. Heat
• 2013 Year of
Dehydration
• Heat Fatal in
Chicago in June
2013 on first day of
work