School Safety Training

Welding, Cutting and Brazing WAC 296-24-Part I

1/03

Notice
This presentation is provided to all Educational Service
District 101 (ESD 101) schools at no cost. This presentation contains copyrighted materials purchased by ESD 101 for the exclusive use of training school personnel within ESD 101. This presentation may not be reproduced except to print handouts or notes pages for use during training within ESD 101 school districts. If the school district does not have Microsofts PowerPoint software available, a PowerPoint viewer can be downloaded from the internet at no cost. Questions may be directed to the ESD 101 Risk Manager.

Compressed Gases

Compressed gases are covered in WAC 296-24-Part K, but are an integral part of welding, cutting, and brazing Compressed gas hazards Gases used for cutting, brazing, and shielding the weld Refer to another ESD 101 program titled Compressed Gases.

Cylinder Inspection

Most compressed gas cylinders must be periodically tested/ recertified (DOT) All cylinders contain markings/ symbols that indicate certification status

Specific Gases

Several of the gases have specific WISHA standards These gases include acetylene, hydrogen, oxygen, nitrous oxide, ammonia, and LPG

Basic Fire Prevention

Fire hazards must be removed, or Guards installed, or Welding/cutting must NOT

take place

Hot work permit should be used to ensure that all fire hazards are controlled Use of fire watch 1/2 hour after operation
ceases

Fire Prevention (cont.)

Fire extinguishers must be charged/available Never weld in the presence of explosive atmospheres Do not weld on used drums, barrels, tanks, or other containers Test potentially explosive containers for flammable atmospheres Shut off cylinder valves when they are not in use

Protection of Personnel

Keep working surfaces clean and unobstructed Wear eye protection Use safety glasses under welding
hood

Protective clothing must be used per WAC 296-800-160 Welding in confined spaces Machines located outside of
space Other confined space precautions apply (1910.146)
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Oxygen-Fuel Welding

WAC 296-24-68221 Acetylene

Flammable Unstable Cannot be piped above 15 psi

Basic Rules for Oxyacetylene Welding

Blow out cylinder valve Release regulator Stand to one side of regulator Open cylinder valve slowly Not more than 15 psi

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Basic Rules (cont.)

Purge oxygen and acetylene passages Light the acetylene Never use oil or grease Do not use oxygen Keep your work area clean

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Storage of Fuel Cylinders

Storage area must be well ventilated Cylinders must be at least 20 feet from combustibles Valves must be closed Valve protection must be in place Inside storage must be limited to 2,000 cubic feet. Cylinders must be stored in upright position Oxygen must be at least 20 feet from fuel gas or 5 feet with a 1/2 hour fire barrier
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Gas Cylinder Precautions

Never lift cylinders by the service valve or valve protection (use slings, net, etc.) Keys, handles, hand wheels must be present Use proper regulator Open acetylene valve no more than 11/2 turns

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Protective Devices

Pressure relief valves Backflow preventer Fuel gas hosered (sometimes black) Oxygen hosegreen Hose protection required Pressure-reducing regulators

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Arc Welding

Electric current fuses parent metal and welding rod Indispensable in metal working Used for carbon and alloy steels and nonferrous metals

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Shielding

Air must be kept away from weld area Shielding protects the integrity of the weld joint Flux or gas mixture is used as a shield

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Common Arc Welding Processes

Shielded metal arc welding (stick welding) Gas metal arc welding (MIG welding) Gas tungsten arc welding (TIG welding) Flux cored arc welding Submerged arc welding Arc cutting Plasma arc cutting

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Installation and Maintenance

Welding machine must be grounded Work area must be dry and free of hazards Connections must be tightly made Splices within 10 feet of holder are prohibited Cables must be maintained and conductors well insulated

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Welding Health Hazards

Zinc Cadmium Beryllium Iron Oxide Mercury Lead Fluorides

Chlorinated hydrocarbon solvents Phosgene Carbon monoxide Ozone Nitrogen Oxides

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Welding Physical Hazards

Ultraviolet radiation Infrared radiation Intense visible light

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Lens Shades for Typical Welding

Welding Process Shielded metal arc Gas metal arc Gas Tungsten arc Torch brazing Gas welding

Lens Shade Number 10-14 11-12 12 3 or 4 4-8

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Quiz
1.

2.
3. 4. 5.

Fuel cylinders must be stored at least ____ feet from combustibles. Shielding is a process used to protect the eyes from welding fume. True or False Three physical welding hazards are ___________ radiation, infrared radiation and intense visible light. You should not use oxygen as a substitute for air. True or False As long as they are secure, fuel cylinders can be stored on their side. True or False

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Quiz (cont.)
6.
Gas Metal Arc Welding is also known as _____________ welding. 7. Exposure to zinc fumes may cause metal fume fever. True or False 8. Cylinder inspection requirements are regulated by the Department of__________. 9. Acetylene has a very narrow flammable range. True or False 10. Backflow prevention should be provided for oxygen cylinders. True or False

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Quiz Answers
1.

2.
3. 4. 5.

Fuel cylinders must be stored at least 20 feet from combustibles. False. Shielding is a process used to keep air away from the weld. Three physical welding hazards are ultraviolet radiation, infrared radiation, and intense visible light. True. You should not use oxygen as a substitute for air. False. Fuel cylinders must always be stored upright.

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Quiz Answers (cont.)

6.
Gas Metal Arc Welding is also known as MIG welding. True. Exposure to zinc fumes may cause metal fume fever. Cylinder inspection requirements are regulated by the Department of Transportation.

7.
8.

9. False. Acetylene has a very wide flammable range. 10. True. Backflow prevention should be provided for
all oxygen cylinders.

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