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

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

OSHA REGULATORY STANDARDS 29CFR - SAFETY AND HEALTH STANDARDS 1910 - GENERAL INDUSTRY 252 - GENERAL REQUIREMENTS 253 - OXYGEN WELDING 254 - ARC WELDING 255 - RESISTANCE WELDING DANGER HOTWORK IN PROGRESS 7

REGULATORY STANDARD NFPA and ANSI WELDING CRITERIA NFPA - 51B FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES NFPA - 51B SAFETY IN WELDING AND CUTTING ANSI - Z49.1 8

GENERAL PROGRAM REQUIREMENTS THE SAFETY PROGRAM 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 12

TRAINING REQUIREMENTS WELDING SAFETY 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. 13

RETRAINING REQUIREMENTS WELDING SAFETY 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 14

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. 15

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. 16

PROGRAM MANAGEMENT FORMS COMMONLY USED PROGRAM MANAGEMENT FORMS DANGER FIRE HAZARD HOTWORK PERMIT REQUIRED 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 17

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. DANGER HOTWORK IN PROGRESS 18

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. 19

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. 20

SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS - INHALATION: MOST COMMON ROUTE OF ENTRY. SMALLER PARTICULATES ARE TRAPPED IN LUNGS AND ABSORBED. 21

SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS - INGESTION: EATING, DRINKING, OR SMOKING WITHOUT WASHING HANDS FIRST. EATING, DRINKING, OR SMOKING CONTAMINATED CONSUMABLES. 22

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. 23

SPECIFIC TYPES OF HAZARDS ROUTES OF ENTRY FOR METALS - INJECTION. USUALLY CAUSED BY PUNCTURE WOUNDS INVOLVING METALS. COMPRESSED AIR CAN ALSO CAUSE INJECTION OF 24

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. 25

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. 26

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. 27

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. 28

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. 29

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! 30

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. 31

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 32

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 33

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 34

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. 35

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 36

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 37

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 38

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 39

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 40

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! 41

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 42

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 43

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? DANGER NO SMOKING, MATCHES OR OPEN FLAME 44

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. 45

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 46

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 47

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. 48

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 49

IMPORTANT! CONFINED SPACE OPERATIONS 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! 50

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 51

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; 52

CONFINED SPACE OPERATIONS CONTINUED CONTAINS ANY OTHER RECOGNIZED SERIOUS SAFETY OR HEALTH HAZARD 53

CONFINED SPACE OPERATIONS CONTINUED EXAMPLES OF CONFINED SPACES INCLUDE: SILOS TANKS SEWERS BOILERS FLOOR PITS CRAWL SPACES REACTORS VESSELS DANGER CONFINED SPACE ENTRY PERMIT REQUIRED 54

CONFINED SPACE OPERATIONS CONTINUED THE FOLLOWING TRAINING MUST BE PROVIDED: EMERGENCY ENTRY AND EXIT PROCEDURES USE OF APPLICABLE RESPIRATORS FIRST AID PROCEDURES LOCKOUT PROCEDURES LOCAL PERMIT SYSTEMS STANDARD SAFE WORK PRACTICES IN USE 55

CONFINED SPACE OPERATIONS CONTINUED THE FOLLOWING PRECAUTIONS MUST BE TAKEN: PROPER TRAINING IS ESSENTIAL AND MANDATORY FOLLOW LOCAL ENTRY PERMIT PROCEDURES SHUT OFF ALL UNNECESSARY PIPES, AND DUCTS SHUT OFF ALL UNNECESSARY ELECTRICAL LINES PROVIDE CONTINUOUS MECHANICAL VENTILATION PERFORMED PROTOCOL FOR INITIAL AIR MONITORING LOCATE GAS CYLINDERS AND POWER SOURCES FOR WELDING OUTSIDE OF THE SPACE 56

CONFINED SPACE OPERATIONS CONTINUED THE FOLLOWING PRECAUTIONS MUST BE TAKEN: ATTENDANTS MUST BE DESIGNATED TO MAINTAIN VISUAL AND VOICE CONTACT WHEN NOT IN USE, GAS SUPPLIED EQUIPMENT MUST BE REMOVED FROM THE SPACE WHEN NOT IN USE ARC WELDING ELECTRODES MUST BE PREVENTED FROM MAKING CONTACT CONFINED SPACE EXTRACTION EQUIPMENT MUST BE USED AND OR WORN 57

OXYGEN-FUEL GAS WELDING FUMES AND GAS HAZARDS: PROVIDE SUFFICIENT VENTILATION FOR OPERATION NEVER BREATH FUMES OR GASES REMOVE PAINTS OR COATINGS FROM WELDING SURFACE CONSIDER EFFECTS ON CO-WORKERS CONSIDER ALL FUMES, GASES, SMOKES HAZARDOUS 58

OXYGEN-FUEL GAS WELDING OXYGEN HAZARDS: KEEP OIL AND GREASE FROM HOSES, REGULATORS ETC. NEVER USE LUBRICANTS ON OXY-FUEL EQUIPMENT OXYGEN ENRICHED MATERIAL BURNS MUCH HOTTER! KEEP OXYGEN FROM ENTERING PERMEABLE MATERIAL NEVER HANDLE OXYGEN IN GREASE OR OILY AREAS CONSIDER ALL FUMES, GASES, SMOKES HAZARDOUS OXYGEN IS “NOT” AIR, NEVER USE FOR DUST-OFF OF CLOTHING OR WORK SURFACES! 59

OXYGEN-FUEL GAS WELDING FUEL GASES: CAN DISPLACE BREATHING AIR WORK AREAS MUST HAVE AT LEAST 18% OXYGEN CONTACT THE GAS SUPPLIER FOR SPECIFIC INFORMATION RELATIVE VAPOR DENSITY IS A CRITICAL CONSIDERATION! FUEL GASES CAN COLLECT IN HIGH OR LOW AREAS VAPOR DENSITY WILL DETERMINE WHERE THESE GASES GO HOSES CAN LEAK AND DISPERSE GASES IN UNWANTED AREAS FORCED VENTILATION AND EXHAUST DUCTS MAY BE NEEDED 60

OXYGEN-FUEL GAS WELDING FUEL GASES (Cont.): FUEL GAS RELATIVE VAPOR DENSITY WITH AIR NATURAL GAS 0.55 ACETYLENE 0.91 BREATHING AIR 1.00 PROPYLENE 1.42 MAPP 1.48 PROPANE 1.56 BUTANE 2.05 LIGHTER THAN AIR HEAVIER THAN AIR NEVER RELEASE FUEL GASES INTO THE AIR NEAR OTHER WELDING OR CUTTING OPERATIONS OR POTENTIAL SOURCES OF IGNITION! 61

OXYGEN-FUEL GAS WELDING FUEL GASES (Cont.): FUEL GAS EXPLOSIVE CONCENTRATION IN AIR NATURAL GAS 2.8% TO 17% ACETYLENE 2.3% TO 80% PROPYLENE 2.0% TO 11.1% MAPP 3.4% TO 10.8% PROPANE 2.1% TO 9.5% BUTANE 1.9% TO 8.5% NEVER RELEASE FUEL GASES INTO THE AIR NEAR OTHER WELDING OR CUTTING OPERATIONS OR POTENTIAL SOURCES OF IGNITION! 62

HANDLING GASES GASES - GENERAL SAFETY REQUIREMENTS UNLESS IN USE, VALVES SHOULD BE KEPT CLOSED. NEVER TAMPER WITH SAFETY RELIEF DEVICES. ALWAYS USE AN APPROVED PRESSURE-REDUCING REGULATOR. LEAVE “T” WRENCHES IN PLACE AT ALL TIMES. THAW ICE WITH WARM (NOT BOILING) WATER. NEVER LET RECESSED TOPS OF CYLINDERS FILL WITH WATER. NEVER USE A CYLINDER AS A ROLLER OR SUPPORT. 63

HANDLING GASES GASES - GENERAL SAFETY REQUIREMENTS CONTINUED GASES - GENERAL SAFETY REQUIREMENTS NEVER TRANSFER ANY GAS FROM ONE CYLINDER TO ANOTHER. NEVER TRANSPORT USING ELECTRO-MAGNETIC LIFTS. SECURE CYLINDERS FROM TAMPERING WHEN NOT IN USE. TREAT EVERY CYLINDER LIKE A BOMB. 64

HANDLING GASES GASES - PRE-OPERATION SAFETY REQUIREMENTS CONTINUED GASES - PRE-OPERATION SAFETY REQUIREMENTS 1. INSPECT CYLINDER FOR DAMAGE BEFORE USE. 2. ENSURE “IN USE” LABEL IS PRESENT. 3. ENSURE ALL LABELS AND WARNINGS ARE READABLE. 4. PLACE UPRIGHT ON STABLE DRY SURFACE. 5. ENSURE CYLINDER IS RESTRAINED ABOVE MID-POINT. 6. NEVER SECURE TO ELECTRICAL LINES OR CONDUITS. 7. KEEP HEAT, FLAME, AND ELECTRICITY AWAY FROM CYLINDER. 8. OPERATE IN ACCORDANCE WITH WELDING PROCEDURES. 65

HANDLING GASES GASES - POST-OPERATION SAFETY REQUIREMENTS CONTINUED GASES - POST-OPERATION SAFETY REQUIREMENTS 1. ENSURE “EMPTY” OR LIKE LABEL PRESENT. 2. ENSURE VALVE IS CLOSED COMPLETELY AND CAP CYLINDER. 3. REMOVE FROM OPERATION FOLLOWING PROCEDURES. 4. NEVER ROLL, TRANSPORT CYLINDERS USING HANDTRUCK. 5. NEVER UNDERESTIMATE HAZARDS ASSOCIATED WITH COMPRESSED GASES. 66

TRANSPORTING GASES GASES - TRANSPORTING REQUIREMENTS TRANSPORT WITH REGULATOR REMOVED. NEVER TRANSPORT IN CONFINED SPACES. ALWAYS PROVIDE PLENTY OF VENTILATION. PREVENT ICE OR SNOW FROM ACCUMULATING. USE SUITABLE HAND TRUCK OR RACKS TO MOVE CYLINDERS. NEVER USE OR TRANSPORT A LEAKING CYLINDER. NEVER TRANSPORT USING SLINGS OR ELECTRO-MAGNETS. 67

STORING GASES GASES - STORAGE REQUIREMENTS STORE ONLY IN DESIGNATED AREAS. STORE AND USE ON A FIRST-IN, FIRST-OUT BASIS. NEVER STORE WITHOUT PROPER LABELING. IDENTIFY ALL EMPTY CYLINDERS. STORE LIKE GASES WITH LIKE GASES. SEPARATE EMPTY CYLINDERS FROM FULL ONES. STORE WITHIN PROPER TEMPERATURE RANGES. 68

ELECTRIC WELDING FUMES HAZARDS: PROVIDE SUFFICIENT VENTILATION FOR OPERATION NEVER BREATH FUMES REMOVE PAINTS OR COATINGS FROM WELDING SURFACE CONSIDER EFFECTS ON CO-WORKERS CONSIDER ALL FUMES AND SMOKES HAZARDOUS 69

ELECTRIC WELDING UNDERSTAND THE FOLLOWING: MANUFACTURERS’ INSTRUCTIONS FOR SAFE USE MAINTENANCE REPORTING REQUIREMENTS INDIVIDUAL MACHINE HOOK-UP PROCEDURES GROUNDING REQUIREMENTS LEAK DETECTION OF WATER, OR FUELS SAFE USE OF SHUT-DOWN SWITCHES SAFE USE OF ELECTRODES SAFE USE OF ELECTRIC CABLES 70

ELECTRIC WELDING FUMES HAZARDS: CONTINUED FUMES HAZARDS: PROVIDE SUFFICING VENTILATION FOR OPERATION NEVER BREATH FUMES REMOVE PAINTS OR COATINGS FROM WELDING SURFACE CONSIDER EFFECTS ON CO-WORKERS CONSIDER ALL FUMES AND SMOKES HAZARDOUS 71

ELECTRIC WELDING SAFETY PRECAUTIONS FOR ARC WELDING: CONTINUED SAFETY PRECAUTIONS FOR ARC WELDING: ENSURE EQUIPMENT IS INSTALLED PROPERLY ENSURE EQUIPMENT IS SERVICEABLE ALWAYS WEAR SUITABLE PROTECTIVE CLOTHING AVOID BREATHING AIR IN THE FUME PLUME KEEP THE WORK AREA FREE OF FIRE HAZARDS CONSIDER HAZARDS ASSOCIATED WITH WET AREA SAFELY DISPOSE OF ELECTRODE STUBS SHIELD OTHERS FROM LIGHT RAYS DO NOT WELD NEAR DEGREASING OPERATIONS 72

ELECTRIC WELDING SAFETY PRECAUTIONS FOR ARC WELDING: CONTINUED SAFETY PRECAUTIONS FOR ARC WELDING: CONSIDER LOCATION OF WORK: - FALL HAZARDS - MULTILEVEL WORK OPERATIONS - CONFINED SPACE HAZARDS - LOCKOUT TAGOUT REQUIREMENTS - EFFECT ON LOCAL PROCESSES - CO-WORKER PROTECTION 73

CONTRACTOR SAFETY REQUIREMENTS OUTSIDE CONTRACTORS MUST: INFORM REPRESENTATIVES OF THE FACILITY OF THE TYPES OF WELDING THAT THEY WILL BE PERFORMING AND BE PREPARED TO PROVIDE SAFETY INFORMATION UPON REQUEST FACILITY OR EMPLOYER REPRESENTATIVES MUST: INFORM THE CONTRACTOR OF HAZARDS IN THE AREA WHERE CONTRACTOR PERSONNEL WILL BE WORKING 74

TIPS FOR USING CONTRACTORS REMEMBER, YOU CONTROL YOUR FACILITY OR AREA! REVIEW THEIR PROCEDURES WITH THEM BEFORE STARTING THE JOB! DETERMINE THEIR SAFETY PERFORMANCE RECORD! DETERMINE WHO IS IN CHARGE OF THEIR PEOPLE! DETERMINE HOW THEY WILL AFFECT YOUR EMPLOYEES! 75

OF A SUCCESSFUL PROGRAM OSHA'S PERCEPTION OF A SUCCESSFUL PROGRAM 1. DETAILED WELDING SAFETY PROCEDURES 2. EXTENSIVE EMPLOYEE TRAINING PROGRAMS 3. PERIODIC REINFORCEMENT OF TRAINING 4. SUFFICIENT DISCIPLINE REGARDING IMPLEMENTATION 76

WORK AT WORKING SAFELY Training is the key to success in managing safety in the work environment. Attitude is also a key factor in maintaining a safe workplace. Safety is, and always will be a team effort, safety starts with each individual employee and concludes with everyone leaving at the end of the day to rejoin their families. Patricia A. Ice Industrial Hygienist 77