1. WELDING SAFETY
OSHA TRAINING
OSHA 29 CFR
WELCOME 1

2. 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

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

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

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

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

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

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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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

25. 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

26. 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

27. 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

28. PERSONAL PROTECTIVE EQUIPMENT
EYE PROTECTION:
FOLLOW LOCAL JOB PROCEDURES
SEE ANSI STANDARD Z87.1 FOR SHADING CRITERIA
SEE CHART IN 29CFR 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

29. PERSONAL PROTECTIVE EQUIPMENT
GUIDE FOR SELECTION OF SHADE NUMBERS:
WELDING OPERATION SHADE #
Soldering
Torch Brazing or 4
Light Cutting, up to 1 Inch or 4
Medium Cutting, 1 to 6 Inches or 5
Heavy Cutting, 6 Inches and Over 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

30. 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
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
Shielded Metal Arc Welding 5/16, 3/8 , Inch Electrodes
Atomic Hydrogen welding
Carbon Arc Welding 34

31. 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

32. 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 AND 252 FOR GENERAL CRITERIA
REVIEW THE JOB HAZARD ANALYSIS ASSESSMENT
IF YOU HAVE QUESTIONS CONSULT YOUR SUPERVISOR 36

33. 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

34. 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

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. 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

46. 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

47. 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

48. 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

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

50. 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

51. 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

52. 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

53. 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

54. 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

55. 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

56. 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

57. OXYGEN-FUEL GAS WELDING
FUEL GASES (Cont.):
FUEL GAS RELATIVE VAPOR DENSITY WITH AIR
NATURAL GAS
ACETYLENE
BREATHING AIR
PROPYLENE
MAPP
PROPANE
BUTANE
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

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

59. 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

60. 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

61. 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

62. 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

63. 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

64. 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

65. 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

66. 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

67. 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

68. 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

69. 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

70. 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

71. 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

72. 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

73. 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