Employee Safety Training Series - fescodirect.com · ¾Disconnect machine from power source ......
Transcript of Employee Safety Training Series - fescodirect.com · ¾Disconnect machine from power source ......
1
Get the PointEmployee Safety Training Series
Get the Point
Training Series
by
TechneTrain, Inc.140 Wooster Pike
Milford OH 45150
Copyright © 2010 TechneTrain, Inc.
Welding, Cutting
& Brazing
29 CFR 1910 Subpart Q
Welding, cutting and brazing can be exceptionally dangerous.
Compressed gases are typically used to create an extremely hot flame.
Various welding techniques create fumes, radiation and other hazards.
Extremely Hazardous Work
2
The purpose of this
program is not to teach
you how to weld, cut or
braze, but to train you on
OSHA’s safety
regulations for this work.
1.OSHA Welding, Cutting &
Brazing Standard
2.Personal Protective Equipment
3.Oxygen-Fuel Gas Welding and
Cutting
4.Arc Welding and Cutting
5.Resistance Welding
Objectives
Objectives
1.OSHA Welding, Cutting & Brazing Standard
2.Personal Protective Equipment
3.Oxygen-Fuel Gas Welding and Cutting
4.Arc Welding and Cutting
5.Resistance Welding
3
OSHA’s Welding Cutting
& Brazing Standard
Safe operating procedures
Safe equipment maintenance
Safe storage of gases and supplies
Fire protection
Personal Protective
Equipment (PPE)
Health protection
and ventilation
Key Areas
Fire Prevention
Establish a safe area for hot
work
Check the work area and move
or guard any hazards.
If these requirements cannot be met,
welding and cutting are prohibited!
4
Managing your location and
surroundings are not enough.
You must also:
Have proper extinguishing
equipment available.
Maintain a fire watch if
needed.
Fire Watch
The fire watch is maintained by a
designated attendant in hot work
locations where:
A fire could develop
Combustible materials are within 35’
Combustible materials are > 35’, but
could be easily ignited by sparks
Hot Work in a Confined Space
A confined space is a restricted work area such as a tank, tunnel or pit.
Hot Work in confined spaces requires even more precautions.
Must also have a designated attendant
5
Confined Space Hot Work
Precautions
Ventilation
Gas cylinders and welding machines
must remain outside the space
Emergency procedure for removal of
workers
Attendant must be present at all times
When Suspending Work
Remove electrodes from holders
Disconnect machine from power
source
Close torch valves
Shut off torch gas supply
outside the confined space
Where practical, remove torch
and hose from space
Areas not authorized by management
Buildings with impaired sprinkler systems
Explosive atmospheres
Unclean tanks
Accumulation of combustible dusts
Locations where explosive atmospheres
can develop
Forbidden Areas
6
Engineering and Work
Practice Controls
The first step to protecting employees
are these engineering and safe work
practice controls.
Additionally, your employer must
provide you with PPE.
Objectives
1.OSHA Welding, Cutting & Brazing
Standard2.Personal Protective Equipment3.Oxygen-Fuel Gas Welding and Cutting
4.Arc Welding and Cutting
5.Resistance Welding
Hazards Requiring Protection
Ultraviolet and infrared
radiation
Metal fumes and welding gases
Electrical current
Hot metal and sharp edges
Noise
7
Personal Protective
Equipment
Eye Protection
Helmet
Hand shields
Booths or
Screens
Protective Clothing
Safety Shoes
Gauntlet Gloves
Fall Protection
Respirators
Goggles
Must be used to protect the eyes from UV
and IR light.
A face shield may be needed.
Proper lens shade number for the operation.
Welding Hood with Dark Glass
Must be used with appropriately dark
glass viewing ports while carbon
arcing to protect from UV and IR light.
Proper lens shade number for the
operation.
8
Welding Curtains or Booths
Welders should be enclosed in an
individual booth or work behind a
non-combustible screen.
Screens are coated with a low
reflecting finish, such as zinc oxide
and lamp black.
Booths and screens must permit
free circulation of air.
Hand Protection
Long-cuffed leather gloves required while arc welding.
Leather or similar gloves required for other hot work.
Protective Clothing
Wear fire retardant garments such as
aprons, leggings, capes, sleeves.
Remove combustible items from pockets
or clothing.
Prevent sparks or slag from catching in
clothing.
Wear cotton or wool clothing to protect
from UV and IR light.
When hoods are used, they must be fire-
retardant.
9
Foot Protection
Wear high-top boots or safety shoes
with spats.
Wear pant legs outside the shoes to
prevent slag from entering.
Boots should be fully laced or zipped.
Hearing Protection
When noise is above
acceptable limits, you must
wear ear muffs or ear plugs
to protect your hearing.
Fall Protection
Railings
Safety Lifelines
Other Safeguards
10
Respirators
Respirators may be required for hot
work on some materials or in certain
environments.
If you wear a respirator, you must be
included in a respirator safety
program.
Other workers exposed to the same
atmosphere must also be protected.
Flourine
Zinc
Lead
Chrome
compounds
Beryllium
Cadmium
Mercury
Ventilation Required
Along With PPE
Confined or Enclosed Spaces
Hot work in confined space consumes
oxygen and requires ventilation or
supplied air respirators.
Air-line respirators supply air to the
welders through a hose.
Air-line respirators may not be enough
and an SCBA may be required.
Don’t allow ventilation to block access.
11
Air-line Respirators
Air-line respirators are always required
in addition to ventilation if surfaces:
Contain lead, cadmium, or mercury.
Are covered with toxic preservatives.
Contain beryllium.
Hot Work in Open Air
Air-purifying respirators required when:
Surface contains lead, cadmium, or mercury.
Surface contains beryllium.
You need a filter type respirator when doing hot work on surfaces covered with toxic preservatives.
You may need a respirator if you work on stainless steel or surfaces containing chrome.
While PPE is required for all
types of hot work, OSHA has
additional requirements for:
• Oxygen-fuel gas welding/cutting
• Arc welding and cutting
• Resistance welding
12
Objectives
1.OSHA Welding, Cutting & Brazing
Standard
2.Personal Protective Equipment3.Oxygen-Fuel Gas Welding and
Cutting4.Arc Welding and Cutting
5.Resistance Welding
One of the most
serious issues with
fuel gas welding is
the handling and
storage of gas
cylinders.
Compressed Gas
High pressure cylinders
can be dangerous.
Can be highly flammable.
Can asphyxiate.
Can increase fire hazards.
13
Cylinder Safety
Cylinder marking
Safe storage
Safe operating
procedures
Cylinder Marking
Must be legibly marked
Chemical or trade name
Marking must be done by
Stenciling
Stamping
Labeling
Should be located on the
shoulder
Cylinder Storage
Must be stored in protected, ventilated
locations
Away from sources of heat
At least 20’ away from highly
combustible materials
Away from elevators, stairs or
gangways
14
Cylinders must be chained to prevent damage due to falling.
Empty cylinders must have valves closed.
Valve protection caps must always be in place.
Valve Outlet
Valve protection caps protect
the valve on the cylinder from
oil, grease and damage.
Valve protection caps should
never be used for lifting
cylinders.
If the valve outlet becomes
clogged with ice, thaw with
warm water.
Regulators must be removed before
cylinders are moved.
Regulators must be compatible with
gas and pressure needs.
Use only clean regulators and filters.
“Crack” the valve before attaching.
Close valve and release gas before
removing regulator.
15
Cylinders, valves, couplings,
regulators, hose and
apparatus must be kept
free from oily or greasy
substances.
Oxygen
Acetylene
Anhydrous ammonia
Liquefied petroleum gases
Hydrogen
Nitrous oxide
SpecialRegulations
Oxygen- Acetylene
Welding & Cutting
Acetylene Safety
Pressure Limits
Cylinder Usage and Handling
Storage of Fuel Gas and Oxygen
Regulators
Service Pipe System
16
Acetylene
Acetylene at gage pressures over 15 psig is hazardous.
Acetylene is potentially unstable at higher pressure and can decompose explosively.
Acetylene is stored as a gas in liquid solution in special cylinders.
Cylinders must be stored upright.
Cylinder Manifolding
All manifolds must be used
only for the gases for which
they are approved.
Manifold systems must meet
the requirements of
ANSI/NFPA.
Combine (manifold) gases.
Manifolds and service piping
must be located outside.
Acetylene piping must be
steel or wrought iron.
Clearly mark all cylinder
connection points.
Service Pipe Systems
17
Objectives
1.OSHA Welding, Cutting & Brazing
Standard
2.Personal Protective Equipment
3.Oxygen-Fuel Gas Welding and Cutting4.Arc Welding and Cutting5.Resistance Welding
Electric arc produces intense heat capable of melting metal.
Arc welding is used on carbon or alloy steels and nonferrous metals.
Arc cutting primarily used for rough cuts or scrapping.
Arc Welding and Cutting
Processes
Shielded Metal-Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)
Flux Cored Arc Welding (FCAW)
Plasma Arc Cutting (PAC)
Air Carbon-Arc Cutting (AAC)
18
Electric Current
100 Volts100 VoltsAutomatic
100 Volts80 VoltsManual
Direct
Current (DC)
Limit
Alternating
Current (AC)
Limit
AC Welding
It is easy to receive an electric shock
when AC equipment is not handled
properly.
When AC welding under wet
conditions or where perspiration is a
factor, use reliable automatic controls
for reducing no-load voltage.
Equipment Installation
Arc welding requires proper
installation.
The case of the welding machine
must be grounded.
All connections must be checked
each time the equipment is used.
Coiled welding cable must be
spread out.
19
Cables
Do not use cables with splices within 10’ of the electrode holder.
Do not coil or loop cables around body parts.
Replace damaged insulation or conductors.
Use the right connectors.
Shielding
Preserves the integrity of the
weld joint
Provided by:
Decomposition of the electrode
covering, known as flux
Gas or a gas mixture
Objectives
1.OSHA Welding, Cutting & Brazing
Standard
2.Personal Protective Equipment
3.Oxygen-Fuel Gas Welding and Cutting
4.Arc Welding and Cutting5.Resistance Welding
20
Utilizes pressure and heat
that is generated in the
pieces to be welded by
resistance to an electric
current.
Resistance Welding
Must be installed by qualified electrician.
Circuits must be low voltage.
Doors and access panels must be locked to prevent access by unauthorized persons.
Equipment
Foot switches must be guarded to prevent accidental operation.
All equipment suspended from overhead structures must be equipped with safety cables.
Effective guards must be used if there is a possibility of the operator’s fingers being under the point of operation.
Guarding
21
Shield guards made of safety glass or suitable fire-resistant plastic must be installed at the point of operation and as needed to protect from flying sparks.
Flying Sparks
Inspections
Periodic inspections must be made by
qualified maintenance personnel and a
certification record maintained.
Operator must report any equipment
defects to his supervisor.
Use of equipment must be discontinued
until safety repairs are completed.
Be mindful of fire hazards.
Remember the specific hazards for
the type of hot work that you do.
Compressed gases
Electrical
Ultraviolet and infrared radiation
Noise
Always wear the required PPE.
Key Points for Safety
22
Great Job!!
You still need training on:The specific hazards at your job.How your employer protects you
with engineering controls and safe work practices.
The PPE that you are required to wear.
Stay Safe!
Get the PointTechneTrain, Inc. has no control over the use of this
material. This product is meant to be only an overview of the subject matter. Any specific use or application of this
product is beyond the scope of responsibility of TechneTrain, Inc.
TechneTrain, Inc. makes no warranties, either expressed or implied, and assumes no responsibility for the use of
this product. Some states may have more stringent regulations than the Federal OSHA Standard. This product is solely intended to address Federal OSHA
regulations.
No part of this presentation may be copied or reproduced without the express written consent of TechneTrain, Inc.
Copyright © 2010 TechneTrain, Inc.