WELDING SAFETY - Safety Training · PDF fileWELDING SAFETY. Part of the SAFETY ... copies of...

LEADER'S GUIDE

0450-LDG-E

WELDING SAFETY

Part of the SAFETY MEETING KIT Video Series

Quality Safety and Health Products, for Today...and Tomorrow

106 Capitola Drive Durham, NC 27713

(P) 919-544-6663 (F) 919-544-5800 Trainingnetwork.com



THE SAFETY MEETING KIT VIDEO SERIES This education program is part of the Safety Meeting Kit Video Series. The programs in this series have been created to provide employees with good, basic information on everyday safety and health topics. This series includes programs on the following topics: - Accident Investigation - The ANSI MSDS - Back Safety - Compressed Gas Cylinders - Computer Workstation Safety - Conflict Resolution (Industrial and

Office versions) - Crane Safety (Industrial and

Construction versions) - Driving Safety - Dealing with Drug and Alcohol

Abuse (Employees and Managers/Supervisors versions)

- Electrical Safety - Eye Safety (Industrial and

Construction versions) - Ergonomics (Industrial and Office

versions) - Fall Protection - Fire Extinguishers - Fire Prevention (Healthcare,

Industrial and Office versions) - First Aid (Industrial and

Construction versions) - Hand and Power Tool Safety

(Industrial and Construction versions)

- Hand, Wrist and Finger Safety (Industrial and Construction)

- Hazardous Materials Labels - Hazardous Spill Cleanup - Heat Stress (Industrial and

Construction versions) - Ladder Safety (Industrial and

Construction versions) - Machine Guard Safety - Materials Handling Safety - Office Safety - Rigging Safety (Industrial and

Construction versions) - Safety Audits - Safety Housekeeping and

Accident Prevention - Safety Orientation - Safety Showers and Eye Washes - Sexual Harassment (Employees &

Managers/ Supervisors versions) - Sexual Harassment Investigations - Slips, Trips and Falls - Welding Safety (Industrial and

Construction versions) - Wellness and Fitness - Winter Safety - Workplace Harassment (Industrial

and Office versions) - Workplace Stress - Workplace Violence

Other products in the Safety Meeting Kit line include employee booklets and posters which have been designed specifically to be used with the programs. By combining these three products you have all of the materials you need to promote and conduct a complete safety meeting (for information on booklets and posters contact your local distributor).



WARRANTY/DISCLAIMER "This program has been created to assist companies that are endeavoring to educate their employees regarding good safety and health practices. The information contained in this program is the information available to the producers of the program at the time of its production. All information in this program should be reviewed for accuracy and appropriateness by companies using the program to assure that it conforms to their situation and recommended procedures, as well as to any state, federal or other laws, standards and regulations governing their operations. There is no warranty, expressed or implied, that the information in this program is accurate or appropriate for any particular company's environment."

Copyright 1996, The MARCOM Group, Ltd.



TABLE OF CONTENTS 1 INTRODUCTION TO THE PROGRAM

— Structure and organization — Background — Objectives — Reviewing the program

2 PREPARING FOR THE PRESENTATION

— Structuring the presentation — Setting up the class and classroom

3 CONDUCTING THE SESSION

— The initial steps — Showing the program — Conducting the discussion — Concluding the presentation — Wrapping up the paperwork

4 OUTLINE OF MAJOR POINTS IN THE PROGRAM 5 ACCOMPANYING MATERIALS

— Scheduling and Attendance Form — Quiz — Training Certificate — Employee Training Log



INTRODUCTION TO THE PROGRAM Structure and Organization Information in this program is presented in a definite order, so that employees will see the relationships between the various groups of information and can retain them more easily. The sections in this program include:

- Inspecting welding equipment.

- Eye protection.

- Hazardous fumes

- The use of respirators.

- Hearing protection.

- Other personal protective equipment.

- Sparking and the risk of fire. Each of the sections gives an overview of important information in one topic area, providing employees with the basis for understanding how to weld safely. Background People have been welding in one form or another for over 2,000 years. But like many other industrial processes, welding can be very dangerous. Whether an employee is working with the hazardous gases of an oxyacetylene unit, the high voltage of stick welding or the combination of gas and electricity that powers "MIG" and "TIG" operations... flying sparks, toxic fumes, electric shock and high temperatures are just some of the things that can make welding a dangerous proposition.



Because of all of the potential hazards surrounding welding operations, when a welder strikes an arc or sparks a torch, safety must be the number one priority. Objectives To help employees understand how to weld safely, this education and training program is designed to present basic safety information in these areas. Upon completion of the program, employees should:

- Understand why inspecting welding equipment before starting operations is vital.

- Know how using glasses, goggles and/or welding helmets can

protect against the intense light emitted during welding.

- Understand how welding fumes can contaminate the workplace, and how to avoid exposure to this hazard.

- Know what substances can be especially hazardous when they are

being welded, and how mechanical ventilation devices can help control toxic fumes.

- Understand how personal protective equipment, such as respirators

and hearing protection, can prevent injuries during welding operations.

- Know how to guard against sparks and prevent fires when welding.



Reviewing the Program As with any educational program, the presenter should go through the entire program at least once to become familiar with the content and make sure the program is consistent with company policy and directives. An Outline of Major Program Points section is included in this Leader's Guide to help with this task and for general reference. As part of this review process, you should determine how you, as the presenter, will conduct your session. The use of materials such as handouts, charts, etc., that may be available to you needs to be well thought out and integrated into the overall program presentation.



PREPARING FOR THE PRESENTATION Structuring the Presentation In conducting this education session, you should proceed with a friendly and helpful attitude. Remember that the trainees are looking to your experience and knowledge to help them relate to the situations shown in the program. It is important to let the trainees interact with you and each other during the training session. Stimulating conversation within the group is one of the best things you, as the presenter of the program, can do to help everyone get as much as possible from the session. Be alert for comments that could help in this area in future sessions and make note of them. As the presenter, you also should:

- Keep the session related to the topic of welding safety.

- Relate discussions to how to develop better welding safety skills and minimize the risk of a fire or injury occurring when operating any type of welding equipment.

- Prevent any one person or small group of employees in the session

from doing all the talking.

- Get everyone involved. Ask questions of those who don't participate voluntarily.

- Clarify comments by relating them to the key points in the program.

Use the Outline of Major Program Points section in this guide, as well as the information included in the quiz, as the basis for answering any questions. If you don't know the answer, say so. Tragic results may occur should you provide incorrect or inaccurate information. Remember, this is a positive program on welding safety. Make sure your attitude and words reflect this and that the emphasis is always on providing the information needed by the attendees to improve their ability to work safely.



Setting Up the Class and Classroom Remember, there are a number of things that must be done to set up the class as well as the classroom. These fall into several groups of activities, and include:

- Scheduling and Notification - Use the enclosed form to schedule employees into the

session. - Make sure that the session is scheduled so that it fits

into your attendees' work day. - Send out notification of the session well in advance, to

give people enough time to incorporate it into their schedule for that day.

- If possible, post a notification on bulletin boards in the affected employees' areas.

- The Classroom

- Schedule the room well in advance. - Make sure the room can accommodate the expected

number of attendees. - Check it again on the day of the program to make sure

there is no conflict. - Make sure the room can be darkened, and won't create

a glare on the television screen. - Locate the light controls and test them. - Make sure the power for the videotape or DVD player

you are using operates separately from the room light. - See if you can control the room temperature. - Know where the closest restrooms are located. - Assure that the room is free from distracting noises. - Make sure emergency exits are marked and known to

the attendees.

- Seating - Make sure everyone can see the screen from their seat. - Make sure everyone can hear the videotape/DVD and

you (when you speak). - Check to see that seating is such that writing can be

done easily. 106 Capitola Drive

Durham, NC 27713 (P) 919-544-6663 (F) 919-544-5800

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- Make sure the seating arrangement allows eye contact between attendees, and between you and attendees.

- Equipment and Materials

- Make sure the videotape or DVD player, monitor, and all appropriate cables and extension cords are available.

- Make sure a stand or table is available and is of appropriate height for all attendees to easily see the monitor.

- If you plan on using a chartpad, blackboard, or other writing board, make sure it is available, easy to see, and you have the proper writing implements.

- Make sure you have 6" x 8" index cards or other materials to be used as name tents for attendees.

- Make sure you have made up a sufficient number of copies of the quiz, as well as any other handouts you are using.

- Final Check

- Make sure equipment is in the room prior to the scheduled session.

- Check to see that the room is set up properly. - Check equipment prior to the presentation to assure

that it works. - Make sure extension cords, etc. are taped down, if need

be, to avoid tripping. - If you are using the videotape versions of the program,

run the leader up to the point where the program begins.



CONDUCTING THE SESSION The Initial Steps In conducting the session remember the positive nature of this presentation. Everyone is attending in order to learn more about how to weld safely, as well as how to avoid hazardous situations during welding operations. Initially, you need to:

- Introduce yourself as the session leader.

- State the title of the program, Welding Safety, and the purpose of the session (to learn about how to weld safely and reduce the risk of fires and injuries while welding is taking place).

- Inform the attendees when there will be breaks (if you plan them) the

location of exits and restrooms and if water, coffee, or other refreshments will be available.

- Make sure all of the attendees have signed in on your scheduling

and attendance sheet. Remember, it is very important to document peoples' attendance at the session.

Once this housekeeping is done, it is time to move to the meat of the session. First, the attendees need to be informed about the objectives of the session (this is where you can use a flip chart or board to list the objectives, which should be done prior to the class starting). This listing should be preceded with some introductory remarks. Your own words are always best, but the remarks should include information such as the following paragraphs:

"Welding, like many other industrial processes, can be very hazardous. The chance of a spark starting a fire is always present. And you could get badly burned or permanently damage your vision if you do not follow proper safety procedures. When you are welding, safety should always be the first priority."



"In addition to the potential for fire and eye damage due to the intense light, there are several other types of hazards associated with welding. Arc welding has special safety requirements, since it uses electricity to generate the heat that is needed for welding. We all know that electricity can be dangerous, so we need to be especially cautious when using this type of equipment."

"Toxic fumes can also be a serious problem. This isn’t something that we always think about when we are welding, but many substances can give off hazardous fumes when they are heated."

"The program you are about to watch today provides a lot of good information about how to make welding less dangerous. In spite of the hazards, you can perform welding operations safely if you follow proper safety procedures and guidelines."

"To make this the most productive session possible, we need to look at what we want to accomplish here today (verbally reference the Objectives list from the first section in this guide, or point to the blackboard or chart where you have written them down)."

Once the objectives have been provided, you are ready to show the program. However, you do need to let the attendees know that they will be taking a quiz at the end of the session (if you are using it). It needs to be emphasized that they are not being graded, but that the quiz is being used to see if the session is effectively transmitting information to them in a way they will remember. Showing the Program At this point, you need to introduce the title of the videotape program once again, Welding Safety, darken the lights if necessary, and begin the showing of the program. If you are using the DVD version of the course you have several options as to how you can move through the program and what employees see.



T

he DVD menu has two selection bars:

- Play. - Contact Us.

To just play the program from beginning to end, select Play. If you would like information on other programs and products that are available from Training Network you can select Contact Us for information about how to contact us. Conducting the Discussion After the program has been shown, it is time for the group discussion on the information contained in the session. Care must be taken to make sure that the discussion is kept to the general topic of welding safety. There are several ways to conduct this discussion. These include:

- Calling for questions from the attendees and using these questions as the basis for the discussion.

- Leading the discussion through the points covered in the program

using statements such as: - "One of the sections that we saw in the program

discussed how some materials can give off toxic fumes when they are heated during welding. Who can name some of these substances, and tell us how we can protect ourselves against their fumes?"

- "We saw an interesting sequence discussing how the light given off by welding can be very hazardous. What should we do before we start welding operations to protect ourselves from hazardous light?"



You should use the discussion format that you are most comfortable with. The Outline of Major Program Points section in this guide, and the questions and answers in the master copies of the quiz can also be very useful as a basis for discussion. Remember, you have allocated a limited amount of time in which this discussion can take place. It is important to blend the attendees' questions and areas of obvious interest with the objective of trying to touch on each major area within the session in the discussion. By touching on each area, the attendees are much more likely to retain the information presented in the session. Concluding the Presentation Once discussion has concluded, whether naturally or you have had to bring the discussion to a close in order to complete the session within the time allowed, it is time to give the quiz (if you are using it). Again, remind the attendees that the quiz is only meant to help determine how effective the presentation of the information is, and that they will not be graded on it. Let them know that they have approximately five minutes to complete the quiz. At the end of the five minute period, remind the attendees to date and sign their quizzes, and then collect them. The attendees should be thanked for attending the session and reminded of any other sessions in the educational program that they may be attending. They can then be dismissed to return to their normal activities. *(An alternative to this approach is to give the quiz immediately after showing the program, then use a review of the quiz as a basis for your group discussion.)



Wrapping Up the Paperwork Before much time has passed, and the subject matter is fresh in your mind, several areas of paperwork must be completed. First, check to make sure that all attendees signed the scheduling and attendance form. Next, make sure that you have a quiz from every attendee, dated and signed. Also, depending upon what you have decided to do, a copy of the attendance sheet and the quiz for each attendee should be either filed in your files, or turned over to the attendee's department manager (or the personnel office) so that this paperwork can be included in their personnel file. The attendees' training logs should also be updated, and each attendee should be given a filled out and signed training certificate, signifying that they have successfully completed the course. Remember, it is always a good idea to document information about employee’s attendance at these sessions, as well as the fact that the employee has come away from the session with an increased knowledge of how to weld safely, and what to do to avoid fire and injury when they are welding.



OUTLINE OF MAJOR PROGRAM POINTS The following outline summarizes the major points of information presented in the program. The outline can be used to review the program before conducting a classroom session, as well as in preparing to lead a class discussion about the program.

- Every day, welders in various industries use high temperatures to shape metal.

- Sometimes the metal is bonded together. - Other times it is cut apart.

- Over the years, engineers have developed a variety of welding

methods, such as: - Oxy-fuel, combining a spark, oxygen and a flammable

gas for cutting, welding and brazing. - Arc welding, using high voltage electricity alone or in

tandem with various gases.

- All welding methods can be very hazardous because of the heat and the material involved.

- But no matter what type you use, there are ways to make your work safe.

- The first thing to do is to inspect your equipment. When working with

an oxy-fuel unit: - Make sure your torch has the right tip for the job at

hand. - Examine the cylinder valves and fittings before

connecting the torch and hoses.

- Once everything is set up, apply a soap solution to check for gas leaks.

- Some problems can be solved by simply tightening the connection.



- Arc welding units also need to be checked out. - Inspect the frame of the generator for proper grounding. - Make sure that the work lead and the electrode lead are

both properly connected. - Examine cables for damaged insulation or bare

conductors (these can cause severe shock if left unrepaired).

- It is important to be prepared for hazards throughout the entire

welding process. You need to protect yourself and others from: - Intense light. - Flying sparks. - Toxic fumes. - Electric shock.

- The powerful ultraviolet and infrared light produced during welding

can be extremely hazardous. If left unprotected: - Your eyes can suffer the short-term discomfort of

welder’s flash. - Your retina may be burned, resulting in permanent

damage. - You could even be blinded.

- Goggles fitted with specially tinted lenses must be worn during oxy-

fuel cutting, welding and brazing. - These special lenses block hazardous light. - They also help shield your eyes from molten spatter.

- Arc welding produces an intense light that requires even stronger

protection. - A helmet or hand shield should be used. - These are fitted with specially designed filters, which

screen out harmful light rays. - The helmet or shield's design and size can also prevent

the light from burning your face, neck and ears.

- Don’t forget that safety glasses must still be worn underneath your helmet or hand shield for complete protection.



- Make sure that all of your protective equipment is in good condition before you begin welding.

- If you spot any imperfections, get a replacement.

- Hazardous light can also affect those around you, so you should: - Set up protective screens to shield other workers from

the light you generate. - Warn workers in the area before you strike an arc.

- Hazardous fumes are a by-product of many welding operations.

- Without proper ventilation, these fumes will collect and contaminate the air.

- Protect yourself by using exhaust fans or other mechanical ventilation devices.

- Substances that require mechanical ventilation when being welded

(or used in the process) include: - Stainless steel. - Lead. - Mercury. - Fluorine compounds. - Zinc. - Cadmium. - Beryllium. - Chemical cleaning compounds.

- It is especially important to use mechanical ventilation:

- In rooms with less than 10,000 cubic feet of space per welder.

- Where ceilings are lower than 16 feet. - In confined spaces where regular ventilation is blocked.

- Short periods of exposure to hazardous fumes can lead to irritation of the:

- Eyes. - Nose. - Throat. - They can even cause metal fume fever.

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- To avoid these problems, you must maintain a healthy breathing zone.

- This means getting plenty of air flowing around your work.

- When using screens or other barriers, leave enough space to allow for good air movement.

- Sometimes even mechanical ventilation devices are not enough

protection. In these situations, you will need a respirator. - Before starting work, fit test the respirator. - This ensures that it is the right size for your face.

- Remember that respirators are fitted with filters that capture

hazardous fumes. - Make sure to use the correct filter for the fumes and

gases you will be exposed to. - Wearing the wrong filter can be disastrous.

- Hearing protection is also a necessity on many welding jobs. Things

that can be very noisy include: - Moving pieces of metal around. - Banging away at slag.

- If you don’t take proper precautions, you can be exposed to noise

levels that can result in real problems. - Short periods of loud noise can lead to fatigue and

irritability. - Extended exposure can lead to partial or even total

hearing loss.

- To guard against these hazards, you need to protect yourself by using:

- Earplugs. - Canal caps. - Or earmuffs.

- Ask your supervisor if you have any questions about which type of

hearing protection you should use.



- Welding can produce a lot of heat. To protect your hands, you need a strong pair of leather gloves.

- Many welding gloves offer additional protection with welting, an extra piece of leather sewn into the finger and the palm.

- This protects the threads in the glove from getting burned.

- But even with this extra protection, you need to be careful.

- Never hold heated metal with your gloved hands (it can burn right through the gloves).

- Use insulated clamps or other tools if you need to manipulate hot objects.

- The type of clothing that you wear also plays an important role in

welding safety. - Dress in natural fibers like cotton or wool. - These are less likely to ignite than synthetic fibers.

- Wear long sleeve shirts with closable collars for protection from

hazardous light. - Just like from the sun, UV light from welding can burn

your skin. - Wearing leather aprons and sleeves will also keep

sparks from burning through your clothes.

- Another good idea is to wear high-top shoes. - These keep sparks and molten metal away from your

ankles and feet.

- Once you are dressed for work, you need to set up your work to reduce the risk of fire from:

- Sparks. - High temperatures. - Flammable gases.



- To combat the risk of fire, many facilities limit the areas where welding can take place.

- Never begin to weld unless your facility has authorized the work.

- This confirms that the area is considered safe for welding operations.

- Sparks are a by-product of just about every welding operation.

- Preventing them from starting fires requires a concentrated effort.

- Before welding, remove anything that can burn from the area.

- It is especially important not to weld around combustible materials

such as: - Wood. - Paper. - Fuel. - These ignite easily and can quickly burst into flames.

- Aerosol cans should also be removed from welding areas.

- They hold gases under pressure. - When exposed to intense heat, the gases expand and

could cause the can to explode.

- Use guards or barriers to protect ignitable materials that can’t be easily moved away from sparks and heat.

- Sweep up any debris that may be on the floor.

- It is best to sweep in a 35-foot radius, beginning at the spot where you are going to weld.

- If it is possible that a fire could still ignite, a trained fire watcher is

required to stand by. - This person should be ready to extinguish a fire if it

breaks out. - Because metal will stay hot for some time, the fire watch

must be maintained for at least half an hour after welding has ended.



* * * SUMMARY * * *

- Welding can be a powerful tool, but we need to respect the dangers it presents.

- Always check out your equipment before starting any welding jobs. - By following safe work practices, you’ll avoid accidents. - Always wear the appropriate protective clothing and equipment. - Keep your area well ventilated, making sure the air you breathe is

safe and clean. - Prevent fires by removing or shielding any flammable objects in the

welding area. - Defeating the hazards of welding can be easy. All you have to do is

follow the rules and work safely.



ACCOMPANYING MATERIALS In order to assist you in conducting your session on welding safety, we have provided some materials that can be used with this program. Many of these materials have been furnished in master form. This will enable you to make as many copies of these forms as you need. If you have colored paper available to you, it is often useful to put each form on a different color. This enables you to easily differentiate between the materials. The materials enclosed with this guide include: Scheduling and Attendance Form This form is provided so you can easily schedule your attendees into each session of the program. It is important that you have each attendee sign in on the appropriate form, documenting their attendance at the session. Usually, a copy of this form is filed in the employee's personnel folder. Quiz The quiz is normally given after viewing the program. However, if you want an indication of the increase in the attendees' knowledge of how to weld safely, you can give the quiz both before and after the videotape is shown. You can also use the quiz as the basis for class discussion. If you have decided to give the quiz both before and after the attendees view the program, it is often interesting to have the attendees compare their before and after answers as part of the session. Typically, the quiz is filed in the employee's personnel folder.



Training Certificate This form allows you to give each employee their own certificate of completion showing that they have attended the course and taken the quiz. Space is provided to insert the employee's name, the course instructor and the date of completion. Employee Training Log This log helps you to keep track of when each employee has taken the course, as well as associated courses/training. Space is provided to list pertinent data about the employee, as well as information such as the date the course was taken, and the instructor conducting the course. A copy of this form should be kept in each employee's training or personnel file.



SCHEDULING AND ATTENDANCE FORM

WELDING SAFETY

TRAINING SESSION SCHEDULE

ATTENDEE DATE TIME SIGNATURE



QUIZ

WELDING SAFETY

Name: Date: 1. Which of the following hazards can be encountered during the welding process?

Flying sparks. Electric shock. Toxic fumes. All of the above.

2. True or False... Welding may be prohibited in certain areas of your facility?

True False

3. True or False... To reduce the risk of fire, experts recommend that debris be cleared for

a 10 foot radius around the welding work area? True False

4. Which of the following substances are so hazardous that mechanical ventilation must be

used when welding them? Stainless steel. Mercury. Zinc. All of the above.

5. True or False... Mechanical ventilation is called for in welding areas where ceilings are

less than 16 feet high? True False

6. True or False... It is not necessary to warn others in the area when you are arc welding,

since the light it gives off isn't hazardous? True False

7. True or False... Never begin to weld unless you have received authorization?

True False





QUIZ

WELDING SAFETY

PRESENTER'S COPY WITH ANSWERS 1. Which of the following hazards can be encountered during the welding process?

Flying sparks. Electric shock. Toxic fumes. X All of the above.

2. True or False... Welding may be prohibited in certain areas of your facility?

X True False

3. True or False... To reduce the risk of fire, experts recommend that debris be cleared for

a 10 foot radius around the welding work area? True X False

4. Which of the following substances are so hazardous that mechanical ventilation must be

used when welding them? Stainless steel. Mercury. Zinc. X All of the above.

5. True or False... Mechanical ventilation is called for in welding areas where ceilings are

less than 16 feet high? X True False

6. True or False... It is not necessary to warn others in the area when you are arc welding,

since the light it gives off isn't hazardous? True X False

7. True or False... Never begin to weld unless you have received authorization?

X True False



EMPLOYEE TRAINING LOG

WELDING SAFETY Employee: Employee #: Social Security #: Department: Date of Next Required Training:

DATE

TYPE OF TRAINING

OR COURSE DESCRIPTION LOCATION OF COURSE MATERIALS

INSTRUCTOR'S NAME AND ADDRESS/DEPARTMENT

CERTIFICATION OF TRAINING AND TESTING

(Instructor's Signature)



TRAINING CERTIFICATE

This is to certify that _____________________________________ has

completed the course Welding Safety and has been tested on the contents of

the course, as required. This training, as well as the associated testing was

conducted by ___________________________ and was completed on

_________.

_____________________________ ____________ (date)

(employee name)

(course instructor)

(course instructor)

(date)

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