Welding inspectors often work in the same

environm~nt as the "':elder, so they can be

exposed 10 man~. potential safety hazards.
Among these hazards are electric shocks,
falling, rac,iation. eye hazards such as ultraviolet
light and particulate matter in the air. smoke and
fumes, ami falling objects. Safety is not to be
taken lign tly, although the welding inspector
may onl) be exposed to these conditions
momentarily. The \\'elding inspector should
strive to observe all safety precautions such as:
use .of safety glasses. hard hats, protective
clothing or an~: other appropriate apparatus for a
given siUlation. For a more detailed look at
recommended safet~' precautions refer to
"ANSI/ASC 249.1. Safer.,' in Welding and
CLltring. Figure 2.1.
AA__-
-AoICl-,-

Safety is an important consideration in all

welding, cutting, and related work. No activity
is satisfactoril~..completed if someone is injured.
The hazards that may be encountered, and the
practices that will reduce personal injury and
property [Link] discussedhere.
The most important component of an
~ effective safety and health [Link] is
~..leadership support and direction. Management
must clearly state objectives and show its
commitment to safety and health by consistent
support of safe practices. Management must
designate approved safe areas for conducting
welding and cutting operations. When these
operations are done in other than designated
,~ Aa.""~ WekII8I
Soc:8ty . .areas. management must assure that proper
procedure is establishedand followed to protect
~~ personneland property.
Fig.2.1 .ANSI/ASC 249.1 "Safety in Welding and
Cutting"
2-1
 Welding Inspection Technology
Module 2 .Safe Practices

WARNING: PROTECTyourself and others. Read and understand this label.

FUMESAND GASEScan be dangerousto your health.
ARC RAYScan injure your eyes and burn your skin.
ELECTRICSHOCKcanKILL.

Before use, read and understand the manufacturer's instructions, Material Safety Data Sheets (MSDSj, and your
employer's safe practices.
Keepyour head out of fumes.
Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the
generalarea.
. Wear correct eye, ear, and body protection. ..[
. Do not touch live electrical parts.
See American Welding National Standard Z49.1, Safety in Welding and Cutting, published by the American
Welding Society, 550 N.W. LeJeune Rd., Miami, Florida 33135; OSHA Safety and Health Standards, 29 CFR
1910, available from U. S. Government Printing Office, Washington, DC 20402

DO"NOTREMOVELABEL

Figure 2.3 .Typical (MSDS)Warning Label for Arc Welding Processes and Equipment.

Managementmust also be certain that only Before work begins. users must always read
approvedwelding, cutting, and allied equipment and understandthe manufacturer's instructions
are used. Such equipment includes torches, on safe practices for the materials and,
regulators, welding machines,electrode holders, equipment. and the Material Safety Data Sheets. 5"
and personal protective devices, Adequate (MSDS). Cenain A WS specifications call for "--'"
supervision must be provided to assure that all precautionary labels on consumables and,
equipmentis properly used and maintained. equipment. These labels concerning the safe .
Thorough and effecti,'e training is a key use of the products should be read and followed.
aspectof a safetyprogram. Adequate training is SeeFigure 2,3 above.
mandated under provisions of the U.S. Manufacturers of welding consumables
L ~ Occupational Safer)' and Health Act (OSHA), must, upon request. furnish a [Link]
/ ;/especially those of the Ha:ard Communication Data Sheet that identifies materials present in "'"
Standard (29 CFR 1910.1200). Welders and their products that have hazardous properties.
other equipment operators work most safely The MSDS provides OSHA permissible
when they are properly trained in the subject. exposure limits, known as the Threshold Limit bB
Proper training includes instruction in the Value (TLV), and any other expos1:irelimit ?-
safe use of equipment and processes. and the used or recommended by the manufacturer.
safety rules that must be followed, Personnel TL V is a registered trademark of the American
need to know and understandthe rules and the Conference of Governmental and Industrial
consequences of disobeying them. For Hygienists (ACGIH).
example, welders must be trained to position Employers that use consumablesmust make
themselves while welding or cutting so that all applicable MSDS data available to their ~ ~
their headsare not in the gasesor fume plume. employees. and also train them to read and
A fume plume is a smoke-like cloud containing understand the contents. The MSDS contain
minute solid particles arising directly from the important information about the ingredients"
area of melting metal. The fumes are metallic contained in welding electrodes, rods, and
vapors that have condensedinto a solid. fluxes. These sheetsalso show the composition
2.2

..
 Welding Inspection Technology
Module 2 -Safe Practices

of fumes generared and orher hazardsthaI may

be caused dl ring use. They also pro,,'ide a
ffic:lnS to be follo\,,'ed ro prorecr the \,,'elderand
othcrs who mighr be involved.
Under rhe OSHA Ha:ard CommunicaTion
Silln,lard, 29 CFR 1910.1200, employers are
responsibl~ for employee hazurdous material
training in t1e ~'orkplace. Many welding
consumables are included in the definition of
hazardous materials according to this st~ndard.
Welding employers must comply with the
communicati)n ~nd training requiremen~s of
this standard.
Proper use ~nd m~intenanc~ of the the floor. Therefore. welders and supervisors
equipment mlSt also be rought. For example. must always make sure tJ.,atthe area is clear of
defecti ve or worn electrical insulation in arc tripping hilzards. A shop production area
we Icing or cutting should not be used. should be designed so that [Link]. cables,
Defective. worn hoses used in oxyfuel gas mechilnic~ [Link] other equipment do
~'elding ~nd cutting. brazing. or soldering not cross walk',,~ys or interi:re with routine

e should also n:>tbe used. Training in equipment

' eration is nmdarnental to safe operation.
tasks.
When work is abo\'e ground or floor level.
safety rails or lines musLbt: pro\.ided to prevent
Personnel must also be trained to reco~ze f;?
safety haza]'ds. If they are to work i-n an Y falls bec~use of restricted ',oision from eye
unfamiliar siluation or environment. they must protection devices. Safer: lines and harnesses
be thoroughl:' briefed on the porential hazards can be helpful to restrict '[Link] to s~fe areas.
involved. Fcr example. considera person who ~nd to catch them in case of a f:[Link]. l7 nexpected
must work in confined ~[Link] the ventilation events, such as fume rele~ses. fire and
is poor and c.n air-supplied helmet is required. explosions. do occur in industri~ environments.
the need and instructions for itSproperuse must All escape rouresshould be idenrified and kept
be thoroughl:' explained to the employee. The clear so that orderly, r~pid, and safe e..oacuarion
consequences of improperly using the of an area can take place. Employees must be
equipment must be covered. When employees trained in c:vJcuation proc~dures, Storage of
believe that the safety precautionsfor a given goods and equipment in e\Oacuation routes
task are not adequate. or not understood. they should be avoided. If an evacuation roure must
should question th~ir sup~rvisor before bc: remporarily blocked. employees who would
normally use that route must bc: trained to use
proc~~ding.
Good hcluseke~ping is also ~ssential to an alternate route,
avoid injuri~s. A weld~r's vision is often Equipment, machines. cables, hoses, and
restricted b~ necessary eye prorection. and other apparatusshould ~ways be placed so that
persons pas~;inga welding station must often. tht:y do not present a hazard to personnel in
shi~ld their eyes from the name or 'JICradiation. p:l$sagew:[Link], on ladders, or on stairways,
This limited vision makes both the welder and \\I'arning signs should be posted to identify
eCl.'\sersby vu ln~r~ble to tripping o\'er objectS on welding areas,~d to specify th:lt eye protection
must be worn, Occ~sion~lly~ ~ 'fire watch'
2-3
Welding Il:lspection Technology
Module 2 ..Safe Practices

person must be assigned to maintain [Link] source and fall even greater distances. Sparks
during weldingor cutting operations. c:ln P:l$Sthrough or lodge in cr~cks. holes. and
Personnel in areas [Link] to welding and other small openings in floors and walls.
cutting must also be protected from radi:[Link] The risk or tire is increasedby combustibles
en~rgy and hot spatter. This is accomplished in the work are:l. or by welding or cutting too
\vith fl~me-resistant screens or shields. or close to combustibles that hav~ not been
suit:[Link] and face protection and protective shielded. M~terials most commonly ignited are
clothing. Appropriate radiation-protective, combustibl~ floors. roofs, partitions, and
semi-transparent materials are permissible. building contentSincluding trash, wood, paper,
\\Inere operationsallow. work stations should textiles, plastics. chemicals, and flammable
be separated by noncombustible screens or liquids and gases. Outdoors, the most common
shields. Booths and screens should allow combustibles are dry grass and brush.
circulation of air at floor level and above the The best protection against fire is to do
scr~n. welding and cutting in specially designated
Where arc welding 'Or cutting is regularly areas or enclosures of noncombustible
.performed next to painted walls. the walls construction kept free of combustibles.
should be painted with a finish having low Combustibles should always be removed from
reflectivity of ultraviolet radiation. Paint fInish the work area or shielded from the operation.
formulated with certain pigments. such as Common combustibles found in welding
titanium dioxide or zinc oxide, have low manufactUringinclude fuels for both equipment
reflectivity to ultraviolet radiation. Color engines and welding or cutting operations.
pigmentS may be added if they do not increase These fuels should be stored :l.T1d used with care. .;-.\
reflectivity. Pigments based on powdered or Equipment manufactUrers' instructions should
flaked metals are not recommended because be followed becausefuels and th~ir vapors are
tL'leyreflect ultraviolet radiation. combustible and can be explosive under some
In most welding, cutting. and allied conditions. Acetylene, propane and other
processes, a high-temperature he:[Link] is flammable gases used in cutting and welding
present. Openflames: electric arcs. hot metal. areas required careful handling. Special
sparks. and spanerare re:[Link] ignition. attention should be given to fuel gas cylinders,
M:[Link] fires are staned by sp:[Link] can hoses,and apparatUsto preventgasle:[Link].
travel horizontally up to 35 feet from their Combustibles that cannot be removed from
the area should be covered with tight -fitting.
flame resist~nt material. These include
combustible walls and ceilings. Fioors around
the work area should be free of combustible
materials for a r~dius of 35 feer. All doorways,
windows. cracks. and other openings should be
covered with a flame-resistant material. If
possible, the work area should be ~nclosed with
portable flame-resistantscreens.
Combustibles on the other side of metal
walls, ceilings or partitions must be moved to
safe locations when welding or cutting is done

2-4
 Welding Inspection Tecnnology
Module 2 .Safe Practices

peRMIT NO

'0' ..00.", .noOC"V'.Mbu,n.n; ana-'do"; wo,"po"a.,'.

_._n. ona"'oca'oon,
OU"'o. of "'00

Clock "0

All preaul,on,n... been,...n '0 "o,p anVpo"'O'. ,,'.

nua'd. ,no .,.,m,p,on"9,.,n to, "',' wo'"

S,9"OO
"[Link]
$09"'"
Solety ou"e'V"o' 0.
"'8n, lupe"ntenGent

PERMIT NO OU812

Figure :[Link] SafetyCouncil"Hot Work Permit"

on or next to the rocation. If this cannot be Welding, brazing, or cutting should not be
done, a fIre watch should be stationed near the done on combustible floors or platforms that
combustibles. Welding heat can conduct may readily be ignited by heat from the
throug;h metal partitions and ignite combustibles operation. Welders and inspectors must be alert
on the: opposite side. A thorough examination for traveling vapors from flammable liquids.
for evidence of fire should be made before Vapors are often heavier than air. Vapors from
leaving the work area. Fire inspection should flammable liquid storage areas can travel
be coJr1tinuedfor at least 30 minutes after the several hundred feet along floors and in
operation is completed. depressions. Light vapors can travel along
Welding or cutting should not be done on ceilings to adjacentrooms.
ma[Link] having a combustible coating or When welding, cutting or similar hot'!
internal structure, as in walls or ceilings. Hot working operations are to be performed in areas ( ',9
scrap or slag must not be placed in containe.r~ not normally assigned for such operations, a ,-?
holding combustible materials.. Suitable fire{ 'hot work
purpose of permit' system
the hot work should
permit be used.
system The --
is to alert
extinguishers should always be available
nearb:y, and the fire watch trained in their use. area supervisors to an extraordinary danger of

2-5

000"'0'
Welding Inspection Technology
Module 2 -Safe Practices

fire that will exist at a particular time. The

permit system should include a check list of
safety precautions. A checklist often includes ,.-
fire extinguisher [Link] fire
watches if necessary. a flammable material
search. and area safety instructions for
personnel not involved in the hot work. When ."-'
hot work permits are issued, the welding ,_.
inspector must be aware of and adhereto all itS
requirements.
Flammable [Link], and dust mixed ~ ~'f":':.~j:i
with cenain proportions of air or oxygen present Figure 2.7 -Eye, Ear, and Face Protective Equipment.
explosion and fire dangers. To prevent
explosions, avoid all sources of ignition. be used by welders and welding operators and
Welding, brazing, soldering, cutting, or nearby personnel when viewing an arc.
operating equipment that can produce heat or Standards for welding helmets, handshields,
sparks must not be done in atmospheres face shields, goggles, and spectacles are given
containing flammable gases,vapors, or dusts. in. ANSI Publication Z8?1, PracTice for
Such flammables must be kept in leak-tight OccupaTional and EducaTional Eye and Face
containers or be well removed from the work [Link].
area. Heat or sparks may causeotherwise low- Safety spectacles,goggles. or other suitable
volatile materialsto produceflammable vapors. eye protection must also be worn during other
Hollow containers must be vented before, welding and cutting operations. Such devices
and during, any appiication of heat. Heat must - must have full conforming side shields when
not be applied to a container that has held an there is danger of exposureto injurious rays or
unknown material, a combustiblesubstanceor a flying particles from grinding or chipping
substance that may form flammable vapors operations. Spectaclesand goggles may have
without consideringthe potential hazards. Such clear or colored [Link] depends on the
containers must first be thoroughly cleaned or intensity of the radiation that comes from
filled with an inen gas. Adequateeye and body adjacentwelding or cutting operations when the
protection must be worn if the operation welding helmet is raised or removed. Number-
involves explosion risks. Burns of the eye or 2 filter plates are recommended for .genera1
body are serious hazards in the welding purposeprotection. (SeeTable 2, page 22.)
industry. Eye, face, and body protection for the
operator and others in the work area are Oxyfuel Gas Welding and Cutting, Siubmerged
required to prevent bums from ultraviolet and Arc Welding
infrared radiation. sparks,and spatter. Safety goggles with filter plates and full
conforming side shields must be worn while
EYE AND FACEPROTECTION performing oxyfuel gas welding and cutting.
During submerged arc welding, the arc is
Arc Welding and Cutting covered by flux and not readily visible;
Welding helmets or handshieldscontaining Therefore, an arc welding helmet is not needed.
appropriate filter plates and cover plates must However, becausethe arc occasionally flashes

2-6
 Welding Inspection Technology
Module 2 -Safe Practices

8hrough thle flux burden, the operator should should be worn outside shoes. Protection of the
wear tinted safety glasses. (SeeTable 2, page hair with a cap is recommended, especially if a
22.) hairpiece is worn. Flammable hair preparations
should not be used.
Torch Brazing and Soldering Durable gloves of leather or other suitable
Safety spectacles with side shields and material should always be worn. Gloves not
appropriatj~ filter prates are recommended for only protect the hands from burns and abrasion,
torch brazing and soldering. As with oxyfuel but also provide insulation from electrical
gas welding and cutting, a bright yellow flame shock. A variety of special protective clothing
may be vi:;ible during torch brazing. A filter is also available for welders. Aprons, leggings,
similar to that used with those processesshould suits, capes, sleeves, and caps, all of durable
be used fo:r torch brazing. (See Table 2, page materials, should be worn when welding
22.) overhead or when special circumstances warrant
additional protectionof the body.
Brazing Sparks or hot spatter in the ears can be
Operators and helpers engaged in these panicularly painful and serious. Properly fitted,
processesmust wear safety spectacles,goggles, flame-resistant ear plugs should be worn
and a face shield to protect their eyes and face whenever operationspose suchrisks.
from spane:r. Filter plates are not necessarybut
ma)' be used for comfon. (Refer to Table 2, NOISE
page 22.) Excessive noise, particularly continuous
noise at high levels, can severely damage
aROTECTllVECLOTHING hearing. It may cause either temporary or
Sturdy shoes or boots, and heavy clothing permanent hearing loss. U.S. Department of
should be ,worn to protect the whole body from Labor Occupational Safety and Health
flying sparks, spatter, and radiation burns. Administration regulations describes al1ow~ble
Woolen clothing is preferable to conon because noise exposure levels. Requirements of these
it is not so readily ignited. Conon clothing, if resrulations may be found in. General Industry .
used. should be chemically treatedto reduce itS -~.-
Standards,29 CFR 1910.95.
combustibility. Clothing treated with In welding, cutting, and allied operations.
nondurablc: flame retardants must be treated noise may be generated by the process or the
again after each washing or cleaning. Clothing equipment. or both. Hearing protection devices
or shoes of synthetic or plastic materials. which are required for some operations. Additiona~
can melt arid causeseverebums, should not be information is presented in Arc Welding and
I
worn. Outt~rclothing should be kept free of oil Cutting Noise, American Welding Soci~rj,,}979: ~
and grease, especially in an oxygen-rich Air Carbon Arc and Plasma Arc Cutting are
atmosphere. processes that have high noise levels. Engine-
Cuffle~;s pants and covered pockets are driven generatorssometimes emit a high noise
recommended to avoid spatter or spark level, as do somehigh-frequency. and induction
entrapment. Pockets should be emptied of welding power sources.
flammable or readily ignitable material before
welding becausethey may be ignited by sparks
'Jr weld spatterand result in severebums. Pants

2.7
Welding lru;pection Technology
Module 2 .Safe Practices .

machines. jigs. and fixtures. To avoid injury

with such equipment. the machine should be
equipped so that both of the operator's hands
must be at safe locations when the machine is
actuated. Otherwise, the pinch points must be
suitably guarded mechanically. Metal working
equipment should not be located where a welder
could accidentally fall into or against it while
welding. During maintenanceof the equipment,
pinch points should be blocked to prevent them
from closing in case of equipment failure. In
very hazardoussituations. an observer should be
stationed to prevent someone from turning the
power on unti1the repair is comp1eted.
MACHINIERY
GUARDS
Weldc~rsand other workers must also be
protected from injury by machinery and FUMES ANDGASES
equipment that they are operating or by other Welders, welding operators, and other
machinery operating in the work area. Moving persons in the area must be protected from over-
componentsand drive belts must be covered by exposure to fumes and gases produced during
guardsto prevent physical contact. welding, brazing, soldering, and cutting.
Because welding helmets and dark filter Overexposure is exposure that is hazardous to
plates restrict the visibility of welders, they may health, or exc,eeds the permissible limits
be evenmore susceptiblethan ordinary workers specified by a government agency. The U.S.
to injury from unseen, unguarded machinery. Department of Labor, Occupational Safety and
Therefore, special attention is required to this Health Administration (OSHA). Regulations 29
hazard. CFR 1910.1000, or other reco!mized authoritY.
When repairing machinery by welding or such as the American Conference of
brazing, the power 'to the machinery must be Governmental Industrial Hygienists (ACGIH)
disconnected,locked out, 'tried', and tagged to in their publications, Threshold Limit Valuesfor I
prevent i,nadvertent operation and injury. Chemical Substancesand Physical Agents in"
Welders assigned to work on equipment with the Workroom Environment. Persons with
safety devices removed should fully understand special health problems may have unusual
the hazards in vol ved, and the stepsto be taken sensitivity that requires even more stringent
to avoid injury. When the work is completed, protection.
the safety devices must be replaced. Rotating Fumes and gases are usually a greater
and automatic welding machines,fixtures. and concern in arc welding than in oxyfuel gas
welding robots must be equipped with welding, cutting. or brazing. A welding arc may
appropriate guards or sensingdevicesto prevent generatea larger volume of fume and gas, and a
operation when someoneis in the dangerarea. greater variety of materials are usually involved.
Pinch points on welding and other -' Protection from excess exposure is usually
mechanical equipmentcomalso result in serious accomplished by ventilation. Where exposure
injury. Examples include resistance welding would exceedpermissible limits with available
ventilation, suitable respiratory protection must
machine~), robots, automatic arc welding
2.8
 Welding Inspection Technology
Module 2 .Sate Practices

be used.. Protection must be provided for Design of Welding Helmet

welding, cutting and other personnelin the area. The extent a helmet curves under the chin
toward the chest affects the amount of fume
EXPOSUIRE
FACTORS exposure. Close-fitting helmets can be effective
in reducing exposure.
Position of the Head
The single most important factor influencing Base Metal and Surface Condition
exposure to fume is the position of the welder's The type base metal being welded
head wid} respectto the fume plume. When the influences fume components and the amount
head is iI1lsucha position that the fume envelops generated. Surface contaminants or coatings
the face or helmet, exposurelevels can be very may contribute significantly to the hazard
high. Therefore, welders must be trained to potential of the fume. Paints containing lead,
keep their headsto one side of the fume plume. and platings containing cadmium, generate
Som'[Link] work can be positioned so the dangerous fumes during welding and cutting.
fume plume risesto one side. Galvanized material creates zinc fumes which
are harmful.
Types of Ventilation
[Link] has a significant influence on VENTILATION
fume amounts in the work area, and the The bulk of fumes generated during welding
welder's exposureto them. Ventilation may be and cutting consists of small particles that
local, where the fumes are extracted near the remain suspended .in the atmosphere for a
point of "leIding, or [Link] the shop air considerable time. As a result, fume
is changedor filtered. The appropriatetype will
concentration in a closed area can build up over
depend on the welding process. the material time, as can the concentration of any gases
being wielded, and other shop conditions. evolved or used in the process. Particles
Adequate: ventilation is necessaryto keep the eventually settle on the walls and floor, but the
welder's exposure to fumes and gases within settling rate is low compared to the generation
safe limi~s.
rate of the welding or cutting processes.
Therefore. fume concentration must be
Work Are:a controlled by ventilation.
The s:lzeof the welding or cutting enclosure Adequate ventilation is the key to control of
is important. It affects the background fume fumes and gases in the welding environment.
level. Fume exposure inside a tank. pressure Natural, mechanical, or respirator ventilation
vessel, or other confined space will be higher must be provided for all welding, cutting,
than in a high-bay fabrication area. brazing. and related operations. The ventilation
must ensure that concentrations of hazardous
BackgroundFumeLevel airborne contaminants are maintained below
Background fume levels depend on the recommendedlevels.
number ~md type of welding stations and the Many ventilation methods are available.
duty cycll~ for each station. They range from natural drafts to localized
devices, suchas air-ventilated welding helmets.

2.9

1J:;
 Welding In~;pectionTechnology
Module 2 .Safe Practices

Examples of ventilation include: avoid possible contamination of the space with

leaking gases or volatiles, Welding power
(1) N,lturaI
sources should also be located outside to reduce
(2) GEineral areamechanicalventilation
(3) O~'erhead exhausthoods danger of engine exhaust and electric shock.
(4) P~lrtablelocalexhaus1devices Lighting inside the work area should be low
(5) Downdrafttables voltage. 12 v. or if 110 v is required. the circuit
(6) Crossdraft tables must be protected by an approved Ground-Fault
(7) Ex1ractors built into the weldingequipmen1
(8) Air-ventila1edhelme1s Circuit-Interrupter (GFCI)
A means for remo\fing persons quickly in
case of emergency has to be provided. Safety
Welding in ConfinedSpaces belts and lifelines. when used. should be
Special consideration must be 2:iven to the attached to the worker's body in a way that
~/ safety and health of welders and other workers avoids the possibility of the person becoming
'7j in confined spaces. See ..ANSI Publication jammed in the exit. A trained helper. a
~ Zl17.1. Safet)~Requirements for Working in . 'standby'. should be stationed outside the
I Tanks and Other Confined Spaces, latest confined space \\'ith a preplanned rescue
edition. " for further precautions. Gas cylinders procedure in case of an emergency,
must be located outside the confined space to
2-10
 Welding Inspection Technology
Module 2 .Safe Practices

and vapors, and adequateor excessoxygen. The

tests should be made with instruments approved
by the U.S. Bureau of Mines.
Heavier-than-air gases. such as argon.
methylacetylene-propadiene, propane, and
carbon dioxide. may accumulate in pits, tank
bonoms, low areas, and near floors. Lighter-
than-air gases. such as helium and hydrogen,
may accumulate in tank tops, high areas, and
near ceilings. The precautions for confined
spaces also apply to those areas. If practical, a
continuous monitoring system with audible
alarms should be used for work in a confined
space.
Oxygen-enriched atmospheres pose great
danger to occupantsof confined areas. They are
especially hazardous at oxygen concentrations
above 25 percent. Materials that burn normally
in air may flare up violently in an oxygen-
enriched atmosphere. Clothing may burn
fiercely; oil or greasesoaked clothing or rags
may catch fire spontaneously; paper may flare
into flame. Very severe and fatal burns can
Besides keeping airborne contaminants in result.
breathing atmospheres at or belo~ Protection in confined spaces must be
recommended limits. ventilation in confinedi
\I'
provided'welders
I,
and other personnel in the
spaces must also (1) assure adequate oxygen for enclosure. QI!~y clean. respirable air must be
life support (at least 1.9.5o/cby volume) (2)
used for ventilation. Oxygen, other gases, or
pre\:ent accumulation of an oxygen-enriched, mixtures of gases must never be used for
atmosphere. (i.e.. nor over 23.50/, by volume) ventilation.
and (3.1 prevent accumulation of flammable
Positive pressure self-contained breathing
mixtures. Asphyxiation can quickly result in apparatUsmust be used when welding or cutting
unconsciousness and death without warning if related processes are done in confined areas
oxygen is nor presem in sufficiem concentration where proper ventilation cannot be provided
ro support life. Air comains approximately 21 % and there is immediate danger to life and health.
oxygen b~: volume, Confined spaces must nor It must have an emergencyair supply of at least
be entered unless well ventilated. or the five minutes duration in the event that the main
inspector is wearing an approved air supplied source fails.
breathing apparatus and has proper training to
work in such spaces. A similarly equipped Welding of Containers
second person must be presem as a standby.
Welding or cutting outside or inside
Before entering confined spaces. the space containers and vesselsthat have held dangerous
-hould be tested for toxic or flammable gases
substances presentspecial hazards. Flammable

2-11
Welding Inspection T~chnology
Module 2 -Safe Practices

or toxic vapors may be present, or may be

Table 1, Toxic Metals
generated by the applied heat. The immediate
area outside and inside the container should be (1 ) Antimony (9)
Lead "
cleared of all obstaclesand hazardousmaterials. (2) Arsenic (10) Manganese
If repairing a container in place, entry of (3) Barium (11 ) Mercury
Nickel "
hazardous substances releasedfrom the floor or (4) Beryllium (12)
(5) Cadmium (13) Selenium
the soil beneath the container must be Chromium Silver
(6) (14)
prevented. The required personal and fire (7) Cobalt (15) Vanadium
protection equipment must be available, (8) Copper
serviceable. and in positionfor immediate use.
Manufacturer's Material Safety Data Sheets
When welding or cutting inside vessels that
should be consulted to find out if any of these
have held dangerousmaterials, the precautions
materials are present in welding filler metals
for confined spaces must also be observed.
and fluxes being used. Material Safety Data
Gases generated during welding should be
Sheets should be requested from suppliers.
-.
dischar!!ed in a safe and environmentallv
However, welding filler metals and fluxes are
acceptable manner according to government
not the only source of these materials. They
rules and regulations. Provisions must be made
may also be presentin base metals, coatings, or
to prevent pressurebuildup inside containers.
other sources in the work area. Radioactive
Testing for gases,fume, and vapors should be
materials under Nuclear Regulatory
conducted periodically to ensure that
Commission jurisdiction require special
recommended limits are maintained during
considerationsand may also require compliance
welding. with state and local regulations. These
An alternative method of providing safe
materials also include x-ray machines and
welding of containers is to fill them with an
inert medium suchas water. inert gas, or sand. radiographicisotopes.
When toxic materials are encountered as
When using water, the level should be kept to
desie:natedconstituents in welding;. brazing;, or
within a few inches of the point where the ~ ~ ~

cutting operations. special ventilation

welding is to be dqne. The space above the
precautions must be taken. The precautions
water should be ventedto allow the heated air to
assure that the levels of these contaminants in
escape. With inert gas. the percentage of inert
the atmosphere are at or below the limits
gas that must be presentin the tank to prevent
allowed for human exposure. All persons in the
fire or explosion mustbe known. How to safely
immediate vicinity of welding [Link]
produce and maintaina safe atmosphere during
operations involving these materials must be
welding mustalso beknown.
similarly protected.
HighlyToxicMaterials
Certain materials. which are sometimes
HANDLINGOF COMPRESSEDGASES
present in consumables,base metals, coatings.
Gases used in welding and cutting
or atmospheres for welding or cutting
operations are packaged in containers called
operations. have permissibleexposure limits of
1.0 mg/mJ or less. Among these materials are- ' cylinders. Only cylinders designed and
maintained in accordancewith U.S. Depanrnent
the metals and theircompoundsnoted in Table 1.
of Transportation (DOT) Specifications may be
used in the United States. The use of other
2-12
 Welding Inspection Technology
Module 2 -Safe Practices

.Ylinders m~y be extremely dangerous and is

illegal. Cylinders requiring periodic retest
under DOT regulations may nor be fill~d unless
the retest is current.
Cylinders may be filled only with the
permission of the owner. and should be filled
only by recognized gOlSsuppliers or those with
the proper training and facilities to do so.
Filling one cylinder from anotheris dangerous
and should not be attempted by anyone not
qualified to do so. Combustibleor incompatible
combinations of gasesmust never be mixed in
cylinders.
\;V-elding must nor be performed on gas
cylinders. Cylinders must not be allowed to
become pan of an electrical circuit because
arcing may result. Cylinders containing
shielding gases used in conjunction with arc \ ~
welding must not be grounded. Electrode
holders, welding torches. cables. hoses. and
-('ools should not be stored on Q:ascvlinders to
.Oid arcing or interferen;e w-ith valve
operation. Arc-damaged gas cylinders may
ruptUre and result in injury or death.
Cylinders must not be used as work rests or
rollers. They should be protected from bumps, system
falling objects, weather, and should not be position. Other cylinders are preferably stored
dropped. Cylinders. should not be kept in and used in the upright position. but this is not
passageways where they might be struck by essential in all circumstances.
vehicles. They should be kept in areas where Before using gas from a cylinder, the
temperatures do nor fall below -200F or exceed contents should be identified by the label
1300 F. Any of these exposures, misuses, or thereon. Contents should not be identified by
abuses could damage them to the extent that any other me:lns such as cylinder color,
they might fail with seriousconsequences. banding. or sh~pe. These may vary among
Cylinders must not be hoisted using manufacturers. geographical area. or product
ordinary slings or chains. A proper cradle or line :1ndcould be completely misleading, The
cradle sling that securely retains the cylinder label on the cylinder is the onl~' proper notice of
should be used. ElectromagnetSshould not be the contents. If ~ l:1belis not on a cylinder, the
used to handle cylinders. contents should not be used and the cylinder
Cylinders must always be secured by the ..should be returnedto the supplier,
user against falling during either use or storage. A val,'e protection cap is provided on many
J¥:etylene and liquefied gas cylinders should cylinders to protect the safet~' device and the
~ways be stored and used in the upright cylinder val\'e. This cap should always be in

2.13
Welding Inspection Technology
Module 2 -Safe Practices

plOlceunless the cylinder is in use. The cylinder Before connecting a gas cylinder to a
should never be lifted manually or hoisted by pressure regul:ltor or a manifold. the valve
the valve protection cap. The threads that outlet should be cleaned. The valve outlet
secure these valve protectioncapsare intended should be wiped clean with a clean, oil-free
only for [Link] may not support full cloth to removedin. moisture, and other foreign
cylinder weight. The caps should always be matter. Then the valve should be opened
threaded completely onto the cylinders and momentarily and closed immediately. This is
h~d tightened. known as "cracking the cylinder valve." Fuel
Gas cylinders and other containersmust be gas cylinders must never be cracked near
stored in accordance with all state and local sources of ignition (i.e., sparks and flames),
regulations and the appropriate standards of while smoking, nor in confined spaces.
OSHA and the National Fire Protection A regulator should be relieved of gas
Association. Safe handling and storage pressure before connectingit to a cylinder, and
procedures are discussedin the Handbook of also after closing the cylinder valve upon
Compressed Gases published by the shutdown of operation. The outlet threads on
CompressedGasAssociation. cylinder valves are standardized for specific
Many gases in high-pressurecylinders are gases so that only regulators or manifolds with
filled to pressuresof 2000 psi or more. Unless similar threadscanbe attached.
the equipment to be usedwith [Link] designed It is preferable not to open valves on low
to operate at full [Link] approved pressure, fuel gascylinders more than one tUrn.
pressure-reducing regulator must be used to This usually providesadequateflow and allows
withdraw gas from a cylinder or manifold. rapid closure of the cylinder valve in an
Simple needle valves should neverbe used. A emergency. High pressure cylinder valves, otf
pressure-relief or safetyvalve, ratedto function the other hand. usually must be opened fully to
at less than the maximumallowablepressure of backseat (seal) the packing, to prevent leaks
the welding equipment. should also be during use.
employed. Valve f\lnctions prevent equipment The cylinder valve should be closed after
failure at [Link] working limitS if the each use of a cylinder and when an empty
regulator should fail in service. cylinder is to be retUrnedto the supplier. This
Val ves on cylinders containing high prevents loss of product through leaks that
pressure gas, [Link] always might develop and go ~ndetected while the
be opened slowly to avoid the high temperature cylinder is [Link] avoids haZards that
of adiabatic recompression. Adiabatic might be caused by leaks. It also prevents
recompression can occur if the valves are backflow of contaminantSinto the cylinder. It
opened rapidly. With oxygen. the heat can is advisable to rerum cylinders to the supplier
ignite the valve seatthat. in turn. may cause the with about 25 psi of contentSremaining. This
metal to melt or burn. The cylindervalve outlet prevents possible contamination by the
should point away from the ope~tor and other atmosphereduring shipment.
persons when openingthe valve to avoid injury
should a fire occur. The ope~tor should nevel' ' Pressure Relief Devices
stOlndin front of the regulatorwhen opening a Only trained personnelshould be allowed to
cylinder to avoid injury from high pressure adjust pressure relief devices on cylinders.
release if the regulatorfails. These devices are intended to provide

2-'4
 Welding Inspection Technology
Module 2 .Safe Practices

--
and re!!ula~or,
or between the re£ulator and hose
suggests an improper combination of devices
being used.
Use of adapters to change the cylinder
connectionthread is not recommended because
of the danger of usin£ an incorrect re2:Ulatoror
of contaminating the regulator. For example.
gases thar are oil-contaminated can deposit an
oily film on the internal pans of the regulator.
This film cancontaminate oil-free gas and result
in fire or explosion when exposed to pure
oxygen.
The threads and connection glands of

~ regulators should be inspected before use for

dirt and damage. If a hose or cylinder
connection leaks, it shouid not be forced with
excessive torque. Damaged regulators and
components should be repaired by properly
trained mechanics or returned to the
manufacturerfor repair.
A suitable valve or flowmeter should be
used to control gas flow from a regulator. The
internal pressure in a regulator should be
-~
0c 00

drained before it is connected to or removed

--'" 0 ;:"05/' -~

Figure 2.12. Acetylene and Oxygen Regulators and from a gascylinder or manifold.
Inert GasFlowmeters.

protection in the eventthe cylinder is subjected

MANIFOLDS
to a hostile :nvironment. usual1yfire or other
A manifold is used when gas is needed
source of heat. Such environments may raise
without interruption or at a higher delivery rate
the pressure within cylinders. To prevent
than can be supplied from a single cylinder. A
cylinder pressuresfrom exceeding safe limits,
manifold must be designed for the specific gas
the safety devices are designed to relieve the
and operatingpressure, and be leak tight. The
contents.
manifold components should be approved for
A pressure reducingregulator should always
such purpose, and used only for the gas and
be used when ~.ithdra wing gas from gas
pressure for which they are approved. Oxygen
cylinders for welding or cuning operations.
and fuel gas manifolds must meet specific
Pressure reducing regulators must be used
design and safety requirements.
only for the gas and pressuregiven on the label. Piping and fittings for acetylene and
The)' should not be used with other gases or at
methylacetylene-propadiene (MPS) manifolds
other pressures although the cylinder valve
must not be unalloyed copper or alloys
outlet threads may be the same. The threaded containing 70'70 or more copper. These fuel
connections to the regulator must not be forced.
gases reactwith copper under certain conditions
~proper fit of threadsbetween a gas cylinder
2-15
Welding inspection Technology
Module 2 -S,lfe Practices

to form 1.]nstable copper acetylide. This sufficient to prevent development of pressure in

compound may detonate under shock or heat. the system be~'ond the capacity of the weakest
Manifold piping systems must contain an element.
appropriat~: overpressure relief valve. Each fuel Such pressure relief devices may be relief
gas cylinder branch line should incorporate a valves or bursting discs. A pressure reducing
backf10w check v~lve and flash arrester. regulator must never be solely relied [Link] to
Backflow (:heck v~lves must also be installed in pre\'ent over pressurization of the system. A
e~ch line £,t e~ch st~tion outlet where both fuel pressure relief device must be located in every
gas and ox:'gen is provided for a welding. section of the system that could be exposed to
cutting. or preheating torch. These check valves the; full source supply pressure whi1e isolated
must be checked periodically for safe operation. from other protective relief de\'ices (such as by
Unless ir is known thar a piping system is i.l l:losed valve;). Some pressure regu1arors have
speci fica I!:' design~d and constructed to inre;gral safety relief valves. These va1ves are
~.ithstand ::ull cylinder pressure or tank pressure. . designed for the protection of the regulator
of the conlpressed gas source supplying it. the only. and should nor be relied upon to protect
piping s:~,tem must be ,protected with safety the; downstre:lm system.
pressure relief devices. The devices must be

2-16
 Welding Inspection Technology
Module 2 -Safe PracticE!S

In cryog~nic piping systems. relief devices device should be returned to the manufacturer
should be lol:ated in every section of the system or authorized representativefor service.
where liquefied gas may becometrapped. Upon Oxygen must never be used to power
warming. su,:h liquids vaporize to gas. and in a compressed air tools. These are usually oil
confined spilce. the gas pressure can increase lubricated. Similarly. oxygen must nor be used
dramatically to blow dirt from work and clothing because
Pressure relief devices protecting fuel gas they are often contaminated with oil. or grease,
piping systems or other hazardousgas s)'stems or combustible dust.
should be ve rltedto safelocations. Only clean clothing should be worn when
working with ox)'gen systems. Oxygen must
not be used to ventilate confined spaces. Severe
GASES burns may result from ignition of clothing or the
hair in an oxygen-rich atmosphere.
Oxygen
Oxygen :s nonflammable but it supports the Fuel Gases
combustion of flammable materials. It can Fuel gases commonly used in oxyfuel gas
initiate combustion and vigorously accelerateit. welding (OFW) and cutting (OFC) are
Therefore, [Link] and liquid oxygen acetylene, methylacetylene-propadiene (MPS),
containers should not be stored near natural gas, propane, and propylene. Hydrogen
combustibl(~s or with cylinders of fuel gas. is used in a few applications. Gasoline is
Oxygen should never be used as a substitUte for sometimes used as fuel for oxygen cutting. It
8 ompressecl air. Pure oxygen supports vaporizes in the torch. These gases should
ombustion more vigorously than air, which always be referred to by name.
contains only 21 % oxygen. Therefore, the Acetylene in cylinders is dissolved in a
identification of the oxvp:en solvent so that it can be safely stored under
-- and air should be
differentiatecl. pressure. In the free state, acetylene should
Oil, greise, and combustible dusts may never be used at pressuresover 15 psi (100,000
spontaneously ignite on contact with oxygen. Pa) because it can dissociate with explosive
All systems and apparatUsfor oxygen service violence at higher pressures.
must be kepI free of any combustibles. Valves, Acetylene and MPS should never be used in
piping. or system components that have not contact with silver, mercury. or alloys
been expresslymanufactUredfor oxygen service containing 70 percent or more copper. These
must be cle,med and approved for this service gases react with these metals to form unstable
before use. compounds that may detonate under shock or
Apparatus expressly manufactured for heat. Valves on fuel gas cylinders should never
oxygen service, and so labeled, must be kept in be opened to cleanthe valve outlet nearpossible
the clean c:>ndition as originally received. sources of flame ignition, or in confined spaces.
Oxygen valves, regulators,and apparatUsshould When fuel gases are used for a brazing
never be lubricated with oil. If lubrication is furnace atmosphere, they must be vented to a
required, the type of lubricant and the method of safe location. Before filling a furnace with fuel
applying the lubricant should be specified in the gas, the equipment must first be purged with a
manufacturers literature. If it is not, then the nonflammable gas. Nitrogen or argon can be

2-17
 Welding Inspection Technology
Module 2 .Safe Practices

used to prevent formation of an explosive air- removed by trained fire personnel to a safe
fuel mixture. outdoor location. and the supplier notified, A
Special attention must be given when using warning sign should be posted,and no smoking
hydrogen. Flames of hydrogen may be difficult or other ignition sources should be allowed in
to see and parts of the body. clothes. or the area.
combustibles may. therefore. unknowingly V,I'ith a large fire at a fuel gas cylinder, the
come in contacrwith hydrogen flames. fire alarm should be actuated,and all personnel
should be evacuated from the area. The
Fuel GasFires cylinder should be kept wet by fire personnel-
The bestprocedure for avoiding fire from a with a heavy stream of water to keep it cool. It
fuel gas or liquid is to keep it contained within is usually better to allow the fire to continue to
the system, that is, to prevent leaks. All fuel burn and consume the issuing gas rather than
systems should be checked carefully for leaks attempt to extinguish the flame. If the fire is -
u~n assembly and at frequent intervals after extinguished, there is danger that the escaping
that. Fuel gasc~rlindersshould be examined for gas may reignite with explosive violence.
leaks, especiall:-'at fuse plugs. safety devices,
and valve packing. One common source of fIre ShieldingGases
in welding and cutting is ignition of leaking fuel Argon. helium. carbon dioxide (CO2), and
by flying sparksor spatter. nitrogen are used for shielding with some
In caseof a fuel fire, an effective means for welding processes. ~: except carbon dioxide,
controlling the fIre is to shut off the fuel valve, ~used as b!azing atmospheres. They are
if accessible. A fuel gas valve should not be odorless and colorless and can displace air
opened beyond the point necessaryto provide neededfor breathing.
adequateflov.'. Open in this way. it can be shut Confined spaces containing these gases
"")/
off q uicklv .' in an emer2encv.-.- Usuallv, this is must be well ventilated before personnel enter
11 less than one turn of the handle. If the them. If there is any question aboutthe space, it
immediate valve controlling the burning gas is should be checked first for adequate oxygen
inaccessible, another upstream valve may cut concentration with an oxygen analyzer. If an
off the flow of gas. analyzer is not available, an air-supplied
Most fuel gases in cylinders are in liquid respirator should be worn by anyone entering
form or dissolved in liquids. Therefore, the the space. Containers of thesegasesshould not
cylinders should always be used in the upright be placed in confined spaces, as discussed
position to prevent liquid surges into the previously.
system.
A fuel gas cylinder can develop a leak and ELECTRICSHOCK
sometimes result in a fire. In case of fire, the Electric shock can cause sudden death.
fire alarm should be sounded. and trained fire Injuries and fatalities from electric shock in
personnelshould be summonedimmediately. A welding and cutting operations can occur if
small fire near a cylinder valve or a safety proper precautionary measuresare not followed.
device should be extinguished. When possible, Most welding and cutting operations employ
extinguish the fire by closing the valve, using some type of electrical equipment. For
water. wet cloths. or fire extinguishers. If the example, automatic oxyfuel gas cutting
leak cannot be stopped, the cylinder should be

2-18
 Welding Inspection Technology
Module 2 .Safe Practice!s

machines use electric motor drives, controls and 100 arc volts. (Fatalities have resulted with
systems. equipment operating at less than 80 volts.)
Some electrical accidents may not be Some arc cutting methodsoperate at over 400V.
~voidable. such as those caused by lightning. and electron beam welding machines at up to
However. the rest are [Link] those about 150 kV. Most electric shock in the
caused by lack of propertraining. ~'elding industry occurs as the result of
Electric shock occurs when an electric accidental contact with bare or poorly insulated
current of sufficient amountto createan adverse conductors operating at such voltages.
effect passesthrough thebody. The severity of Therefore, welders must take precautions
the shock depends mainly on the amount of against contacting bare elements in the welding
current. the duration of flow, the path of flow, circuit. and also those in the primary circuits.
and the state of health of the person. The Electrical resistance is usually reduced in
current is causedto flow by the applied voltage. the presence of water or moisture. Electrical
The amount of currentdependsupon the applied hazards are often more severe under such
voltage and the resistanceof the body path. The circumstances. When arc welding or cutting is
frequency of the current may also be a factor to be done under damp or wet conditions
when alternating currentis involved. including heavy perspiration. the inspector must
Shock currents greater than about 6} wear dry gloves and clothing in good condition
milliamperes (mA) are considered primary ['1-\ to prevent electric shock. The welding
because they can cause direct physiological inspector should be protected from electrically
, ~arrn. Steadv state currentSbetWeen0.5 and 6 conductive surfaces. including: the earth.
e;;A are con;idered secondaryshock currents. Protection can be afforded by ;ubber-soled
Secondary shock currentScan causeinvoluntary shoes as a minimum. and preferably by an
muscular reactions without normally causing insulating layer such as a rubber mat or a df)'
direct physiological harm. The 0.5 rnA level is wooden board. Similar precautions against
called the perceptionthresholdbecauseit is the accidental contact with bare conducting surfaces
point at which mostpeoplejust begin to feel the must be taken when the welding inspector is
tingle from the current. The level of current required to work in a cramped kneeling, sitting.
sensation varies with the weight of the or lying position. Rings and jewelry should be
individual and to someextentbetween men and removed before welding to decrease the
women. possibility of electric shock.
Most electrical equipment if improperly The technology of hean pacemakers and the
installed, used, or maintained can be a shock extent to which they are influenced by other
hazard. Shock can occur from lightning- electrical devices is constantly changing. It is
induced voltage surges in power distribution impossible to make general statements
systems. Even earth grounds can attain high concerning the possible effects of welding
potential relative to true ground during severe operations on such devices. Wearers of
transient phenomenon. Such circumstances, pacemakers or other electronic equipment vital
however, are rare. to life should check with the device
In welding and cutting work. most electrical -" manufacturer or their doctor to find out whether
equipment is powered from ac sources of any hazardexistS.
between 115 and 575 V. or by engine-driven Electric shock hazards are reduced by
t!)generators. Most welding is done with less then proper equipment installation and maintenance,

2.19
Welding Inspection Technology
ModulI! 2 .Safe Practices

good operator practice, proper clothing and nonremovable hinged cover. (3) insulating
body ?rotection, and equipment use designed sleeves. or (4) other equivalent mechanical
for th,~ job and situation. Equipment should means.
meet lpplicable NEMA or ANSI standards. The workpiece being welded and the frame
such :lS ..ANS/IUL 55/. SafeTYSTandard for or chassis of all electrically powered machines
TransJonner TypeArc WeldingMachines. ..
must be connectedto a good electrical ground.
If significant amounts of welding and Grounding can be done by locating the
cutting are to be done under electrically workpiece or machine on a grounded metal
hazarjous conditions. automatic machine floor or platen. The ground can also be
controls that safely reduce open circuit voltage connected to a properly grounded building
are rec:ommended. When special welding and frame or other satisfactory ground. Chains, wire
cuttin~: processesrequire open circuit voltages ropes, [Link], and elevators must not be
higher than those specified in ..ANSI/NEMA used as grounding connectors nor to carry
PublicaTion EW-]. ElecTrical Arc Welding welding current.
ApparaTus." insulation and operating The work lead is not the grounding lead.
procedures that are adequate to protect the The worklead connectsthe work tenninal on the
welder from these higher voltages must be power sourceto the workpiece. A separatelead
provid'~d. is required to ground the workpiece or power
--! -A l~oodsafety training program is essential. sourcework terminal.
Employees must be fully instrUctedin electrical Care should be taken when connecting the
safety by a competent person before being grounding circuit. Otherwise, the welding
allowt~d to commence operations. As a current may flow through a connection intended
minimum, this training should include the only for grounding, and may be of a higher
points covered in "ANSIIASC Z49.1, Safety in amountthan the grounding conductor can safely
Weldi.'lg and CuTTing." (Published by the carry. Special radio-frequency grounding may
Arneric:an Welding Society). Persons should be necessaryfor arc welding machines equipped
not be allowed to operate elec;:tricalequipment with high-frequencyarc initiating devices.
until they have beenproperly trained. Connections for portable control devices,
Eql1ipment should be installed in a clean, such as push buttons carried by the operator,
dry area. When this is not possible, it should be must not be connectedto circuits with operating
adequcLtelyguarded from dirt and moisture. voltages above 120 V. Exposed metal parts of
Installation must be done to the requirements of portable control devices operating on circuits
ANSI/1IFPA 70. NaTional ElecTric Code, and above 50 V must be grounded by a. grounding
local cl)des. This includes disconnects, fusing, conductor in the control cable. Controls using
and types of incoming power lines. intrinsically safe voltages below 30 V are
Terminals for welding leads and power recommended.
cables i1ustbe shieldedfrom accidental contact Electrical connections must be tight, and
by personnel or by metal objects, such as checked periodically for tightness. Magnetic
\'ehicl!~s and cranes. Connections between work clamps must be free of adherent metal
welding leads and power supplies may be particles and spaner on contact surfaces. Coiled
guarded using (I) dead front construction aRd welding leads should be spread out before use
receptacles for plug connections, (2) tenTlinals to avoid overheating and damage to the
located in a recessed opening or under a insulation. Jobs alternately requiring long and

2.20
 1,'-;- -I-1~
fr-VL
~ra- f- - L-&-A.)
I
It;!
.-i
(. [Link]

Welding Inspection Technology

Module 2 .Safe Practices

.rt leads should be equipped with insulated ener2:ized.

cable connectors so that idle lengths can be
-- covered electrodes must be chan2:ed
with dry welding gloves. not with bare hands.
disconnected \llhen not needed. De-energization of the circuit is desirable for
Equipmert. cables. fuses, plugs, and optimum safety even with covered electrodes.
receptacles must be used within their current When a welder has completed the work or
carrying and duty cycle capacities. Operation has occasion to leave the work station for an
of apparatus above the current rating or the duty appreciable time, the welding machine should
cycle results in overheating and rapid be turned off. Similarly, when the machine is to
deterioration of insulation and other parts. be moved, the input power supply should be
Actual welding current may be higher than that electrically disconnected at the source. When
shown by indicators on the welding machine if equipment is not in use. exposed electrodes
welding is done with short leads or low voltage,
-- should be removed from the holder to eliminate
or both. High currents are likely with general the danger of accidental electrical contact with
purpose ..weldin.~ machines when they are used persons or conducting objects. Also, welding
with processes that use low arc voltage, such as guns of semiautomatic welding equipment
gas tungsten arc welding. should be placed so that the gun switch cannot
Welding leads should be the flexible type of be operated accidentally.
cable designec especially for the rigors of Fires resulting from electric welding
welding service. Insulation on cables used with equipment are generally caused by overheating
high voltages or high-frequency oscillators must of electrical components. Flying sparks or
provide adequate protection. The spatter from the welding or cutting operation,
~mmendations and precautions of the cable and mishandling fuel in engine driven
.Qlit)lfacturer should always be followed. Cable equipment are among other causes. Most
insulation must be kept in good condition, and precautions against electrical shock are also
cables repaired or replaced promptly when applicable to the prevention of fires caused by
necessary. overheating of equipment. A voidance of fire.
Welders shodd not allow the metal parts of from sparks and spatter was covered previously.
electrodes, electrode [Link], or torches to The fuel systems of engine driven
touch their bare 5kin or any wet covering of the equipment must be in good condition. Leaks
body. Dry glo"es in good condition must must be repaired promptly. Engine driven
always be worn. The insulation on electrode machines must be turned off before refueling,
holders must be }~ept in good repair. Electrode and any fuel spills should be wiped up and
holders should nt)t be cooled by immersion in fumes allowed to dissipate before the engine is
water. If water-c:>oled welding guns or holders restarted. Otherwise, the ignition system,
are used. they should be free of water leaks and electrical controls, spark producing
condensation that would adversely effect the components, or engine heat may stan a fire.
welder's safety. Welders should not drape or
coil the welding l~:adsaround their bodies.
A welding'- circuit must be de-energized
- to
avoid electric sho:k while the electrode, torch,
or gun is being changed or adjusted. One
exception concerns covered electrodes with
sp; 'ded metal arc welding. When the circuit is

2-2'
 Welding Inspection Technology
Module 2 -Safe Practices

Keywords -Eye protection and lens shade ANSI/AWS

F2.2-fI9

Table 2 -LENS SHADE SELECTOR

Shade numbers are given as a guide only and may be varied to suit individual needs

Operation Electrode Size Arc Current Minimum Suggested'

--., mm (32nd in.) (Ampers) Protective Shade ShadeNo. (Comfort)

ShieldedMetal Arc less than 2.5 (3) lessthan 60 7 -

Welding(SMA~1 2.5 -4 (3 -5) 60 -160 8 10
4 -6.4 (5 .8) >160 -250 10 12
more than 6.4 (8) >250 -500 11 14

Gas Metal Arc 1/Jelding less than 60 7 -

and Flux Cored Arc Welding 60-160 10 11
(GMAWand FC,~W) >160 -250 10 12
>250 -500 10 14

[Link] Welding Less than 50 8 10

(GTAW) 50 -100 8 12
>150 -250 10 14

Air Carbon Arc Cutting (light) lessthan500 '0 12

(CAC-A ) (heavy) 500 .1000 " 14

Plasma Arc WI!lding less than 20 6 6 to 8

(PAW) 20-100 B 10
>100.400 10 12
>400 -800 11 14

Plasma Arc C\Jtting (PAC)

Light' less than 300 8 9
Medium 300-400 9 12
Heavy >400 -800 10 14

TorchBrazing(TB) 3 or4

Torch Solderillg {TS) - 2

CarbonArcW,lding (CAW) '4

Platl~Thickness
mm in.
GasWeldingIGW)
Light' under3.2 under1/8 4 or5
Medium 3.2to 13 1/8 to 1/2 5 or6
Heavy over13 over1/2 6to 8

Oxygen Cuttillg (DC)

Lighf under 25 under 1 3 or 4
Medium 25 to 150 1 to 6 4 or 5
Heavy -.over 150 over 6 5 or 6

Shadenul! bersaregivenasa rule ofthumb. It is recommendedto beginwittl a shadethat is too darkto seethe weldzone. Thenoneshouldgo to a lightershadewhich gives
sufficient~iew of the weldzonewithoutgoingbelowtt1eminimum. In gasweldingor oxygencuttingwherett1etorchproducesa high [Link] Is desireableto use a filter
lensthat allsordsthe yellowor sodiumlinein thevisiblelight oftt1eoperation(spectrum).
2. Thesevalu!sapplywherethe actualarcis clearlyseen. Experience hasshownthat lightfilters maybe usedwhenthe arc is hiddenby theworkpiece.

2.2.2

.
 Welding Inspection Technology
Module 2 .Safe Practices

.EY TERMSj~NDDEFINITIONS filter Lens. in welding, a shaded lens, usually

glass. that protectsthe eyes from radiation from
ACGIH- Amelican Conference of Governmental the welding arc and other heat sources.
and Indust:~ial Hygienists. This group is Welding lens are numbered, with the higher
concerned with the proper. safe levels of numbers offering the greatest protection. See
exposure to hazardous materials. Lens Shade Selector, Table 2, for appropriate
lens selection.
Adiabiatic Recompression -the tenn given to
the temperarJre rise that can occur when some Fire Watch. a person whose primary
gases at hig]} pressuresare released suddenly. responsibility is to observe the work operation
(Normal pre~sure gasreleasesusually result in a for the possibility of fires, and to alert the
cooling of th,~gas by the decompression.) workers if a fIre occurs.

ANSI." Amer:lcan National Standards Institute. flammable. anything that will burn easily or
An organization promoting technical and safety quickly. (Inflammable has the same meaning.)
" --""

standards.
fume plume. in welding, a smoke-like cloud
ANSI/ASC Z49.1 ."Safety in Welding and containing minute solid panicles arising directly
Cutting", a ,iocurnent outlining safe practices from molten metal.
for welding and cutting operations.
fuse plug. a material, usually a metal, that has
~NSI Z87.1 .Practice for Occupational and a very low melting point. Often used as a heat
'tducational EyeandFaceProtection. and/or pressurerelief device.

asphyxiation. loss of consciousnessas a result fume release. a general term given to the
of too littl~ oxygen and too much carbon unexpected and undesired release of materia1$.
dioxide in thc~blood.
galvanized material. any material having a
AWS. American Welding Society. AWS is the zinc coating on its surface. Commonly
technicallea(ler in welding and related issues. galvanized items are sheet metal and fasteners.

combustiblE!S .any material that can easily Hot Work Permit. a form designed to insure
catch fire. that all safety precautions have been considered
prior to any operation having open flames or
cryogenic. very cold service, usually well high heat.
below zero d,~greesF.
Lock, Tag, and Try. the phrase noting the
DOT. Department of Transportation. A federal physical 'locking-out' of equipment, 'tagging' it
or state agc:ncy covering the transport of for identification, and 'trying' the equipment to
materials. .' make sure it is not operable prior to beginning
any repair work.

2-23
Welding Inspection Technology
Module 2 .Safe Practices

MSDS .Materials Safety Data Sheet. A safety glasses. spectacles with hardened and
document that identifies materials present in minimum thickness lens that protect the eyes
products that have hazardous, physical, or from flying objects. The greatesteye protection
health propenies. occurs when side shields are attached to the
safety glasses.
NEMA .Nati~oal Equipment Manufacturers
Association. standby. in welding, a person trained' and
designated to stand by and watch for safety
OSHA-Occupational Safety and Health Act. hazards, and to call for help if needed. Most
This federal law outlines the requirements for often used for vessel entry safety.
safety in the workplace.
TlV .Threshold Limit Value. The pennissible
pascal (Pa) .in the metric system,the unit for level of exposurelimits for hazardousmaterials.
pressure, or tensile strength. The customary
English equivalent is psi, pounds per square toxic. poisonous.
inch. One psi equals 6,895 Fa.
vapors. the gaseousform of a substance.
pinch points -any equipment geometrythat can
lead to pinching pans of the body. especiallythe
hands or feet, while working on the equipment.

2.24