Diploma in Industrial Safety and Fire Management

CHAPTER - 14
WELDING AND GAS CUTTING

In the workshop there are a number of hazards specific to welding or cutting. In addition, there may
be other hazards of a more general nature present in the fabrication environment.

All potential hazards need to be identified, measured (where appropriate) and assessed. Remedial
measures must be put in place wherever necessary.

Although Personal Protective Equipment (PPE) should not be issued as the primary method of
reducing a hazard, it should be issued to all personnel if beneficial.

Employers and employees should be made fully aware of the dangers that can arise and take all
reasonable care to ensure the health and safety of all.

Hazards in Welding and Gas Cutting Operation

 Burns
 Chromium in Fume
 Confined Spaces
 Electrical Safety
 Eye Hazards
 Gaseous Fume
 Heat Stress
 Light and Heat Radiation
 Magnetic Fields
 Measurement of Fume
 Metal Fume Fever
 Noise Hazards
 Ozone Hazard
 Particulate Fume

BURNS
Burn injury is a hazard faced by welders every working day; after all they are using a process that
involves molten metal and high temperature welding arcs.
Avoidable hazards
Most burns suffered by welders and others in the welding environment are avoidable. They are often
caused by carelessness or failure to take the necessary precautions.
Burns may occur to the skin or, potentially more seriously, to the eyes.

The source of the hazard may be:

 hot metal (a welded component or part of the welding equipment such as a MIG gun
nozzle)
 arc rays
 flames
 chemicals

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 Diploma in Industrial Safety and Fire Management
 liquid gases

Taking the necessary safety precautions is largely common sense, although accidents may
happen from time to time.

CHROMIUM IN FUME

Chromium is an element present in the consumables and parent material of stainless steels, heat-
resisting steels, some creep-resisting steels, some high nickel alloys, and armour plate.

It may also be present in some consumables used for hard facing.

Chromium particulate fume

Chromium is also used as a coating for other materials (such as chrome plating) to give corrosion
protection to steel or to give a pleasing aesthetic appearance.

Chromium, as chromate, may also be found as a constituent of some industrial paints.

Welding or cutting materials containing chromium are likely to give chromium compounds in any
particulate fume generated by the process. Whether it presents a significant hazard to health
depends on the concentration and the duration of exposure.

CONFINED SPACES

Many of the everyday hazards encountered in welding can be exacerbated if the work is being
carried out in a confined space.

A significant number of deaths occur each year involving people working in confined spaces.

Asphyxiation is a major cause of those deaths, so extra vigilance is crucial.

Ventilation

In any confined workspace, restricted ventilation will cause the build-up of a potentially hazardous
atmosphere.

An example of confined spaces would be a storage tank. It may also contain, or have contained,
toxic, flammable or hazardous substance, vapour or gas.

It is clear that working in such spaces requires a greater than normal awareness of potential hazards
and increased attention to safe working practices.

Welders working in enclosed spaces must be properly trained, equipped and supervised.

Additional protective and monitoring equipment (over and above that normally necessary) may be
required when welding in a confined space.

It is recommended that a formal 'safe system of work' should be followed at all times.

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 Diploma in Industrial Safety and Fire Management
ELECTRICAL SAFETY
Electrical hazards can prove to be the most serious risks encountered by welders.

Touching 'live' electrical components, including the electrode and the work piece, can result in a burn
injury or, more seriously, electric shock.

ELECTRIC SHOCK

Electric shock can kill, either by direct action on the body or by a resultant fall if working at height.

Most electrical accidents are avoidable and only occur as a result of carelessness, lack of training,
poor workmanship or faulty equipment.

Welders must never become complacent about the hazards associated with electric arc welding.

Safe working practices should be followed at ALL times.

EYE HAZARDS

Eye injuries are among the most common of all injuries caused by welding and cutting.

Damage can be due to non-ionising radiation, foreign bodies, fumes and gases.

Radiation

All welding arcs produce radiation. The energy ranges in the arcs are limited so only certain
wavelengths are generated.

This radiation is divided into three categories:

1. ultraviolet (UV)
2. visible light
3. infrared (IR)

Of these three, UV is the most likely to cause injury as its effects are not noticed by any of the senses
at the time of exposure, so the effects only become apparent later.

Foreign bodies

Welders have a high incidence of eye injury caused by foreign bodies such as slag, spatter, sparks,
dust and grit.

Particulate fumes
Particulate fumes and gases can irritate or damage the eye.
It is known that conjunctivitis may be caused by dust or fume associated with welding.

GASEOUS FUME
Gaseous fume is invisible fume created by the welding and cutting process. It is often present in the
workshop, but undetected.

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 Diploma in Industrial Safety and Fire Management
Pollutant gases

Gaseous fume consists of either one or more specific pollutant gases mixed in the air around the
welding area. As it is present in gaseous form it can easily enter the lungs.

Whether or not the fume is likely to cause damage depends largely on precisely what the gas or
gases are, on the concentration inhaled and on the length of time of exposure to the specific
pollutant(s).

The gases of most concern in the welding environment are ozone, oxides of nitrogen (NO and NO 2),
carbon monoxide, dichloro-acetyl-chloride and possibly phosgene.

HEAT STRESS
Working in an excessively hot environment can cause the body to overheat; this is called 'heat
stress'.

Heat exhaustion
If fluids are not taken to replace those lost by sweating, heat exhaustion can occur. Extreme cases of
this condition can be fatal. Precautions should be taken and work regimes adjusted to ensure that
every worker's core body temperature is maintained within its required operating range.

Magnetic Fields
Magnetic fields are produced by electrical equipment.
In arc welding and cutting, the magnetic fields produced may have an effect on the human body.

Exposure
Electromagnetic, that is to say electrical and magnetic fields (both natural and electrically produced),
exist throughout our environment and we are all exposed to them constantly.

Electric fields are produced by electric charges and measured in volts per metre (V/m) whilst
magnetic fields are produced by the motion of electric charges and measured in amperes per metre
(A/m).

Whether or not these fields are harmful has been a matter of debate for many years and remains
largely unresolved.

LIGHT AND HEAT RADIATION

Electric arc welding and cutting processes produce three forms of radiation; ultra violet (UV), visible
and infra-red (IR).

Arc welding therefore presents a greater hazard than fuel gas processes as these only produce visible
and IR radiation.

Radiation hazards
Arc welding and cutting and fuel gas processes can be damaging to unprotected skin and eyes.
Some of the injuries that can occur include 'erythema' and burning of the skin.

Eye injury
Radiation from welding arcs includes eye damage including:

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 Diploma in Industrial Safety and Fire Management
 'arc eye' (from UV radiation)
 cataracts (from UV and IR radiation)
 retinal burns (from both visible or IR radiation)

Of these non-ionizing types of radiation, UV is the most likely to cause injury primarily because its
effects are not noticed by any of the senses at the time of exposure, they only become apparent
later.

WELDING HEALTH HAZARDS

 Zinc
 Cadmium
 Beryllium
 Iron Oxide
 Mercury
 Lead
 Fluorides
 Chlorinated
hydrocarbon solvents
 Phosgene
 Carbon monoxide
 Ozone
 Nitrogen Oxides

WELDING PHYSICAL HAZARDS

 Ultraviolet radiation
 Infrared radiation
 Intense visible light

SAFE MANUAL HANDLING OF GAS CYLINDERS AND

HAZARD PREVENTION
Loading Gas Cylinder on trolley
• Wear steel toe capped shoes and industrial quality gloves
• Undo securing bars on trolley and slide it near the cylinder
• Unhook chain from rack and place palm of hand on top of
cylinder neck, get a firm grip
• Tilt cylinder slightly forward so it rests on the rim of the base and
use the other hand to rotate cylinder ‘milk churning’ it from rack to
trolley
Pushing trolley and unloading gas cylinder
• Fasten securing bars on the trolley
• Place one foot on the axle and tilt the trolley back so it balances
comfortably on the wheels
• Keeping back straight, push trolley and set it down in front of the
laboratory bench
• Remove cylinder from trolley, milk churning it into its new
position and clamp it securely to the bench using chains, or straps.
 Valve protection caps shall be in place and secured.
 Valve protection caps shall not be used for lifting cylinders from one vertical position to another.
Bars shall not be used under valves or valve protection caps to pry cylinders loose when frozen.
Warm, not boiling, water shall be used to thaw cylinders loose.

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 Diploma in Industrial Safety and Fire Management
 Unless cylinders are firmly secured on a special carrier intended
for this purpose, regulators shall be
 Removed and valve protection caps put in place before cylinders
are moved.
 When cylinders are transported by powered vehicles, they shall
be secured in a vertical position.
 A suitable cylinder truck, chain, or other steadying device shall be
used to keep cylinders from being knocked over while in use.
Cylinder valve
 When work is finished, when cylinders are empty, or when
cylinders are moved at any time, the cylinder valve shall be
closed.
Upright position
 Compressed gas cylinders shall be secured in an upright position
at all times except, if necessary, for short periods of time while
cylinders are actually being hoisted or carried.
 Oxygen cylinders in storage shall be separated from fuel-gas
cylinders or combustible materials(especially oil or grease), a
minimum distance of 20 feet (6.1 m) or by a noncombustible
barrier at least 5 feet (1.5 m) high having a fire-resistance rating
of at least one-half hour
 Inside of buildings, cylinders shall be stored in a well-
protected, well-ventilated, dry location, at least 20 feet (6.1 m)
from highly combustible materials such as oil or excelsior.
Cylinders should be stored in definitely assigned places away
from elevators, stairs, or gangways. Assigned storage places shall
be located where cylinders will not be knocked over or damaged
by passing or falling objects, or subject to tampering by
unauthorized persons.
 Before a regulator to a cylinder valve is connected, the valve
shall be opened slightly and closed immediately. (This action is
generally termed "cracking" and is intended to clear the valve
of dust or dirt that might otherwise enter the regulator.) The
person cracking the valve shall stand to one side of the outlet,
not in front of it.
Suitable regulators
 Fuel gas shall not be used from cylinders through torches or
other devices which are equipped with shutoff valves without
reducing the pressure through a suitable regulator attached to
the cylinder valve or manifold.
Removal of regulator
 Before a regulator is removed from a cylinder valve, the cylinder
valve shall always be closed and the gas released from the
regulator.
Hose colors
 Fuel gas hose and oxygen hose shall be easily distinguishable
from each other. The contrast may be
 Made by different colors or by surface characteristics readily
distinguishable by the sense of touch. Oxygen and fuel gas
hoses shall not be interchangeable. A single hose having more
than one gas passage shall not be used.

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 Diploma in Industrial Safety and Fire Management

Inspections
All hose in use, carrying acetylene, oxygen, natural or manufactured
fuel gas, or any gas or substance which may ignite or enter into
combustion, or be in any way harmful to employees, shall be
inspected at the beginning of each working shift. Defective hose shall
be removed from service.
Hose couplings
Shall be of the type that cannot be unlocked or disconnected by
means of a straight pull without rotary motion.
Torches.
Clogged torch tip openings shall be cleaned with suitable cleaning
wires, drills, or other devices designed for such purpose.
Torches in use shall be inspected at the beginning of each working
shift for leaking shutoff valves, hose couplings, and tip connections.
Defective torches shall not be used.
Lighters
Torches shall be lighted by friction lighters or other approved
devices, and not by matches or from hot work.
FUMES MAY PRODUCE METAL FUME FEVER
SYMPTOMS RESEMBLE:
 Respiratory disturbances
 Infection - Influenza
 Fever - Acute Bronchitis
 Pneumonia - Chills, Shivering,
 Trembling, Nausea, Vomiting may also occur.

Welders Exposed To Fumes Containing Iron, Chromium,

Chromates, Lead And
Aluminum May Suffer:
 DAMAGE TO LUNGS
 LUNG CANCER
 NERVOUS SYSTEM PROBLEMS
 IRRITATION TO EYES, NOSE, AND THROAT

HEARING LOSS CAN BE CAUSED BY HAZARDOUS NOISE LEVELS

EYE INJURIES
• RETINAL
INJURIES
• CATARACTS
• KERATITIS

EXPOSURE TO
ULTRAVIOLET RADIATION CAN CAUSE SEVERE SKIN BURNS

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 Diploma in Industrial Safety and Fire Management
REDUCED POWER AND PAIN DUE TO DISTORTED POSTURE

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 Diploma in Industrial Safety and Fire Management

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