SAFETY IN WELDING AND

CUTTING

INTRODUCTION
Welding is a material joining process used in
making welds. Weld is a localized “ coalescence ’’
of metals or non-metals produced by heating the
materials to suitable temperatures with or without
the application of pressure. ‘ Coalescence ’ means
a growing together or growing onto one body.
There are two types of welding :
1) Welding with pressure.
2) Welding without pressure or fusion welding.
This is further classified into :
a ) Gas welding and
b ) Arc welding .
Why do we have to go for welded connections ? Because,
welding has certain advantages over other processes
such as riveting as given below :
a) Welding is a better substitution for riveting works
because noise hazards is eliminated
b) A welded joint has same strength as the parent metal.
c) A welded structure has a better finish and appearance.
Gas welding

Oxy- Acetylene welding

The gases used for this type of welding are :
I ) Acetylene ( fuel )
II ) Oxygen ( supporter of combustion )
Principles of operation
The cylinder pressure is reduced to a working line
pressure by means of special Regulators. The
gases are transported by hoses to the torch body.
The gases are mixed in the mixing chamber and
then mixture is ejected into the atmosphere. When
the spark of ignition is supplied, the triangle of
combustion completed.
 Torch
i. Select the proper tip or cutting nozzle and screw
carefully but not too tightly on the torch.
ii. When changing torches, shut off gases at pressure
regulators and not by crimping the hose.
iii. The cutting torch should be lighted with a friction
lighter. Matches should never be used because the
operator’s hand has to be too close to the torch tip
and may be burnt when the gases ignite.
iv. When the cutting is finished , extinguish the flame
by closing the acetylene valve first and then oxygen
valve.
v. When the cutting is stopped for a very short time, it is permissible
to close the torch valves only.
vi. When the cutting is stopped for a longer period, close the cylinder
valves and then release all gas pressures from the regulators by
opening the torch valves momentarily. Close the torch valves and
release the pressure adjusting screws. If the equipment is to be
taken down, make certain that all pressure adjusting screws are
completely open.
vii. Don’t leave unlighted torches connected for use in confined
spaces during lunch hour or when leaving work for other reasons.
viii. Torches that leak at any connection should not be used as they get
hot and flash back.
ix. Accumulation of slag on the blow-pipe- tip should be frequently
removed by using hard wood sticks or soft brass wire,
 Hose
i. Hoses of different colors should always be used for
different gases. Red is the generally recognized color to
be used for acetylene and other fuel gases and green or
black for oxygen. Do not interchange the hoses.
ii. Compressed air should never be used for cleaning the
inside of hose as it may contain oil from the compressor .
Oxygen should be used to clean oxygen hose and
acetylene for acetylene hose.
iii. Protect the hose from flying sparks, hot slags and hot
objects.
iv. Do not allow hose to come into contact with oil or
grease. These materials cause deterioration of rubber and
constitute a hazard with oxygen.
v. Do not repair / patch up the hose with tape.
vi. When hose shows wear at a connection. Cut off the
worn portion and reinsert connections surely.
vii. Leaks should be repaired at once by cutting the hose
and inserting a splice. Acetylene escaping from a
defective hose is liable to become ignited and may
become a serious fire.
viii. Should a flash back occur and burn in the hose, discard
that length of hose.
ix. All hose should be examined carefully at frequent
intervals for leaks, wear and loose connections. This
can be done by immersing the hose in water when
under normal working pressure .
 Use of Apparatus
i. Never use any cutting or welding apparatus unless
automatic pressure regulators are fitted to the oxygen and
acetylene cylinders.
ii. Before putting a regulator on to a full cylinder, always
release the adjusting screw for regulating the pressure of
output, otherwise there is a risk of damage to the
regulator.
iii. Make sure that the threads on the regulators and other
auxiliary equipment are the same as those on cylinder
valve outlets. Right hand for oxygen and non-combustible
gases. Left hand for Acetylene, Hydrogen and combustible
gases.
iv. Never force connections that do not fit.
v. Do not use gauges for showing pressures other
than those recommended by the gas suppliers.
Arc Welding
The positive side of the welding generator is connected to the electrode
and negative side to the work. When electrode touches the work,
the arc is produced.
The main function of the arc is to produce heat. This heat is useful for
melting metals and joining them by fusion. The welding arc is a
steady-state condition maintained at the gap between an electrode
and a work that can carry current ranging from 5 amps~200amps
and voltage ranging from 30V~100V.
When the electrode is negative, the polarity is called straight and vice-
versa. The hazards in the welding process are :
a) Electric Shock
b) Infra red and ultra violet radiations
c) Metal fumes and hazardous gases
d) Fire
Electric Shock
Open circuit voltage ( no load voltage ) ranges from
30~100volts and is low compared to other process voltage.
However, it cannot be neglected and is a potential hazard.
Under certain circumstances. Particularly in humid weather,
the danger if the more if the welder is in sweaty condition.
Hence, the welder should develop the habit of always
keeping his body insulated from both the work and the metal
electrode and holder. He should always wear shoes and
gloves.Consistent use of electrode holder with well-
insulated jaws, well-insulation cables, dry cables , protective
coverings on the hands and body and insulation from ground
would be helpful in avoiding contact. Working area must be
dry. Any water in the area must be cleaned before starting
the job.
Radiations
Non-ionizing radiations are produced in Arc
welding and Gas welding. They are
(1) Ultra Violet rays (2) Infra red rays.
Ultra Violet Rays causes irradiation in the
eyes and can cause burning of skin
I R Rays heats up the tissues and eyes.
c) Fumes and Hazardous
Gases
Metal fumes produced during welding and
cutting are an inhalation hazard.
Ozone is produced in the air where arc
welding is done. It is a toxic gas. The
permissible limit of exposure for ozone is 0.1
PPM.
Fire Hazard
If any flammable material is present in the
vicinity of working place, then a flying spark
can ignite the flammable materials leading to
fire hazard. It is recommended that the safe
distance should generally be not less than 15
meters.
 Operational Safety for Oxy-acetylene
Welding Process
The gas cylinders should not be used unless fitted
with the following :
i. High pressure gauge on cylinder, reducing valve with
pressure regulator and safety relief device. Low pressure
gauge for indicating pressure on the torch.
ii. Do not use cutting equipment near spray painting rooms.
iii. If the work can be moved, it is batter to take it to a safe
place for welding or cutting rather than perform the
work in a hazardous location.
iv. Watch the sparks and hot slag. See that they do not come
in contact with combustible material and do not drop
through openings to the floors below.
v. Never do any hot work, such as welding or
cutting on used drums, barrels, tanks, or other
containers, until they have been cleaned
thoroughly to make absolutely certain that no
inflammable materials are present.
vi. When cutting is being performed in a confined
space, always leave the cylinder on the outside
with an attendant and lead the gas in through
the hose to the point where is being done. Bring
the blow pipe out whenever work is stopped.
vii. Make sure that the job or the room where the
welding or cutting is being performed is well
ventilated.
viii. Oxygen should not be used for the purpose of clearing
fumes in a confined space .
ix. Under no circumstances, should Acetylene be used at a
pressure exceeding 15 psi. Oxygen pressure should
always be higher than the Acetylene pressure so that
the acetylene does not flow back into the oxygen
cylinder.
Oxy-Acetylene mixture is highly explosive. Mixtures
of Acetylene and air of 2.6 % - 8 % will explode if
ignited.
O2 Cylinder Pressure ---2200 psi
C2H2 Cylinder Pressure ---250 psi
x. Should the flame flash back / burn inside the blow pipe,
immediately shut off the blow pipe oxygen valve which controls the
flame; then close Acetylene valve. The occurrence of back-fire
indicates that something is wrong with the blow pipe or in the
manner of operating it.
xi. For closing down the equipment follow the procedure given below :
a) First close the Acetylene valve on the blow pipe and next close the
oxygen valve on it .
b) Close acetylene and oxygen cylinder valves.
c) Open the acetylene and the oxygen valves on the torch to permit the
trapped gas to pass out of the regulators and the hose. After this has
been done release the regulator adjusting screws by turning to the
left.
d) Disconnect the hose from the blow pipe .
e) Disconnect the hose from the regulator.
f) Remove the regulators from the cylinders and replace the protective
caps on the cylinder.
 Fire Protection
i. Before commencing the welding operations the location should be
checked for any possible fire hazard.
ii. Welding operations should preferably be done in permanent
locations free from hazards. Booths constructed for non-
inflammable materials are best suited. Proper exhaust ventilation
is to be maintained.
iii. Combustible materials should not be covered with asbestos
curtains or sheet metals during welding operations. Fire
extinguisher of the appropriate type must be kept at hand for any
emergency.
iv. Wooden floors should be swept clean before welding operations
are started. Wooden floors should preferably be covered with
metal or other suitable non-combustible material where sparks of
hot metal are likely to fall.
v. Welding operations should not be permitted in or near
rooms containing flammable vapors,liquids or dust or in
closed tanks or other containers which have held
flammable liquids, until all fire and explosion hazards
have been eliminated.
vi. Hot metal or slag should not to be allowed to fall
through cracks in the floor or other openings into
combustible materials on the floor below.
vii. The usual precautions in handling electric power should
be observed. The insulation ma get cut by dragging the
leads across sharp objects. Electrode holders ma be
carelessly dropped and welding sets may be shorted due
to mishandling. These hazards can be largely eliminated
by good maintenance of equipment and adequate
checks.
 General Precautions
i. The welder should bear in mind at all times the
protection of himself and others working nearby.
ii. If it is necessary for a welder to work at an elevation
of more than 1.5 meters, adequate provisions ( use of
railings, safety belts ) should be made to prevent
falling in case of electric shock or other injury.
iii. If welding is performed in confined spaces some
means should be provided for quickly removing the
person in case of emergency. A helper should always
be stationed where he can readily give assistance to
welders working in such places.
iv. Where the welder has occasion to leave his work or to stop
work for any length of time, the main switch in the
equipment should be opened.
v. After welding, chalk mark the ‘ HOT ’ metal or provide
some warning sign to prevent their workers from coming
into contact with the parts just welded. Do not forget to
erase out the chalk mark ‘HOT’ or remove any warning
sign provided when the hot object has cooled.
vi. Good housekeeping should be maintained on all welding
jobs. Operators should not discard electrode stubs on the
floor or leave tools or other objects where they will
constitute hazards.
vii. All tools such as hammers, chisels, brushes, bars and other
hand tools should be maintained in safe conditions.
viii. All injuries should be reported at once and first aid sought.
Protective Equipment used in
Welding Process

To overcome the above said hazard. Personal

protective equipment are to be used
During the welding process :
Welding Goggles
These are for eye protection. They protect the welder from
ultra violet rays, I. R. rays, flying sparks and reduce the
glare created by torch flame. Glasses of greenish neutral
color are considered to cause maximum protection for the
eyes. Welding Goggles consist of a green or brown tinted
filtered Lents of different shade densities ranging from 1 to
14, with no. 1 indicating lightest shade density and No. 14,
the darkest shade. The average shade density for oxy-
acetylene welding ranges from shade 3 to 8, depending
upon the light sensitive characteristics of the welder . In
electric arc welding, shade intensity from No. 8 to 14 are
used.
Welding Gloves

These are used to protect hands.

Gauntlets to protect the hands and
forearms from heat and metal flashes
due to welding. These are made of
leather and asbestos. They are
considered necessary for protection
from burns.
Face Shield

This is a protective device held in the

hand to shield the face and throat
against harmful rays. The color
density of the lens depends upon the
type of welding amperage being used.
Welding Aprons
Flame proof aprons made of leather or
asbestos protect against radiated heat and
sparks.

Helmet
This is protective device supported on the
head and used to shield the face and throat
from injury during welding.
 Protective Clothing
i. The clothing, preferably woolen rather than cotton
should be free from oil or grease.
ii. Sleeves and collar should be kept buttoned and pockets
eliminated from the front of overalls and aprons.
iii. High boots shall be used, lower cut-shoes with
unprotected tops shall not be used.
iv. Caps or shoulder covers made of leather or other
suitable material shall be worn during overhead welding
or cutting operations. Leather skull caps may be worn
under helmets to prevent head burns.
v. For overhead welding or welding in extremely confined
spaces, ear protection is also desirable.
 Welding Check- Lists
Do’s
i. Use the correct goggles, hand shield or
helmet.
ii. Select the correct grade of filter glass for the
job.
iii. Wear adequate protective clothing.
iv. Protect the eyes with goggles or by other
means when deslagging .
v. Make sure that the earthing and insulation of
arc-welding equipment is satisfactory.
vi. Make sure that the ventilation is adequate.
vii. Respect the warning notices posted during
radiographic inspection work.
viii. Turn off the gas cylinder valve when not in
use.
ix. Release the regulator screw before turning on
the cylinder valve.
x. Open the cylinder valve slowly.
 Don’ts
i. Don’t take risks.
ii. Don’t attempt to repair a tank or other vessel
that has held a combustible. Material until
proper precautions have been taken to ensure
safety.
iii. Don’t weld near inflammable material.
iv. Don’t use an engine- driver generator in a
closed , confined building unless the exhaust
gases are led outside.
v. Don’t use oxygen in place of compressed air.
vi. Don’t weld material cleaned with
trichlorothylene until it is absolutely dry.
vii. Don’t leave a blow pipe in a tank or vessel
when not actually in use.
viii. Don’t weld galvanized or other coated metals
without taking the correct precautions.
ix. Don’t use a compressed gas cylinder as a
work support.
x. Don’t allow a gas cylinder to become heated.
xi. Don’t look for a gas leak with a match or
flame.