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MODULE OBJECTIVES
• Discuss the two major welding process;
• Identify the major hazards in welding works;
• Implement safety measures to these major
hazards;
• Perform safety check before start of a welding
process;
• Discuss the proper execution of bonfire;
• Develop and implement a Hot Work Program.

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Common Types of
Welding Process

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ARC WELDING
 Arc – Two metals are joined by generating
an electric arc between a covered metal
electrode and the base metal.

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WELDING ELECTRODE

SHIELDING COVERING
GAS CORE
WIRE

BASE METAL

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General Hazards
in Arc Welding
Works and its
Counter Measures
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ARC WELDING HAZARDS

1. Electric Shock

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Safety Measure

1. Electric Shock

 Insulate welder--use rubber mat or dry wood.

 Keep electrode holder and cable insulation in good


condition.

 Do not touch electrically “hot” parts or electrode with


bare skin or wet clothing.

 Use correct Personal Protective Equipment (PPE).

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ARC WELDING HAZARDS

2. Fumes and Gases

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Safety Measure

2. Fumes and Gases


 Provide room with at least 10,000 cu. ft. per welder
with a ceiling height of at least 16 ft.

 Proper ventilation. 2,000 cu. ft. per min. of air per welder.

 Use correct Personal Protective Equipment (PPE).

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VENTILATION
 Adequate ventilation depends on the
following factors:
 Volume and configuration of the
space where the welding operations
occur.
 Number and type of operations that
are generating contaminants.
 Natural air flow rate where operations
are taking place.
 Locations of the welder’s and other
workers’ breathing zones in relation
to the contaminants or sources. 11
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ARC WELDING HAZARDS

3. Welding Sparks

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Safety Measure

3. Welding Sparks

 All combustible and flammable materials relocated


within 35 ft. from place of operation or shield with metal
guards or flame proof curtains..

 Assign a “Fire Watch” person for dangerous sparks.


 Keep fire extinguisher in the welding area and have
trained personnel to use them.
 Use correct Personal Protective Equipment (PPE).

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ARC WELDING HAZARDS
4. Arc Rays

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Safety Measure

4. Arc Rays

 Use the correct welding lenses base on arc


current.

 Use eye protective lenses when welding using


oxy-acetylene torch

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FILTER SHADE SELECTION

OPERATION ARC MIN. SUGGESTED


CURRENT SHADE SHADE
(amp)

Shielded Metal 60 7 9
Arc Welding
60 - 160 8 10
160 - 250 10 12
250 - 550 11 14

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ARC WELDING HAZARDS
5. General Work Area

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Counter Measure
5. General Work Area

 Keep cables, materials, tools neatly organized.

 Connect work cable as close as possible to area where


welding is being performed.

 Relocate combustible & flammable materials within 35


ft. or provide metal guard or flame proof curtains.
Always disconnect power to equipment before servicing.

 Maintain a standby fire extinguisher at all times with


trained personnel to use them.
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GAS WELDING
 Slower but easier to
control than electric arc.
Uses gas flame over
metals until molten
puddle is formed. Most
popular fuels used with
oxygen include acetylene
and phropane.
 Applicable mostly on
thins sheet metals, but
can be used to cut thick
steel plate. 20
Gas Welding Safe
Operation
-use regulators/hoses of approved standard-
-to avoid confusion, use color coded hoses (eg.,
blue for oxygen, red for acetylene, orange for
propane);
- use non-return valves at the torch/blowpipe;
- use flame-arrester at the outlet connections of
both pressure regulators;
- use worm drive fasteners at hose ends instead
of ‘jubilee clips (over-tightening can damage
hose) 21
Gas Welding Safe
Operation
- make sure oil or grease does not contaminate
oxygen supply;
- always check equipment visually for damage
before use, especially the hose;
- secure gas cylinders in vertical position;
- hose length should be kept to minimum as
much as possible.

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Welding
Checkpoints
Before Work

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Checkpoints Before Work

1. WELDER
•Fit to work.
•Trained for the job.
•Authorized to do the job.

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Checkpoints Before Work
2. EQUIPMENT
•In good condition
•With correct power switch fuses
•Holder insulation in good condition
•Equipment grounded properly
•Welding cable not damaged
•Hoses no leaks
•Accessories in good condition
•Fire fighting equipment available

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Checkpoints Before Work

. CLOTHES AND PROTECTORS

•Correct working clothes are worn.

•Safety shoes.

•Proper welding face protector or goggles must


be ready for use.

•Workers must wear proper gloves, arm covers,


apron and foot covers.

•Use safety belts/body harness for working up high.


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Checkpoints Before Work

4. WORK CONDITIONS

•Use a plate or screen to protect third parties.


•Proper ventilation
•Good housekeeping

•Eliminate flammable or explosive matter near


the working site.
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PERSONAL PROTECTIVE
EQUIPMENT
 Eye and face protection
 Welding helmets with filter
plates
 Protective clothing
 Flame-resistant gloves
 Safety shoes

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Bonfires

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Proper Execution of Bonfires
- light fires on an open site at designated ground
far enough (typically 10m) from adjoining
combustible materials, storage areas or building;
- never leave fires unattended until they are
completely out;
-limit the amount burnt to controllable level
through the use of confinement system such as
drums;

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Proper Execution of Bonfires
- attendant must have the correct fire extinguisher
or other suitable fire fighting equipment, and
importantly they are trained to use it;
- do not light fires on windy days;

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Proper Execution of Bonfires
- check materials for dangerous items such as
empty cylinders, aerosol cans & flammable
substance before it is brought to fire;
- do not light fires where flames, smoke and any
air-borne debris might affect overhead electrical
lines;
- do not use petrol or any similar fuel to light up
fire, use paper or similar kindling instead.

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Follow points (a) to (e) when lighting a bonfire
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HOT WORK PERMIT

A written permit or authorization


before welding or cutting
operations are allowed in
establishments in which the area
shall be inspected by the safety
man indicating therein the
precautions to be followed to
avoid fire or accidents.

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HOT WORK PERMITS

Definition:
HOT WORK is any work using open flames
or sources of heat that could ignite
materials in the work area.

Welding
Brazing
Soldering
Oxy-acetylene cutting

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HOT WORK PERMIT
 Required whenever welding, cutting
or burning is done.
 Serves as a safety inspection
checklist to ensure precautions are
taken.
 Must be posted in a visible location
at the worksite.

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HOT WORK PERMITS

Procedures:

Before beginning hot


work, contact the Fire
Marshal, Safety Officer,
or Maintenance Manager
and obtain the Hot Work
Permit.

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HOT WORK PERMITS

Effectivity:

Permits are issued for


the specific job being
done, and for a specific
time period. The time
period is usually for the
working shift, but may
never exceed twenty four
hours.

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Hot Work Permit
Project Name: Requesting Person/Company:
Job Location: Date of Request:
1. Is welder/s authorized for the job? 6. Are the correct work clothes available?
□ Yes □ No □ Yes □ No

2. Are power switches with correct fuses? 7. Are the appropriate protective equipment provided ?
□ Yes □ No □ Yes □ No

3. Are holder insulator in good condition? 8. Are flammable material s removed from the work area?
□ Yes □ No □ Yes □ No

4. Are the equipment grounded properly? 9. Is work are with adequate ventilation ?
□ Yes □ No □ Yes □ No

5. Are hoses inspected for leaks? 10. Is good housekeeping maintained?


□ Yes □ No □ Yes □ No

Remarks: Date of Inspection: Action:


Job Start Time: □ Approved
Effective Until: □ Disapproved

Inspected By: By:


Note: This permit expires 24 hrs after designated “start time”. If works is to continue, another permit must be issued
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THE END

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