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CWI PREPARATORY
Topics of the day: Safety & Review
If you want something you’ve never had, Then you’ve got to do something, You’ve NEVER DONE.
Primary document governing safety with
regards to welding & cutting This is for the protection of persons from injury, illness & the protection of property (including equipment) from damage by fire & explosions arising from welding, cutting, & allied processes
WELDING SAFETY
Creating a Safe Workplace • Potential risks to health and safety
• Hazards from fire, explosion, fumes & gases • Joint responsibility employer & worker to minimize
WELDING SAFETY
• Use protective clothing and equipment • Follow all safety methods and procedures; ask, if in doubt • Maintain all equipment and report unsafe conditions • Do not bypass the safety features of the equipment • Know the hazards of the materials and processes • Keep work areas clean and organized
MANAGEMENT SHALL:
• Use protective clothing and equipment • Follow all safety methods and procedures; ask, if in doubt • Maintain all equipment and report unsafe conditions • Do not bypass the safety features of the equipment • Know the hazards of the materials and processes • Keep work areas clean and organized
MANAGEMENT SHALL:
Assure only approved equipment/ personal protective devices used Assure that hazards and safety precautions are communicated to and understood by workers prior to the start of work Select contractors • trained and qualified • aware of the risks involved
MANAGEMENT SHALL:
Advise contractors about flammable materials or hazardous conditions Assure personnel are trained in • safe operation of their equipment
• safe use of the process • emergency procedures Safe welding and cutting • designate approved areas • establish procedures • authorize welding/cutting
MANAGEMENT SHALL:
Assure proper personal protective and fire protection equipment is used Assure that fire protection and fire extinguishing equipment properly located Fire watchers are assigned Hot-work authorization procedures are followed where required
SUPERVISORS SHALL:
Assure proper personal protective and fire protection equipment is used Assure that fire protection and fire extinguishing equipment properly located Fire watchers are assigned Hot-work authorization procedures are followed where required
SUPERVISORS SHALL
Determine if flammables present Ensure not exposed to ignition (1) Have the work moved to a location free from combustibles DANGER FLAMMABLE GAS (2) Have the combustibles moved if the work cannot readily be moved (3) Schedule welding and cutting so that such materials are not exposed during welding and cutting operations
WELDERS SHALL
Handle the equipment safely Cut or weld only where all safety precatutions have been met Where others may unkowingly come in contact with hot material remaining from welding, a notice shall be posted.
WELDERS SHALL
Have permission of management before starting to weld or cut Continue to weld or cut only so long as conditions are unchanged from those under which permission was granted Understand the hazards of the operation to be performed and the procedures being used to control hazardous conditions
SAFETY RULES
• Good housekeeping • Post signs designating welding areas • Protect others from radiation Separate welding stations by noncombustible screens or shields (radiation-protective, semitransparent materials) • Should permit circulation of air at floor level as well as above • Adjacent walls and other surfaces shall have low reflectivity
WHAT IS PPE? (PERSONAL PROTECTIVE EQUIPMENT)
• HEARING • PROTECTION • PROTECTIVE • CLOTHING
• HARD TOE SHOES • SAFETY GLASSES • HARD HAT • GLOVE • HELMET
Eye & Face Protection ANSI Z87.1
Helmets or hand shields with filter lenses and cover shall be used when viewing the arc Protective spectacles with side shields, arc goggles or other approved eye protection shall also be worn Operators of resistance welding or brazing equipment and their helpers - spectacles, goggles, or face shields
Goggles or other approved eye protection shall be worn during all OFW, OFC and SAW
PROTECTIVE CLOTHING
Provide sufficient coverage Suitable materials
Wool or chemically treated cotton Sleeves and collars be kept buttoned Pockets be eliminated from front Trousers - no cuffs and not be turned up outside - should overlap shoe top Materials that melt should not be used
Gloves: • Flame-resistant • In good repair • Dry • Protect from electric shock • Leather other suitable materials Aprons: • Durable flame-resistant • Leather or other suitable materials
Confined Space Concerns
Ventialation • Container Cleanliness • Welding Gases - Argon, CO2, Nitrogen • Electrical shock - Use a GFCI • Escape aspects - Usually restricted
• Standby person -Maintain contact -Verbally check -Call for assistance A brazing furnace can be considered a confined space
SHIELDING GASES
Which shielding gases are reactive gases?
Which shielding gases are inert gases? • Argon - heavier than air • Helium - lighter than air
• Nitrogen • Carbon Dioxide
All are: Odorless Colorless Can displace oxygen Check confined spaces for adequate air with oxygen analyzer or use a respirator Same precautions shall apply to pits, tank bottoms, low areas, and areas near floors when heavier than air gases and vapors are present, and to tank tops, high areas and near ceilings when lighter than air gases are present.
RESPIRATORS
• Required when ventilation is not sufficient or available • Requires only approved equipment (respirators) to be used • Requires procedures to ensure proper selection, handling and use (personnel training) • Design is governed by NIOSH (National Institute of Occupational Safety and Health)
Low Allowable-Limit Materials Antimony
Fumes originate from: • Consumables • Base metals and coating • Atmospheric contaminants Gases produced include: • Carbon monoxide • Carbon dioxide • Fluorides • Nitrogen oxides • Ozone (GMAW on aluminum) • Phosgene (UV on chlorinated hydrocarbon) Brazing filler metals contain cadmium. Brazing and gas welding fluxes contain fluorine compounds.
Arsenic Barium
Beryllium| Cadmium Chromium Cobalt Copper Lead Manganese Mercury Nickel Ozone Selenium Silver Vanadium
Material Safety Data Sheet (MSDS)
Identifies materials present in products which have hazardous physical or health properties
Chemical Make-up
Certain specifications call for precautionary labels on consumables & equipment
Should be posted or made available
Expressed in parts per Million (PPM) • Permissible • Exposure • Limits for material • Ingredient • PEL
Listed on MSDS
• Threshold • Limit • Value • TLV
A level to which it is believed a worker can be exposed day after day for a working lifetime without adverse health effects
PELs are regulatory limits on the amount or concentration of a substance in the air. They may also contain a skin designation. OSHA PELs are based on a 8-hour time weighted average (TWA) exposure
• Design properly • Include proper size relief devices • Vent relief devices properly • Label all piping properly • Operate Properly Manifold/Piping Systems
CYLINDER SAFETY COMPRESSED GAS
What’s considered “Compressed Gas”?
Who governs design of the cylinders? DOT and periodic testing is required
Moderate to high pressure 400 to 2200 psig of stored energy
How should cylinders be identified? Chemical element or trade name on label
CYLINDER SAFETY
Approved regulators only can be changed to fit wrong cylinder
Open slowly to allow to pressure to hit regulator slowly
Fuel cylinders - open 1 turn max
High PSI (ie Argon) open all the way
Face away from regulator gage
Close after use
ACETYLENE • One of the hottest burning and most dangerous fuel gases • Very unstable above 15 psi • Will explode at 32 psi • Dissolved in acetone • Requires flash pot on manifold • Made from calcium carbide & water • Laying cylinder on side allows liquid in cylinder to run into hose attached
OXYGEN Not flammable but supports combustion Spontaneously combusts with oil Pressure >2000 psi in cylinder Not a compressed air supply Don't blow off with pure O2
Torch use
Purging - before lighting first time each day not into confined spaces or near ignition sources - after a cylinder change Lighting - friction type, stationary pilot flame or other suitable - matches, cigarette lighters, or welding arcs shall not be used Colors - red for fuel gas hose, green for oxygen hose, and black for inert-gas and air hose
FIRE IN THE WORKPLACE • Designated welding/cutting area • Work areas free of combustibles
• Knowledge of equipment • Knowledge of processes • Fire watch if needed • Hot work permit
Open Circuit Voltage (OCV) - Some processes may utilize open circuit voltages as high as 400 volts dc Welding Terminals - Shall be protected from accidental electrical contact Dead front construction - utilizing receptacles for plug connections, by locating terminals in a recessed opening or under a non-removable hinged covers, by heavy insulating sleeves or by other equivalent mechanical means > 6 ma is considered primary current & harmful .5 ma is the level a tingle will be felt upon contact
Construction's "Fatal Four” Out of 3,945* worker fatalities in private industry in calendar year 2012, 775 or 19.6% were in construction. The leading causes of worker deaths on construction sites were falls, followed by struck by object, electrocution, and caught-in/between. These "Fatal Four" were responsible for nearly three out of five (56%) construction worker deaths in 2012*, BLS reports. Eliminating the Fatal Four would save 435 workers' lives in America every year. Falls - 278 out of 775 total deaths in construction in CY 2012 (36%) Struck by Object - 78 (10%) Electrocutions - 66 (9%) Caught-in/between - 13 (2%)
5) The abbreviation "MSDS" means: a. Management Support and Daily Safety b. Materials Strength and Discontinuity Sheet c. Materials Safety Data Sheet d. Materials Strength and Data Sheet e. none of the above
1) The welding inspector is exposed to which of the following safety hazards: a. radiation
b. falling objects c. electrical shock d. eye hazards e. all of the above
6) The abbreviation "TLV" means: a. Total Linear volume b. Threshold Limit Value c. Tack Length Value d. Threshold Limiting Valve e. None of the above.
2) A document which covers safety in welding and cutting is: a. AWS D1.1 b. API 1104 c. ANSI Z49.1 d. ASME Section VIII e. ASME B31.3
7) Employers must make all applicable MSDS data available to their employees. a. true b. false
3) The most important component of an effective safety and health program is: a. safety rules b. safety procedures C. protective equipment d. welding helmet e. management support 4) Safety training is mandated under provisions of: a. AWS "Safe Practices" b. OSHA c. ASME Code d. Welding Handbook, Volume 2 e. none of the above
8) Personnel must be trained to recognize safety hazards. a. true b. false
9) A "Hot Work Permit" is required for: a. all welding operations b. all cutting operations c. all preheating operations d. areas where a fire hazard may occur during a welding, cutting, or preheating operation e. all of the above
10) Eye hazards found in welding operations include: a. flying particles b. radiation c. smoke and fumes d. all of the above 11) Protective equipment not suitable for eye protection from welding radiation includes: a. welding helmets with filter plates b. clear safety goggles c. safety goggles with filter plates d. protective screens e. properly positioned barricades 12) Suitable clothing materials for welding and cutting are: a. 65% cotton, 35% polyester b. wool c. chemically treated cotton d. "b" and "c" above e. none of the above 13) Before working on equipment where machinery guards have been removed, a "Lock, Tag and Try" procedure should be completed. a. true b. false 14) In avoiding fumes during welding, the most important factor is:
15) It is not important to consider ventilation during welding and cutting operations. a. true b. false 16) When entering confined spaces, a "standby" is not required. a. true b. false 17) Some of the toxic materials the welder may be exposed to are: a. cadmium b. chromium c. nickel d. lead e. all of the above 18) Proper usage and handling of compressed gas cylinders include: a. not welding on cylinders b. not including the cylinders in the ground or electrical circuit c. securing them properly d. identifying the gas prior to use e. all of the above 19) Acetylene becomes unstable above what pressure? a. 5 psi
b. 10 psi c. 15 psi d. none of the above 20) Oxygen is a flammable gas. a. true b. false
a. the type of base metal b. the type of filler metal c. the type of welding process d. the position of the welding machine e. the position of the welder's head
21) Electric currents above approximately 6 milliamperes are considered: a. not harmful b. primary currents c. harmful d. secondary currents e. "b" and "c" above 22) When operating gas cylinders, the primary valve should be opened: a. all the way on an acetylene cylinder b. one turn on an oxygen cylinder c. one turn or less on an acetylene cylinder d. all the way on an oxygen cylinder to backseat the valve e. "c" and "d" above
HOMEWORK FOR TONIGHT
1) QUESTIONS ON PAGES 791 - 794 2) DEFINITIONS ON PAGES 795 - 797
3) THEN IN • PART C BOOK (API 1104) SET 2 • PART D BOOK (AWS D1.1) CE 5
HOMEWORK FOR THE WEEKEND
PART C BOOK (API 1104) • Weekend set 1 & 2 or PART D BOOK (AWS D1.1) CE-6, CE-7, and ST-2
Preassessment test
Then REVIEW
(Bring Part B to class monday)
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