Welding Operation

Based on SECL HSE Procedure : Welding Operation (SEM–1839).

SECL HSE Overseas Support Team

Welding Operation
INTRODUCTION

The main hazards likely to be encountered during welding and

burning processes can be identified as follows

High Temperature causing risk of fire and burns

Fumes emitted from the process likely to cause injury to health

Radiation causing 'arc eye' and burns / Electric shock

Explosions during the welding and cutting of drums, tanks or vessels,

which have contained flammable materials

Oxygen deficiency or enrichment, particularly within an enclosed space

It is therefore imperative that adequate control procedures are put into

practice
Welding Operation
Welding Types

Welding is the most common process method that used in

construction industry to join two piece of metal or more in one

Welding, Cutting and Brazing are safe operations only when carried
out in the correct manner

Where equipment is defective or there is no well-arranged,

well-lit, or properly ventilated working place, hazards can arise

There are many types of Welding operations. This slide focus on Gas
Welding and Arc Welding, which are major process methods using by
Samsung Engineering Construction Site
Welding Operation
Common gases Welding

OXYGEN (O2) is odorless & colorless. Highly

concentrated sources of oxygen promote rapid
combustion and therefore are fire and explosion
hazards in the presence of fuels.

Oxygen cylinders or apparatus shall not be handled

with oily hands or gloves

A jet of oxygen must never be permitted to strike an

oily surface, greasy clothes or enter fuel, oil or other
storage tanks
Welding Operation
Common gases Welding

ACETYLENE (C22H22) has a distinct odor often likened to that of garlic

or sour apples. It is combustible when mixed with air over a wide ra
nge (2.5% - 81%).

Acetylene when burned with oxygen gives a temperature of 3200

°C to 3500 °C (5800 °F to 6300 °F), which is the highest temp
erature of any of the commonly used gaseous fuels

Acetylene becomes unstable at pressures above 103 kPa (15 psig)

which means it may explode

Under no conditions shall acetylene be generated, piped (except

in approved cylinder manifolds) or utilized at a pressure in
excess of 15 psi gauge pressure

Inside the cylinder, acetylene is dissolved in acetone to prevent inter

nal explosion
Welding Operation
Common gases Welding

ƒWelding gas cylinders be stored, handled,

and used in the vertical position to
prevent the liquid acetone from escaping
and damaging the valves and other
equipment

ƒCylinders storage should be planned so

that cylinders will be used in the order in
which they are received from the supplier.

ƒThe storage place shall be a safe, dry,

well-ventilated place prepared and
reserved for that purpose; out of the direct
rays of the sun, in protective enclosures
or sun shelters, which enable the
temperatures not exceeding 54oC (130oF).

ƒCylinders shall not be stored at

ƒFlammable substances such as oil and

volatile liquids or corrosive substances
should not be stored in the same area.
Welding Operation
STORAGE OF CYLINDERS

Oxygen cylinders and flammable gas cylinders shall be stored separately,

at least 6.0 meters (20 feet) apart or separated by a fire proof, 1.6 meters
(5 feet) high partition

All storage areas shall have a “ NO SMOKING " signs prominently displayed

All cylinders should be chained or otherwise secured in an upright position

Valve caps shall be kept in place when cylinders are not in use. Flammable
substances shall not be stored within 15.24 m (50 feet) of cylinder storage
areas

Empty and full cylinders must be stored separately with empty cylinders
plainly marked as such, to avoid confusion

Empty cylinders should be segregated according to the type of gas they

have held

Depleted cylinders shall be returned to the supplier with the valves closed
and the valve protection caps in place

Cylinders, even those marked empty, should be treated as a possible

hazard and handled with great care as they still contain some gas
Welding Operation
HANDLING OF CYLINDERS

ƒSerious accidents may result from the

misuse, abuse or mishandling of cylinders.

ƒCylinders should never be lifted by their

valves since the valves are not designed
to take such stress.

ƒWhen the cylinder is not in use, the valve

shall be protected with the valve cap.

ƒAll valves must be fully closed before a

cylinder is moved.

ƒRegulators and hoses should be detached

from the cylinders, for moving.

ƒDo not lift a cylinder with an

electromagnet

ƒCylinders shall not be dropped, thrown,

dragged, used as rollers or as a support.

Example of purpose built trolley.

Note fitments for the torch, a dry powder or CO2 fire
extinguisher, and a cylinder valve key.
Welding Operation
EQUIPMENT INSPECTION

All equipment should be examined immediately before use and regularly

maintained

All welding operations shall be conducted in well ventilated areas

Use soapy water to check leaks

Cylinders and valves should be kept clean. Valve sockets shall be kept
free of grit, dirt, grease or oil

Hoses should be used for one type of gas only and color coded for
identification

All connections should be made by clips or crimps. The hoses used for
acetylene and for oxygen shall not be interchangeable
Welding Operation
Attention

Means of torch ignition should be readily available. A

friction lighter shall be used for this purpose.

Joint fittings or lines made of copper should not be

used and acetylene should not be allowed to come into
contact with copper pipe work or tubing

"Empty" drums which have contained low flash point

liquids are known to have become lethal bombs when
a hot welding torch was laid down on them
Welding Operation
3 Typical Gas Welding Faults

can occur during use when:

SNAP-OUT Both regulators are set at an incorrect pressure. Torch
nozzle obstructed. Nozzle held too close to the work

A BACKFIRE is when the flame burns back into the blo

BACKFIRE wpipe often with a sharp bang. It can occur on lighting
up when:
Regulators not set to correct pressure. Light applied
Before flow of gas mixture properly established

A FLASHBACK is very dangerous. This could end in

FLASHBACK serious injury to personnel and severe damage to
property.
Most flashbacks are caused by faults in gas hose
fittings, resulting from wear and tear, dirt, excessive
heat, carbonizing, or damage during transport or
storage, or from incorrect operating procedures.
Welding Operation
Corrective Action

✴ shut off the blowpipe valves, oxygen first and then

For Backfire
the fuel gas;
✴ shut off the oxygen and fuel gas cylinder valves;
✴ cool the blowpipe with water, if necessary;
✴ check the equipment for damage or faults,
particularly the nozzle.

For Immediately close the cylinder valves, both fuel gas and
Flashback oxygen, if it is safe to do so. The flame should go out
when the fuel gas is shut off. If the fire cannot be put
out at once, evacuate the area and call the emergency
fire services;
The blowpipe, hoses, regulators, flashback arresters
and other components may have been damaged. Check
carefully and replace if necessary before reuse. If in
doubt, consult the supplier.
Welding Operation
Acetylene cylinders in Flashback

Pay particular attention to any acetylene

cylinder which has been involved in a
flashback or has been affected by fire.
There is a risk that the acetylene could start
to decompose, and the cylinder could
explode within a few minutes. If an
acetylene cylinder becomes hot or starts to
vibrate, you must evacuate the building
immediately and call the emergency fire
services.
Welding Operation
Protective Equipments

To protect a cylinder, you

should fit flashback
arresters onto the regulator, on
both the fuel and oxygen supply.
Arresters may be fitted on the
blowpipe but these do not give
protection from a fire starting
in the hose. For long lengths of Flashback arresters fitted to blow pipe.
hose, you should fit arresters
on both the blowpipe and the
regulator.
The fitting of a flashback
arrester should not be
considered as a substitute for
safe working practice.

Flashback arresters fitted to the regulators of a reticulated system

and blow pipe.
Welding Operation
Bad Example

•Regulator with damaged

Pressure Gauges

•ACETYLENE CYLINDER
Welding Operation
Bad Example

•Cutting Torch

•Hoses are not properly

rolled after finishing the
work
Welding Operation
ELECTRIC ARC WELDING

Electric Arc welding is a process for joining metals by

heating with an electric arc.

For arc welding, two welding leads, the electrode lead

and the work lead, are required

Properly installed and used the arc welder is very

safe, but if used improperly the operator can be
exposed to a number of hazards including toxic fumes,
dusts, burns, fires, explosions, electric shock,
radiation, noise, and heat stress. Any of these hazards
can cause injury or death
Welding Operation
ELECTRIC ARC WELDING

VOLTAGE

Either direct current (DC) or alternating current (AC)

is used. The arc voltage or working voltage is the
voltage present in the welding circuit while an arc is
struck and welding is being done. The arc voltage
ranges from 15V to 40V depending on the arc length

The open circuit voltage is the voltage generated by

the welding machine when no welding is being done.
Open-circuit voltages are normally set between 50V
and 100V, but drops to the arc voltage level when an
arc is struck and welding begin
Welding Operation
ELECTRIC ARC WELDING

Arc Length

In any electrical circuit, there is a correlation between the

voltage, current and the resistance. The best results are
normally obtained with an arc length about the diameter of
the electrode.

When the arc length is increased, less current flow occurs

because of the increased resistance. The result is a cooler
arc and a greater tendency to spatter. There will be less
penetration of the weld, increased exposure to oxidation and
contamination, and an erratic, unstable arc

When the arc length is reduced, less resistance more current

flows with less voltage and the arc becomes hotter. With thin
material, the heat can melt a hole in the welding, porosity,
and undercutting of the adjacent base metal
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

In each welding circuit there are three main connections:

1) the welding lead;
2) the welding return;
3) the welding ground

WELDING LEAD

The WELDING LEAD is the conductor carrying the welding

current from the point of supply to the electrode holder
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

The WELDING RETURN is the conductor carrying the

current back from the work to the point of supply

The welding return should be used to ground the metal

case of the welding machine. This high current
capacity is essential, because all the current fed to
the arc has to be conducted back to the supply point
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

The current involved could be as high as 300 amperes

on a hand welding operation

A continuous WELDING GROUND is essential and

indispensable for conductors since electric currents
as low as 50 mille amperes can be fatal

It is recommended that the welding ground be bonded

to the ground of the main supply system by a separate
substantial conductor
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

The frames of all fixed arc welding and cutting machines

shall be grounded either through a third wire in the cable
containing the circuit conductor or through a separate wire
which is grounded at the source of the current.

Welding grounds and returns should be securely attached to

the work by cable lugs, by clamps in the case of stranded
conductors, or by bolts for strip conductors

Bolts are unsatisfactory for stranded conductors, since the

strands can loosen under the bolt head and become detached
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

ELCB (Earth Leakage Circuit Breaker) or GFCI (Ground Fault

Circuit Interrupter) to be used.

Welding cable insulation needs to be abrasion resistant to

withstand normal treatment over rough ground and the wear
inflicted by foot and vehicular traffic

Where feasible, cables should be additionally protected by

stringing overhead or by using cable covers
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

If joints become necessary, standard plug and socket

coupling shall be used. Holders should be unplugged when
not in use

Too much Splices are not allowed in welding cables

They should be regularly examined for cuts or abrasions to

the insulation; damaged cable shall not be used
Welding Operation
ELECTRIC ARC WELDING

WELDING CONNECTIONS

Electrode holders shall be constructed to accommodate all

sizes of electrodes and with an ejector for hot, spent stubs

A shield should be fitted between electrode holder and

handle to prevent live elements from being touched

The handle itself shall be made of non-flammable insulating

material and be free from joints or holes
Welding Operation
ELECTRIC ARC WELDING

PROTECTIVE MEASURES

Electric welding operations must be effectively screened to prevent

nearby personnel from being affected by harmful radiation

Screens should be made from fire resistant materials or should be

suitably treated with a fire resistant compound

Keep all doors, covers and panels in place when operating the
machine

They ensure the optimum flow of cooling air, and removal of these cover
s and panels will reduce the cooling of the engine and generator,
resulting in overheating and premature failure of the unit

Ensure that the engine protection push button 'pops out' when the
engine is switched off
Welding Operation
ELECTRIC ARC WELDING

PROTECTIVE MEASURES

Cracked insulation is an obvious source of hazard producing

shorts to ground eventually leading to increase of conductor
resistance

Larger-capacity cables must be used to reach distant sites,

because of the buildup of resistance from the extra length of the
leads

Inadequate or weak cable connections can also introduce sparking

hazards, potential shorts to ground, and extra resistance which
reduces effective welding machine capacity
Welding Operation
ELECTRIC ARC WELDING

The full length of cable must be stretched out and

Suitably protected

Leaving the cable coiled on the machine alters the

current flow and disrupts the welding process

Sparks and molten or hot metal coming from the work

area can easily set fire to combustible materials near or
below the working area
Welding Operation
ELECTRIC ARC WELDING

Operators of arc welding equipment must always switch off the

current to the electrode holder and remove the electrode
whenever it is to be set down and is not actually in use

When welding or cutting material that is supported by a crane,

a shield or an effective screen should be provided to protect
the suspension ropes or chains
Welding Operation
WELDING AND CUTTING

CONFINED SPACE

Forced ventilation shall be arranged wherever work is to be carried

out in a confined area

Suitable metal bins shall be provided for spent electrode stubs as

they are usually hot when discarded and can easily cause a fire

Dry chemical fire extinguishers should be kept available while

work is in progress. All completed work should be marked "HOT".
Welding Operation
WELDING AND CUTTING

CONFINED SPACE

Careful tests should be made to establish that the tank, vessel or

drum is free from explosive flammable vapors or substances

Extreme care should be taken in considering methods of tank

welding and cutting as these jobs are hazardous operations unless
correct safety measures are taken

It is vital that forced ventilation be maintained in confined spaces

at all times. Air line respirators may be needed for men working in
side such places
Welding Operation
WELDING AND CUTTING

CONFINED SPACE

Gas cylinders or arc welding machines should never be allowed

into such an area

The hoses and equipment used inside must be in excellent

condition
Welding Operation
WELDING AND CUTTING

HEALTH HAZARDS

Apart from the obvious hazards of physical burns,

health hazards in welding operations fall into two
classes : hazards from radiant energy and hazards from
dusts and fumes
Welding Operation
ARC EYE

The most common for most

radiation damage occurs
when welding has been
carried out without adequate
shielding of the eye.
The corneal epithelium is
damaged by the ultraviolet
ray and the patient typically
Presents with painful,
weeping eyes some hours
after welding. This condition
is commonly known as arc
eye.

Cornea after welding damage, stained

with fluorescein and illuminated with
blue light
Welding Operation
WELDING AND CUTTING

RADIANT ENERGY

The process of welding produces radiant energy in the form of

visible light, ultra-violet rays, and infrared rays

Exposure of the skin to infrared and ultraviolet rays can result in

irritation and burning.

The risk of this energy harming the operator or other personnel can
be minimized by the proper use of protective clothing and shielding
Welding Operation
WELDING AND CUTTING

RESPIRATORY EFFECTS

When working in confined areas, a forced ventilation system

should be in operation to remove any build up of hazardous gases

Oxy-acetylene welding operations can cause the oxygen and

nitrogen of the air to unite to form nitrogen oxides

In well ventilated areas this does not cause any problems;

however, in confined areas or where the welder is working very
close to the job, the amount of nitrogen oxides breathed can
rapidly reach toxic levels
Welding Operation
WELDING AND CUTTING

HAZARDOUS OPERATIONS INCLUDE

Although welding cannot be regarded in general as an extremely

hazardous occupation

Exposure to concentrated fumes may be irritating and in some

cases dangerous

It is essential that each operation be analyzed before work starts

and that the control measures are correctly applied
Welding Operation
PERSONAL PROTECTIVE EQUIPMENT for WELDING OPERATION

•Personnel working with

welding equipment shall be
trained, competent, and
provided with Personal
Protective Equipment.

•It is contractor /
Subcontractor’s
responsibility to provide
proper welding goggles,
helmets, screens, forced
ventilation and similar
equipments to welder.
Welding Operation
Why eye protection is important?

•Eye injury can occur from the

intense light and radiation from
a welding arc and from hot slag
that can fly off from the weld
during cooling, chipping or
grinding.

•Protect your eyes from welding

light by wearing a welder's
helmet fitted with a filter shade
that is suitable for the type of
welding you are doing.

•ALWAYS wear safety glasses

with side shields or goggles
when chipping or grinding a
work piece if you are not
wearing a welding helmet.
Welding Operation
Shade of Protective Lens

ITEM TYPE OF WELDING # SHADE OF LENS

Light Gas cutting and welding and light

1 5
electric spot welding.
Gas cutting, medium gas welding, and
2 6-7
arc welding up to 30 amperes
Heavy Gas welding and arc welding and
3 8-9
cutting up to 75 amperes
Heavy Gas welding and arc welding and
4 10 - 11
cutting up to 100 amperes
Arc welding and cutting up to 400
5 12 - 13
amperes

6 Arc welding above 400 amperes 14

Welding Operation
PERSONAL PROTECTIVE EQUIPMENT for WELDING OPERATION

For gas cutting, welding and

brazing, the intensity of the
light is much less than from
arc welding. Lighter shade
filter lenses are used with
goggles in place of
a helmet.
Welding Operation
PERSONAL PROTECTIVE EQUIPMENT for WELDING OPERATION

‹HAND GLOVES are

necessary protection
against heat, sparks,
molten metal, and radiation.

‹When Hand Gloves are not

long enough, protective
sleeves of similar materials
should be worn.

‹SAFETY BOOTS and

LEGGINGS are essential to
provide effective protection
against heat, flying sparks,
and falling metal
Welding Operation
Any Questions?