MODULES OF INSTRUCTION

COMMON COMPETENCIES

GAS TUNGSTEN ARC WELDING (GTAW) NC II

UNIT OF COMPETENCY : APPLY SAFETY PRACTICES

MODULE TITLE : APPLYING SAFETY PRACTICES

MODULE DESCRIPTION : This module covers safety practices applied in the

workplace.

SUGGESTED DURATION : 4 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Identify hazardous area

LO2. Use personal protective clothing and devices

LO3. Perform safe handling of tools, equipment and materials

LO4. Perform first aid

LO5. Use Fire extinguisher

LO1. IDENTIFY HAZARDOUS AREA

ASSESSMENT CRITERIA:

1. Hazards are identified correctly in accordance with OHS procedures.

2. Safety signs and symbols are identified and adhered to in accordance with
workplace safety procedure.

CONTENTS:

HAZARD TO BE AVOIDED IN WELDING

The terms "hazard" and "risk" are often used interchangeably however, in terms of risk
assessment, they are two very distinct terms. A hazard is any agent that can cause harm
or damage to humans, property, or the environment. Risk is defined as the probability
that exposure to a hazard will lead to a negative consequence, or more simply, a hazard
poses no risk if there is no exposure to that hazard.

Welding is the most economical, efficient and common way to permanently join metals in
industry today. When welded, two or more pieces of similar metals are fused together by the
use of a filler metal, heat, pressure or both to form a strong joint. Once completed, the welded
joint is as strong as or stronger than the pieces from which the joint is formed. There are more
than 100 different ways to weld metals together. With so many different ways to weld, types
of metals, and filler materials comes many hazards such as flying particles, harmful dust,
smoke, fumes, heat and light radiation.

According to the Bureau of Labor Statistics (BLS), in 2014 there were approximately
400,000 welders in the United States with a projected growth rate of 4.4 percent for the next
ten years. With that number of welders and number of hazards associated with welding, the
BLS has determined the rate of injuries and illnesses is higher than the national average.

According to OSHA, the best way to reduce the risk of injury and illness in the welding
profession is to enact the philosophy of the hierarchy of controls. The hierarchy of controls is
a widely accepted concept promoted by numerous safety organizations, and supported by
OSHA. It is a way of controlling hazards in a preferred order from most effective to least
effective.

Types of welding

According to OSHA, welding is classified into two groups: fusion (heat alone) or pressure
(heat and pressure) to join two pieces together. OSHA further breaks fusion welding into
three types:

1. Electric arc – Employs an electric arc to melt the base metals and filler metals and
can be further divided into type based on amount of fumes produced (listed least to
most): Flux Core Arc Welding (FCAW); Shielded Metal Arc Welding (SMAW); Gas
 Metal Arc Welding / Metal Inert Gas (GMAW / MIG); Gas Tungsten Arc Welding /
Tungsten Inert Gas (GTAW / TIG)
2. Gas – Employs a flame from burning a gas (usually acetylene) to melt the base metal
at the joint to be welded.
3. Thermit – Employs a chemical reaction to produce intense heat instead of using gas
fuel or electric current.

Pressure welding usually involves heating the surfaces to a plastic state and then forcing the
metals together.

Welding hazards

All types of welding produce hazards. The most common hazard is welding fumes. Welding
fumes contain a variety of metals, including but not limited to aluminum, arsenic, beryllium,
lead and manganese along with several other gases. Having an awareness of the most
common welding hazards helps to target safety training to proactively avoid an injury/illness. 

Electric shock – Electric shock is one of the most serious and immediate risks facing a
welder. Shock occurs when arc-welders touch two metal objects that have a voltage between
them (typically 20-100 volts), thereby becoming part of the circuit to ground.

Welding areas require adequate ventilation and local exhaust to keep fumes and gases from the breathing zone and the general
area.

Fumes and gases – Due to the high temperatures generated when welding, metal fume and
gas hazards are produced that if inhaled or ingested can result in many health issues.
Fume Exhaust systems can be augmented with a fire safety solution system like the Lincoln Electric Guardian system, designed to
aid fire prevention, detection and suppression within the fume control system.

Exposure to Fumes and Gases

Undertaking welding activities will expose you to invisible gaseous fumes,

including ozone, nitrogen oxides, chromium and nickel oxides, and carbon
monoxide which can easily penetrate into your lungs. Depending on the gas or
fume, the concentration and duration of your exposure, the resultant damage
can be severe.

Illnesses caused by welding fumes and gases include:

 Pneumonia. Regular exposure to welding fumes and gases can result

in a lung infection which could then develop into pneumonia. While
antibiotics can usually stop the infection, severe pneumonia can result
in hospitalisation, serious illness and fatalities.
 Occupational asthma. Chromium oxides and nickel oxides produced
by stainless steel and high nickel alloy welding can both cause asthma.
 Cancer. All welding fumes are internationally considered ‘carcinogenic’.
 Metal fume fever. Welding or hot work on galvanised metal and high
steel weld fume exposure can often result in ‘flu-like’ symptoms, which
are usually worse at the start of the working week. You might have
heard that drinking milk before welding will help you avoid developing
metal fume fever, but this is a myth. 
 Throat and lung irritation, including throat dryness, tickling of the
throat, coughing and tight chests.

Fire and explosions – Welding can create heat, sparks and spatter that can serve as an
ignition source of flammable and combustible materials.

Flash burn – Welding can create intense light that can cause extreme discomfort, swelling
and temporary blindness if proper eye protection is not worn.
Thermal burn – The nature of welding involves extreme temperatures that require controls
to be in place to prevent burns to the skin. This could be present in the form of sparks and
spatter or direct contact with the welded surface.

Noise – Welding processes typically produce noise levels above 85 decibels. Additionally,
welding is typically done in areas where it is not unusual for ambient noise to add to the
decibel level.

Noise Hazards

When carrying out welding activities, you are likely to be exposed to loud,
prolonged noises. A loud noise is considered to be above 85 dB(A), and
welding activities such as flame cutting and air arc gouging can produce noise
levels of over 100 dB(A). This can be very damaging to the ears and can
result in hearing impairment.

Regular or immediate exposure to loud noises can cause permanent noise-

induced hearing loss.

Noise-induced hearing loss can have the following side effects:

 Ringing in the ears, known as tinnitus.

 Occasional dizziness, known as vertigo.
 Increased heart rate.
 Increased blood pressure.

Confined spaces – When the space or area where welding is taking place is small or
confining the amount of ventilation is limited. This can serve as a multiplier to fume and gas
levels making them much more concentrated. Shielding gases such as argon, helium,
nitrogen, or mixtures of these gases can also displace oxygen creating an asphyxiation hazard.

Compressed gases – Welding involves the use of many gases under high pressure contained
in cylinders. The cylinders can be a fire hazard if not stored properly. Cylinders can also be a
physical hazard if not secured properly to prevent valve damage and resulting explosive
release of the gas creating a deadly projectile.

Hazard controls

The best way to prevent injuries and illnesses posed by all workplace hazards is to follow the
concept of hierarchy of controls. This order is typically depicted as an inverted pyramid, with
the most effective control starting at the top.
Hierarchy of controls

Elimination is designed to completely remove the hazard from the workplace. Example
would be not performing welding in a confined space or eliminate the hazards in the space
before welding begins.

Substitution is designed to prevent potentially harmful exposure. Example would be

switching to shielded metal arc welding (SMAW) to gas metal arc welding (GMAW) with a
solid or metal coated wire, or opt to use low-manganese filler metal to reduce the amount of
hazardous fumes produced.

Engineering controls involve physical changes to the workplace. These can include isolation,
such as enclosing the welding process, or ventilation, which includes capturing material at the
source (local exhaust ventilation), and/or ambient collection.

Administrative controls require the welder or employer to do something. This is typically

accomplished through training and policies. Example would be training the welder to,
position their head and body to keep their body part away from the hazard.

Personal protection equipment (PPE) is only considered if the first four controls do not lower
the exposure risk to the hazard(s) to an acceptable level or were infeasible. To maximize the
benefits of PPE, users must be trained on use, limitations, and care of the PPE.

Injuries from insufficient PPE

Personal protective equipment (PPE) helps keep welding operators free from injury, such as burns – the most common
welding injury – and exposure to arc rays. The right PPE allows for freedom of movement while still providing adequate
protection from welding hazards.

Thanks to their durability and fire resistance, leather and flame-resistant treated cotton clothing is recommended in
welding environments. This is because synthetic material such as polyester or rayon will melt when exposed to extreme
heat. Welding leathers are especially recommended when welding out of position, such as applications that require
vertical or overhead welding.

Personal protective equipment (PPE) helps keep welding operators free from injury, such as burns – the most common
welding injury – and exposure to arc rays.

Avoid rolling up sleeves or pant cuffs, as sparks or hot metal will deposit in the folds and may burn through the material.
Keep pants over the top of work boots – don’t tuck them in. Even when wearing a helmet, always wear safety glasses
with side shields or goggles to prevent sparks or other debris from hitting the eyes. Leather boots with 6-to-8-inch ankle
coverage are the best foot protection; metatarsal guards over the shoe laces can protect feet from falling objects and
sparks.  It will not be pleasant if a hot piece of spatter finds its way inside your clothing or shoes.
Heavy, flame-resistant gloves should always be worn to protect from burns, cuts and scratches. As long as they are dry,
they also should provide some protection from electric shock. Leather is a good choice for gloves.

Helmets with side shields are essential for protecting eyes and skin from exposure to arc rays. Make sure to choose the
right shade lens for your process – use the helmet’s instructions to help select the right shade level. Begin with a darker
filter lens and gradually change to a lighter shade until you have good visibility at the puddle and weld joint but it is
comfortable and does not irritate your eyes. Helmets also protect from sparks, heat and electric shock. Welder’s flash
from improper eye protection may cause extreme discomfort, swelling or temporary blindness, so don’t take any risks –
wear a helmet at all times during welding.

To protect ears from noise, wear hearing protection if working in an area with high noise levels. Doing so will protect
your hearing from damage, as well as well prevent metal and other debris from entering the ear canal. Choose ear plugs
or ear muffs to protect the ears.

Conclusion

Hazards change due to new technology involving how metals are joined. It may be a new
base metal alloy, new filler metal, new process, or combination of everything. It is important
welders, and safety and health professionals, continue to follow the hierarchy of controls to
guard against traditional known welding hazards and also stay abreast of new and emerging
welding technologies.

https://www.ishn.com/articles/107699-follow-the-hazards-control-hierarchy-to-
reduce-welding-risks

https://www.lincolnelectric.com/en-us/support/welding-solutions/Pages/Five-
potential-welding-safety-hazards.aspx

WELDING SAFETY SIGNS AND SYMBOLS

SAFETY PRECAUTIONS - READ BEFORE USING

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating
instructions.

Symbol Usage

DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex- plained in the text.
NOTICE − Indicates statements not related to personal injury.

u Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult sym- bols and related instructions below for necessary actions to avoid the hazards.

Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards.
 When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety
information given below is only a summary of the more complete safety information found in the Safety
Standards listed in Section 1-5. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined
as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive
knowledge, train- ing and experience, has successfully demonstrated ability to solve or resolve problems relating
to the subject matter, the work, or the project and has received safety training to recog- nize and avoid the hazards
involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded
equipment is a hazard.
• Do not touch live electrical parts.
• Wear dry, hole-free insulating gloves and body protection.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with
the work or ground.
• Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use remote output control if present on unit.
• Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present:
in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped
positions such as sitting, kneeling, or lying; or when there is a high risk of unavoid- able or accidental contact with the
workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC
constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In
most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
• Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).

Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.
• Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground
terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
• When making input connections, attach proper grounding conduc- tor first − double-check connections.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged
– bare wiring can kill.
• Turn off all equipment when not in use.
• Do not use worn, damaged, undersized, or repaired cables.
• Do not drape cables over your body.
• If earth grounding of the workpiece is required, ground it directly with a separate cable.
• Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
• Do not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage
will be present.
• Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
• Wear a safety harness if working above floor level.
• Keep all panels and covers securely in place.
• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
• Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
• Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process
not in use.
• Use GFCI protection when operating auxiliary equipment in damp or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld- ing power sources AFTER removal of
input power.
• Turn off unit, disconnect input power, and discharge input capaci- tors according to instructions in Manual before touching
any parts.

HOT PARTS can burn.

 • Do not touch hot parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or wear heavy, insu- lated welding gloves and clothing to prevent burns.

FUMES AND GASES can be hazardous

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
• Keep your head out of the fumes. Do not breathe the fumes.
• Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes and gases.
The recommended way to determine adequate ventilation is to sample for the composition and quantity
of fumes and gases to which personnel are exposed.
• If ventilation is poor, wear an approved air-supplied respirator.
• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings,
cleaners, consumables, coolants, degreasers, fluxes, and metals.
• Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained
watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be
sure the breath- ing air is safe.
• Do not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with
vapors to form highly toxic and irritating gases.
• Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the weld.
• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face
and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed
in Safety Standards).
• Wear approved safety glasses with side shields under your helmet.
• Use protective screens or barriers to protect others from flash, glare and sparks; warn others not
to watch the arc.
• Wear body protection made from durable, flame−resistant mate- rial (leather, heavy cotton, wool). Body protection
includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can
fly off from the welding arc. The flying sparks, hot workpiece, hot equipment can cause fires and burns.
Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check
and be sure the area is safe before doing any welding.
• Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover
them with approved covers.
• Do not weld where flying sparks can strike flammable material.
• Protect yourself and others from flying sparks and hot metal.
• Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent
areas.
• Watch for fire, and keep a fire extinguisher nearby.
• Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
Do not cut or weld on tire rims or wheels. Tires can explode if heat- ed. Repaired rims and wheels can fail. See OSHA 29
CFR
1910.177 listed in Safety Standards.
• Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless
they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
• Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline).
• Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock, sparks, and fire hazards.
• Do not use welder to thaw frozen pipes.
• Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
• Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
• Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
• After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
• Use only correct fuses or circuit breakers. Do not oversize or by- pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings,
cleaners, consumables, coolants, degreasers, fluxes, and metals.
 FLYING METAL or DIRT can injure eyes.
• Welding, chipping, wire brushing, and grinding cause sparks and flying metal.
As welds cool, they can throw off slag.
• Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill

 • Shut off compressed gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.

-
Wearers of pacemakers and other implanted medical devices
should keep away.
- Implanted medical device wearers should consult their doctor and
the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting or induction heating operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise lev- el is high.

CYLINDERS can explode if damaged

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder
can explode. Since gas cylinders are normally part of the welding process, be sure
to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechani- cal shocks, physical damage, slag,
open flames, sparks, and arcs.
• Install cylinders in an upright position by securing to a stationary support or cylinder rack to
prevent falling or tipping.
• Keep cylinders away from any welding or other electrical circuits.
• Never drape a welding torch over a gas cylinder.
• Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
• Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain
them and associated parts in good condition.
• Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening
the valve.
• Keep protective cap in place over valve except when cylinder is in use or connected for use.
• Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders.
• Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association
(CGA) publication P-1 listed in Safety Standards.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard
Do not install or place unit on, over, or near combustible surfaces.
• Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is properly sized, rated,
and protected to handle this unit.

FALLING EQUIPMENT can injure.

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other
accessories.
• Use correct procedures and equipment of ade- quate capacity to lift and support
unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of
unit.
• Keep equipment (cables and cords) away from moving vehicles when working from an aerial
 location.
• Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when
manu- ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

Allow cooling period; follow rated duty cycle.
• Reduce current or reduce duty cycle before starting to weld again.
• Do not block or filter airflow to unit.

FLYING SPARKS can injure.

Wear a face shield to protect eyes and face.
• Shape tungsten electrode only on grinder with proper guards in a safe location
wearing proper face, hand, and body protection.
• Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards

Put on grounded wrist strap BEFORE handling boards or parts.
• Use proper static-proof bags and boxes to store, move, or ship PC boards.

MOVING PARTS can injure.

Keep away from moving parts.
• Keep away from pinch points such as drive rolls.

WELDING WIRE can injure.

Do not press gun trigger until instructed to do so.
• Do not point gun toward any part of the body, other people, or any metal when
threading welding wire.

BA TTERY EXPLOSION can injure.

Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature
designed for this purpose.

MOVING PARTS can injure.

• Keep away from moving parts such as fans.
• Keep all doors, panels, covers, and guards closed and securely in place.
• Have only qualified persons remove doors, panels, covers, or guards for maintenance and
troubleshooting as necessary.
• Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting
input power.

READ INSTRUCTIONS.
• Read and follow all labels and the Owner’s Manual carefully before
installing, operating, or servicing unit. Read the safety information at the
beginning of the manual and in each section.
 • Use only genuine replacement parts from the manufacturer.
• Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state,
and local codes.

H.F. RADIATION can cause interference.

• High-frequency (H.F.) can interfere with radio navigation, safety services,

computers, and communications equipment.
Have only qualified persons familiar with electronic equipment perform this
installation.
• The user is responsible for having a qualified electrician prompt- ly correct any interference
problem resulting from the installa- tion.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

• Electromagnetic energy can interfere with sensitive electronic equipment
such as computers and computer-driven equipment such as robots.
• Be sure all equipment in the welding area is electromagnetically compatible.
• To reduce possible interference, keep weld cables as short as possible, close together, and down
low, such as on the floor.
• Locate welding operation 100 meters from any sensitive elec- tronic equipment.
• Be sure this welding machine is installed and grounded according to this manual.
• If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded
cables, using line filters, or shielding the work area.

OCCUPATIONAL SAFETY STANDARDS AND ENTERPRISE SAFETY

POLICIES.
1013: Hazardous Workplaces

For purposes of this Standards, the following are considered “hazardous workplaces:”

a. Where the nature of work exposes the workers to dangerous environmental elements,
contaminants or work conditions including ionizing radiation, chemicals, fire, flammable
substances, noxious components and the like;

b. Where the workers are engaged in construction work, logging, fire fighting, mining,
quarrying, blasting, stevedoring, dock work, deep-sea fishing and mechanized farming;

c. Where the workers are engaged in the manufacture or handling of explosives and other
pyrotechnic products;

d. Where the workers use or are exposed to power driven or explosive powder actuated tools;

e. Where the workers are exposed to biologic agents such as bacteria, fungi, viruses, protozoas,
nematodes, and other parasites.

RULE 1090
HAZARDOUS MATERIALS
1091: Scope

The provisions of this Rule shall apply to all workplaces in which hazardous substances in solid, liquid or
gaseous forms are manufactured, handled and used or in which flammable, irritating, offensive or toxic
dusts, fibers, gases, mists or vapors are generated or released in quantities injurious to health.

1092: Definitions

When used in this Rule the following shall mean as follows:

(1) “Hazardous materials or substances” mean substances in solid, liquid or gaseous forms
known to constitute poison, fire, explosion or health hazard.

(2) “Corrosive” when referred to the action on inanimate surface such as metal, glass or wood
means that a substance will cause the wearing away, or the gradual changing or destroying of
the texture or substance of such materials. When referred to the action on living tissue,
means that it will cause more or less severe destruction of the tissue by chemical action.

(3) “Hot” means that a material or substance possesses or is characterized by a relatively high
temperature.

(4) “Gases” means normally aeroform fluid, which have neither shape nor specific volume but tend
to expand indefinitely and which can be changed to the liquid or solid state by the effect of
increased pressure or decreased temperature.

(5) “Fumes” means suspended solid particles, which are generated by condensation from gaseous
state, generally after volatilisations from molten metals.

(6) “Vapor” means gaseous form of substances which are normally in the liquid or solid state, and
which can be changed to these states either by increasing the pressure or decreasing the
temperature.

(7) “Mists” means suspended liquid droplets generated by condensation from the gaseous to the
liquid state or by breaking up of a liquid into a dispersed state, such as by atomizing, foaming
or splashing.

(8) “Fibers” means any tough solid substance composed of thread-like tissue, whether of mineral,
vegetable or animal origin.

(9) “Dust” means solid particles capable of being blown about or suspended in the air generated
by handling, crushing, cutting, drilling, grinding, rapid impact, spraying, detonations,
or disintegration of inorganic or organic materials and are of a composition similar to the
substance or substances from which derived.
 (10) “Toxic” means acting or likely to act as a poison, or may chemically produce injurious or
deadly effect.

(11) ”Irritating” means causing undue sensitiveness of an organ or part of the body.

1093: General Rules

1093.01: Reduction of Hazards

When practicable, harmless substances shall be substituted for hazardous substances or the process
shall be revised to reduce worker exposure to the hazards.

HAZARDOUS MATERIALS

1093.02: Control of Processes

Any one or a combination of the following methods shall be used:

(1) Hazardous processes shall be carried on in separate rooms or building with a minimum number
workers equipped with suitable protective equipment and trained thoroughly in safety prac-
tices for daily operations and for emergencies.

(2) The process or operation shall be carried out in an air-tight enclosure to prevent personal
contact with the harmful substances and the escape of dusts, fibers, fumes, gases, mists, or
vapors into the air or room in which persons work.

(3) Where airtight enclosures or apparatus cannot be used, harmful dusts, fibers, fumes, gases,
mists, or vapors shall be removed at or near their point or origin by means of fume chambers
or suction hoods properly connected to efficient exhaust system, and

(4) Control by general ventilation to provide a continual inflow of fresh air to keep the
concentration of contaminants within safe limits.

1093.03: Use of Personal Protective Equipment

(1) Workers shall be provided with, and shall use personal protective clothing and equipment in
accordance with the requirements of Rule 1080.

(2) Personal protective equipment shall also be used to supplement control methods when such
measures cannot adequately eliminate the hazard or when other measures are not possible.

1093.04: Marking of Containers

All containers with hazardous substances shall be properly labelled. No employer within the scope of
this Rule shall accept any container of hazardous substances for use, handling or storage unless such
container are labelled.

(1) Specific Labelling Requirements: Labels shall contain the following information:

a. symbol of the relevant category of hazard of the substance contained; categories of

hazards shall be explosive, flammable, oxidizing, toxic, corrosive and radioactive;
symbols shall be in accordance with Figure 10 a;
b. trade name may be used in addition to the chemical name of the substance;
c. a description of the principal risk or risks;
d. a statement of the necessary precautions to be taken; and
e. if necessary, a statement of the first-aid or other simple measures to be taken in
case of injury or emergency.

(2) Other Aspects of Labelling

a. Shape of labels - warning labels shall be in rectangular shapes;

b. size of symbols - the height of the danger symbol shall be in relation to the size of
the package or container upon which the label will be placed.
 c. text on the labels shall be adequate in sizes to be clear and legible, and d.
in black on a white background.

(3) Marking of Labels: All required markings shall be either lithographed or press-printed or
engraved upon a paper label securely attached or applied to the outside surface of the con-
tainer. Receptacles of over 18.92 liters (5 gallons) capacity may be marked with letters sten-
cilled, stamped, or uniformly printed not less than 2.54 cm. (1 in.) in height. Marking shall not
be defaced or obliterated by rain or other weather elements.

(4) Responsibility for Labelling: (a). The primary responsibility for the correct labelling of pack of packages
and containers of hazardous substances manufactured locally shall fall upon the manufacturers. For hazardous
substances imported from foreign countries for purposes of distribution and retail to local users, responsibility
for correct labelling of containers shall be the importer, distributor or retailer. (b). When hazardous substances
in a factory undergo a series of distribution or repacking processes over which the manufacturer has no contact,
responsibility for labelling shall fall upon the distributors, wholesalers or retailers. (c). The employer shall be
responsible for labelling hazardous substances for use in his workplace other than those supplied by
manufacturers or distributors; (d). In case of transfer of hazardous substances from original containers to other
containers, the employer shall be responsible for the proper labelling and identification of such substances;
and (e) Unlabelled hazardous substances received by the employer shall be properly labelled and identified by
him

(5) Samples of Labels: The sample labels in Figure 10a shall be used as guide.

(6) Condensing of Labels: Where small containers present a problem in labelling for lack of
adequate space, the following shall be applied:

a. retain the symbol and the name of the product;

b. retain the statement of hazards;
c. consider omission of precautionary measures if they are clearly indicated in the
symbol and in the statement of hazards; and
d. include precautionary measures for any additional hazards, which may be present
because of the characteristic of the container, the nature of its use, and the train-
ing and experience of the user.

1093.05: Testing of Atmosphere

The atmosphere of workrooms shall be tested periodically at such intervals as may be necessary but not
longer than annually, to ensure that the concentration of irritating or toxic dusts, fibers, fumes, gases,
mists or vapors are kept within the threshold limit values specified in Rule 1070.

1093.06: Ventilation and Exhaust Equipment

Ventilation and exhaust equipment shall be inspected and tested periodically for safe and efficient
operational performance.

1093.07: Prevention of Dust Accumulation

(1) All parts of structure or equipment in which harmful dust is liberated shall be designed and
installed so that the surfaces on which dust can accumulate are reduced to a minimum and
shall be frequently cleaned.

(2) In rooms where materials producing flammable dusts are processed, handled and stored;

a. dusts shall be removed daily from floors, equipment and other horizontal surfaces,
preferably by means of appropriate vacuum apparatus; and

b. all fixtures, ledges, projections, bearings, sidewalks, ceilings and other parts shall
be cleaned and freed of dusts at least once a week.

(3) Floors:
Where practicable, floors or rooms in which harmful dust is liberated shall:

a. be smooth, impervious and easy to clean; and

 b. not be covered with loose sheets, metal or other materials under which dust can
accumulate.

093.08: Cleaning

Where toxic and irritating substances are being handled, manufactured or used, the floors, walls,
structural surfaces, work benches, tables and equipment shall be thoroughly cleaned daily by means of
vacuum cleaning, wet brushing or sweeping, outside of working hours.

1093.09: Precautionary Measures for Emergencies

(1) Warning Devices:

In all workplaces where hazardous substances are manufactured, handled or used, suitable
warning device shall be installed wherever possible, to alert the personnel in case of the
liberation of dangerous quantities of said substances.

(2) Training of Personnel:

Workers shall be trained on procedures to control the liberation of hazardous substances,
eliminate pollution, and to evacuate from the affected area in an orderly manner.

1093.10: Working Clothing

All personnel exposed to irritating or toxic substances shall be provided with appropriate protective
clothing including head covering, which shall:

(1) be removed before eating or leaving the premises and kept in places provided for the
purpose;

(2) not be taken out of the factory by the users for any purpose; and

(3) be maintained in good condition and washed or cleaned at least once a week.

1093.11: Spillage

Spillage of irritating or toxic substances shall be removed as quickly as possible by the best technical
and scientific means possible. and available.

1093.12: Instruction on Health Hazards

All workers shall be thoroughly informed of the health hazards connected with their work and the
measures to be taken to protect themselves there from.

1093.13: Meals

The introduction, preparation and consumption of food, drink and tobacco in the workroom shall be
prohibited.

1093.14: Personal Cleanliness

All workers exposed to toxic substances which enter the body through ingestion, shall be required to
wash their faces and hands thoroughly before eating, drinking, smoking or before leaving the premises.

1093.15: Time for Use of Washrooms

A time allowance for the use of the washroom before the meal period and for the use of the shower
bath at the end of the days’ work shall be allotted to each worker employed in the manufacture or
handling of the following:

(1) irritating or toxic dry mineral or organic substances such as arsenic, chrome, lead,
manganese, mercury, phosphorus, zinc and their compounds;
(2) Superphosphates and their compounds;
(3) Dust-producing toxic dyestuffs and pigments;
(4) Dust-producing and coal-tar products such as pitch and soot; and
(5) Radioactive substances.

1093.16: Medical Aid

All workers exposed to irritating or toxic substances shall be required to report promptly any physical
complaints.

1093.17: Exposure Records

The employer shall maintain accurate record of employee exposure to potentially toxic materials which are
required to be measured or monitored. This record shall be open to authorized agents and the workers
exposed to such hazards.

1094: Hot and Corrosive Substances

1094.01: Protection of Structure & Equipment

In all workplaces where corrosive gases, fumes, mists or vapors are generated and liberated, adequate
measures shall be taken to prevent damage to structural parts and factory equipment by corrosion.

1094.02: Handling

(1) Corrosive or hot liquids should be handled in bulk by gravity system or pressure pump system,
extending to the point or points of use so as to eliminate transporting in small container.

(2) Emptying receptacles containing corrosives or hot liquids not provided with drain cock shall be by
pumps, tipping appliances or other suitable apparatus.

(3) Where portable receptacles are used for corrosive liquids, transport inside factories shall be
effected without the escape of fumes or mists and preferably by mechanical means.

(4) Receptacles shall be kept securely closed except during extraction of the contents.

1094.03: Spillage of Acids and Alkalies

(1) Floors in rooms where corrosive liquids are manufactured, handled or used shall be kept as dry as
possible.

(2) Spillage should be avoided. Spilled corrosive liquid shall be guarded until removed to prevent
workers from stepping or getting into contact with it.

(3) Spilled or escaping corrosive acid shall not be absorbed by sawdust, waste cloth or other
organic materials but shall be flushed out with water or neutralized with chalk or lime.

1094.04: Diluting Acids

When diluting acid with water, the acid shall be poured slowly into the water, with constant stirring of the
mixture. Water shall never be poured into acid.

1094.05: Physical Contact With Corrosive Substances

(1) Workers exposed to physical contact with corrosive or hot liquids or to caustic compounds of
calcium, potassium, sodium or their dusts, shall be provided with and shall use protective clothing and
equipment conforming to the requirements of Rule 1080.

HAZARDOUS MATERIALS 43
(2) In workrooms where corrosive liquids are manufactured, handled or used, clean running
water, and quick operating eye fountains and shower baths shall be installed and maintained in or
adjacent to such workrooms readily accessible to all workers.

1095: Storage

1095.01: Vats and Tanks

(1) Vats, pans, and open tanks containing hot corrosive or toxic liquids shall, when the opening
or top is less than 1 m (3.3 ft) above the floor or working level, be either:

a. raised so the top will not be less than 1 m(3.3 ft.) from the floor or working level, or
b. guarded on all sides by enclosures or by standard railings and when the top is less
than 15 cm. (6 in.) above the floor shall be provided with standard toe- boards.

The provisions of a. and b. shall apply to every vat, pan or tank irrespective of the nature of the liquid it
may contain.

(2) Where vats, pans or open tanks containing hot, corrosive or toxic liquids adjoin, the space
shall be fenced.

(3) Vats, pans, or open tanks containing hot, corrosive or toxic liquids shall be provided with
pipes or drains of sufficient capacity to carry off the contents without spilling or their backing up on
the floor.

(4) Above-ground tanks containing hot, corrosive or poisonous liquids shall be:

a. surrounded by pits, catch basins or depressions of sufficient size to hold the

entire contents in case of rupture; and

b. provided with overflow pipes leading to tanks or to safe places outside the building. (5)

Walkways shall not cross over open vats, pans or tanks containing hot, corrosive or toxic
liquids. Where it is necessary to install service walkways for access to agitator drives or
valves or for taking samples, such walkways shall be:

a. not less than 50 cm (20 in.) in width;

b. provided on both sides with standard railings and toeboards; and
c. kept clean and dry at all times.

1095.02: Storage Tanks for Non-Flammable Hazardous Liquids

(1) Tanks used for storage of non-flammable hazardous liquids shall be:

a. located above ground or floor level;

b. supported so that leakage from any part of the tank will be noticeable;
c. surrounded with pits, catch basins or depressions of sufficient size to hold the
entire contents of the largest tank in the event of rupture;
d. covered with protective paint to prevent corrosion from moisture or fumes; and
e. provided with stairways or permanent ladders and platforms, where necessary,
for convenient and safe access to all parts of the tank and with floors or platforms
preferably of metal grating.

(2) Tanks used for storing non-flammable hazardous liquids shall not be placed above
passageways.
44 RULE 1090
(3) Tanks used for storing non-flammable hazardous liquids stored in pits below ground level:

a. the pits shall be of concrete or masonry with sufficient space between the walls
and the tanks to permit the passage of any person at any point; and

b. the tanks shall be mounted 38 to 45 cm. (15 to 18 in.) above the bottom of the pit.

(4) Pits containing sunken tanks used for storing non-flammable hazardous liquids shall be
provided with covers and fixed ladders for safe access.

(5) All control-valves for sunken tanks used for storing non-flammable hazardous liquids shall be: a.

situated or of such design that they can be turned without any person entering the pit; and b. provided

with locking devices operated from the outlets of the pit.

(6) Workers entering storage tanks and pits containing hazardous liquids shall be provided with
personal protective clothing and equipment conforming to the requirements of Rule 1080.

(7) Tanks used for storing corrosive or caustic liquids shall be provided with:

a. a permanent open wet pipe not less than 5 cm. (2 in.) in diameter at the highest
point in the tank; and

b. a drain connection at the lowest point in the tank discharging into a safe place.

(8) Tanks used for storing corrosive or caustic liquids shall have the filling connections at the
top and the discharge pipes 15 cm. (6 in.) above the bottom.

1095.03:

Drums containing acids shall be stored in cool places with the bung up. They shall be carefully opened
each time the drum has been moved or once a week if stored for a period of time to relieve any
internal pressure and subsequently sealed again.

1095.04: Carboys for Acids

(1) Carboys containing acids shall be encased singly in baskets or in boxes cushioned with
noncombustible packing material.

(2) Carboys containing acids shall be stored in separate store rooms or buildings with concrete
floors having anti-acid protection or with brick floors properly drained to catch basins, dry and
protected from dampness, extreme heat or sudden change in temperature.

(3) Carboys containing acids shall not be piled one on top of another but should be placed in
suitable storage racks or on wooden strips laid on the floor.

(4) Special handling equipment such as two-wheeled carboy trucks shall be provided for trans-
porting carboys containing acids to and from storage.

(5) Adequate equipment shall be provided and used for the emptying of carboys.

(6) Empty acid carboys shall be stored apart from filled carboys.

(7) Empty carboys shall be thoroughly washed out by turning them upside down over and up-
ward with stream of water and drained before they are stored.

(8) Carboys together with their baskets or boxes shall be examined as to their condition before
they are filled with acid.

HAZARDOUS MATERIALS 45
1096: Use of Lead and Its Compounds

1096.01: Definitions

“Lead Compounds” means any organic or inorganic derivatives of lead.

1096.02: Control Measures

(1) A substitute substance or agent less injurious or harmful shall be used instead of lead such
as zinc oxide or titanium oxide instead of white lead in paint manufacture.

(2) Processes involving the use of lead and its compounds shall be enclosed and mechanical
handling methods should be used or employed.

1096.03: Storage and Handling

Stocks of lead materials shall be kept in special storage rooms outside the workrooms. Workrooms in which
lead materials are handled shall be located in relation to other parts of the shop of factory in as small an
area as possible to confine the lead and to concentrate control measures in that area.

1096.04: Local Exhaust System

Properly designed exhaust systems, capable of carrying or drawing of air contaminants to maintain or
control the threshold limit value of lead in the atmosphere, shall be provided for all processes which
generate lead, fumes or dusts. The contaminants removed shall not be allowed to re-enter the workrooms or
to pollute other parts of the workplace or the surrounding areas.

1096.05: Personal Protective Equipment

Appropriate protective equipment and clothing such as overalls, head covering, goggles, gloves, aprons and
respirators shall be issued free of charge to lead workers by the employer who shall see to their proper use
and maintenance.

1096.06: Smoking or Eating

Smoking, chewing, eating and the keeping of food in workrooms where lead or its compounds are used and
handled shall not be allowed.

1096.07: Storage Lockers

Suitable storage lockers for street and work-clothes shall be issued to each worker exposed to lead and its
compounds. Adequate washing facilities shall be provided.

1096.08: Physical Examination

Workers exposed to lead shall be subjected to periodic physical examination and laboratory examination at
intervals of not more than six (6) months and where the degree of contamination rises above the threshold
limit value, such physical examination shall be conducted at least once every three (3) months and a record of
such examinations shall be open to authorized agents and to the exposed workers.

RULE 1100
GAS AND ELECTRIC WELDING AND CUTTING OPERATIONS

1100.01: General Provisions

(1) Welding or cutting operations shall not be permitted in rooms or areas containing combusrible
materials or in proximity to explosives or flammable liquids, dusts, gases or vapors, until
all fire and explosion hazards are eliminated.

(2) Welding or cutting operations on containers filled with explosives or flammable substance is
prohibited. Welding closed containers that have held explosive or flammable substance shall
 only be undertaken after the containers have been thoroughly cleaned and found com- pletely
free of combustible gases or vapors or the containers are filled with inert gas or with water.

(3) Welding and cutting operations carried out or done in places where persons other than the
welders work or pass shall be enclosed by means of suitable stationary or portable screens.
Screens shall be opaque, of sturdy construction to withstand rough usage of a material which
will not readily be set on fire by sparks or hot metal, at least 2 m. (6.5 ft.) high, and preferably
painted with light flat paint.

(4) A portable fire extinguisher shall be provided at the place where welding and cutting operations
are being undertaken.

(5) Authorization, before welding and cutting operations are allowed in large establishments, the
area shall be inspected by the safetyman. He shall issue a written permit or authorization for
welding and cutting, indicating therein the precautions to be followed to avoid fire or
accidents.

1100.02: Personal Protective Equipment

(1) All workers or persons directly engaged in welding or cutting operations shall be provided with
the following personal protective equipment:

a. goggles, helmets or head shields fitted with suitable filter lenses and hand shields; and

b. suitable aprons.

(2) all persons directly assisting in welding or cutting operations shall be provided with gloves,
goggles or other protective clothings, as may be necessary.

1100.03: Welding or Cutting in Confined Spaces

The inhalation of any fumes, gases or dusts by persons welding or cutting in confined spaces shall
be prevented by the provision of:

(1) Local exhaust and general ventilation system to keep fumes, gases or dusts within allowable
concentrations or threshold limit values;

(2) Approved types of respiratory protective equipment.

CONDITION:

The students/ trainee should be provided with:

 Safety sign and symbols

 Instructional materials
- Reference book
- Learning modules/manuals
- Safety standards manual
- Enterprise safety policies/guidelines

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion
ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
LO2. USE PERSONAL PROTECTIVE CLOTHING AND DEVICES

ASSESSMENT CRITERIA:

1. Personal protective clothing/equipment (PPE) identified as per job

requirements
2. Proper wearing of PPE are properly observed in accordance with
workplace safety policies.
3. PPE conformed with the approved occupational safety standards.

CONTENTS:

PERSONAL PROTECTIVE EQUIPMENT (PPE) FOR DIFFERENT WELDING

OPERATIONS

Personnel Protective Equipment (PPE)

Welding Cap

height=”300″

A welder’s cap should be worn to protect the head from hot metal and slag splatter.
In addition, long hair should be tied back and tucked inside the welding jacket.
Baseball caps that are made of cotton are allowed. Hats that are mainly polyester or
have significant plastic content are not allowed.Recommended: Cotton welding
caps or cotton doo-rags.
Eye protection

height=”166″ Safety glasses for use over glasses

height=”166″ Safety glasses

Approved eye protection must be worn at all times while in the lab. This can be
safety glasses or goggles. Eye protection must fit properly, and be in good condition.
It must be properly worn, protecting the user’s eyes at all times. Mirrored or heavily
colored lenses do not protect the eyes and are not approved for use in the welding
laboratory. Eye protection must meet American National Standards Institute
standards: ANSI Z87.1-1989, blocking 99% UVA and 60% UVB

.Recommended: Clear ANSI 87.1 compliant safety glasses made of

polycarbonate. Prescription glasses must be covered by safety glasses,
prescription safety glasses with side shields are recommended.
Hearing Protection

Silicon ear plugs with string attachment and case

There are many noise-generating devices in the welding laboratory that can damage
your hearing, and there are circumstances in which debris can penetrate the ear
canal. Earplugs are required to protect your ears from both loud noises and foreign
object damage. Ear muffles can be worn to provide even greater noise reduction.

Recommended: Washable Silicon earplugs on a string.

Gloves
 

Leather welding gloves are required to protect the hands while welding. They should
match the welding process that you are performing. Thick leather welding gloves are
recommended for SMAW and FCAW. High-temperature welding gloves are
recommended for FCAW. Medium-weight welding gloves are recommended for
GMAW. Thinner welding gloves that allow increased dexterity are recommended for
GTAW and OAW. Gloves should not be used where the glove can get caught in
rotating machinery, especially pedestal grinders.

Recommended: Weld 205 Introductory Course: Medium weight GMAW (MIG)

gloves, such as Black Stallion Mighty MIG or Miller MIG glove.

Recommended: Weld 203A-D GTAW (TIG) classes: GTAW (TIG) gloves.

Recommended: Weld 204A-D SMAW (Arc weld or STICK) classes: Medium

weight GMAW (MIG) gloves, such as Black Stallion Mighty MIG or Miller MIG
glove.

Recommended: Weld 211A-D Wire Feed classes: Medium weight GMAW (MIG)
gloves, such as Black Stallion Mighty MIG or Miller MIG glove.
Recommended: Weld 221A-D OAW (Oxygen-Acetylene or gas welding)
classes: Medium weight GMAW (MIG) gloves, such as Black Stallion Mighty
MIG or Miller MIG glove.

Breathing Protection

There are many fumes and gases produced from welding and associated processes.
It is highly recommended that a filter mask or a ½-mask respirator be worn for
welding and grinding. FCAW, SMAW and grinding are processes that produce fumes
and particulates.Nuisance filter masks, type N95 with charcoal, are recommended as
minimum protection. The N95 filters 95% of particles 0.3 micrometers (µm) and
larger, while the charcoal filter reduces ozone (O3) created in the weld process.

For heavy particulate generation and harmful materials (for example, chromium 6+),
a ½-mask respirator with P100 filter with charcoal filter is highly recommended. A
P100 filters 100% of particles 0.3 micrometers (µm) and larger. P100’s are also
called high efficiency particulate absorbing (HEPA) filters. As with the N95’s, the
charcoal filter reduces ozone (O3).

Highly recommended: half-mask Respirator with a P100 filter and charcoal

filter (for example, 3M part number 2097).

Recommended: N95 or N100 mask.

NOTE: if you have respiratory health issues you should consult with your doctor first
before use and read the manufacture instructions regarding use.
Clothing
 

Proper clothing can provide a great amount of protection. Welding students are
required to wear natural fiber materials, such as cotton or wool. Long sleeved shirts
and long pants are also required. A welding jacket is highly recommended.

Items that are not allowed include fleece jackets or pants (polyester fibers) or
pantyhose (nylon). Pants should not have cuffs that can catch sparks or hot slag.
Sagging is not allowed for the same reason. Frayed clothes or clothes that have
holes are not allowed.
Recommended: Natural fiber such as cotton or leather. For FCAW and SMAW
processes, leather or welding-approved jacket is highly recommended.
Leather chaps that cover the legs are also encouraged.

Shoes

Proper shoes will protect your feet from hot sparks or falling objects. Here are some
guidelines for buying protective footwear. The protective footwear you choose should
comply with the American Society for Testing and Materials (ASTM) standard F2413-
05, which separates safety footwear into different categories such as Impact and
Compression Resistance.Impact and compression resistant footwear is constructed
with a toe-cap to protect your foot from falling objects that could crush or break your
toes. The new ASTM F2413-05 standard does not approve of “strap-on” toe-caps.
Any protective toe-cap must be designed and constructed into the shoe during the
manufacturing process and tested as an integral part of the footwear in order to
protect feet.
The ASTM F2413 standard has two classifications for compression ratings. A rating
of 75 has been tested to withstand compressive 2,500 lbs and a rating of 50
withstands loads up to 1,750 lbs. before the toe-cap will start to crush or crack.

Also, safety toe shoes/boots are tested to meet one of two units of measurement for
impact rating i.e.75 or 50 foot-pounds. A foot-pound is determined through a test,
which is performed by dropping a steel weight from a predetermined height at a
designated speed. For example, I/75 rated shoes/boots will protect a worker from an
impact of 75 foot-pounds.

You can determine if your footwear complies with the ASTM F2413-05 standard by
looking for this type of information on the label.

ASTMF2413-05 or M/I/75/C/75

ASTM F2413-05: The letters F2413 reference the performance requirement for foot
protection. The additional digits following the standard designation indicate the year
of the standard to which the protective footwear complies, for example: 05 refers to
2005.
M = Footwear designed for a male.
F = Footwear designed for a female.
I/75 = Impact rating of 75 (foot pounds)
C/75 = Compression rating of 75 (2500 lbs. of pressure)

Recommended: Closed-toed shoes are required. Leather shoes are

recommended. Leather high top work boots or metal-toe safety shoes are
highly recommended.

Welding Helmet
 

A limited number of welding helmets are provided for use in the laboratory. SMAW,
FCAW, GMAW, GTAW and plasma cutting require a welding helmet with a welding
approved shaded lens. The amperage used during the welding process determines
the lens shade. See Table 1 for recommendations as specified by the ANSI Z49.1

Recommended: students are encouraged to wait to buy a helmet. Because

there is such a large range of helmet types and prices the choice is highly
dependent on the welding process(es), frequency, environment and fit.
 Personnel Protective Equipment (PPE)
WELDING TECHNOLOGY
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 Used properly, Personnel Protective Equipment
(PPE) greatly reduces the risk of injury and minimizes the effects of toxins.
PPE is required in the Laney College welding lab. If you do not wear
approved PPE, you will not be allowed in the lab.
You are required to provide your own PPE for the lab. The following table
lists PPE that is required (indicated with an “R”) and optional (indicated with
an “O”). A description of each item is listed below, along with
recommendations.

OAW GogglesOOOOO

Weld Weld Weld Weld

Course Number Weld 205
203A-D 204A-D 211A-D 221A-D
Course Title Introduction GTAW SMAW GMAW OAW
to (TIG or (Arc or (Wirefeed (Oxy-
Welding Heli-Arc) Stick) or MIG) Acetylene)
Welding cap R R R R R
Safety glasses R R R R R
Earplugs R R R R R
Gloves R R R R R
Respirator or Dust
R R R R R
mask
Jacket (long sleeved,
R R R R R
high collar shirt)
Long pants, no
R R R R R
sagging
Close-toed leather R R R R R
shoes
Welding helmet O O O O O
Face shield O O O O O
 

Welding Cap

height=”300″

A welder’s cap should be worn to protect the head from hot metal and slag
splatter. In addition, long hair should be tied back and tucked inside the
welding jacket. Baseball caps that are made of cotton are allowed. Hats that
are mainly polyester or have significant plastic content are not
allowed.Recommended: Cotton welding caps or cotton doo-rags.

 
Eye protection

height=”166″ Safety glasses for use over glasses

height=”166″ Safety glasses

Approved eye protection must be worn at all times while in the lab. This can
be safety glasses or goggles. Eye protection must fit properly, and be in good
condition. It must be properly worn, protecting the user’s eyes at all times.
Mirrored or heavily colored lenses do not protect the eyes and are not
approved for use in the welding laboratory. Eye protection must meet
American National Standards Institute standards: ANSI Z87.1-1989, blocking
99% UVA and 60% UVB.Recommended: Clear ANSI 87.1 compliant
safety glasses made of polycarbonate. Prescription glasses must be
covered by safety glasses, prescription safety glasses with side shields
are recommended.

 
Hearing Protection

Silicon ear plugs with string attachment and case

There are many noise-generating devices in the welding laboratory that can
damage your hearing, and there are circumstances in which debris can
penetrate the ear canal. Earplugs are required to protect your ears from both
loud noises and foreign object damage. Ear muffles can be worn to provide
even greater noise reduction.Recommended: Washable Silicon earplugs
on a string.

 
Gloves
 

Leather welding gloves are required to protect the hands while welding. They
should match the welding process that you are performing. Thick leather
welding gloves are recommended for SMAW and FCAW. High-temperature
welding gloves are recommended for FCAW. Medium-weight welding gloves
are recommended for GMAW. Thinner welding gloves that allow increased
dexterity are recommended for GTAW and OAW. Gloves should not be used
where the glove can get caught in rotating machinery, especially pedestal
grinders.

Recommended: Weld 205 Introductory Course: Medium weight GMAW

(MIG) gloves, such as Black Stallion Mighty MIG or Miller MIG glove.

Recommended: Weld 203A-D GTAW (TIG) classes: GTAW (TIG) gloves.

Recommended: Weld 204A-D SMAW (Arc weld or STICK) classes:

Medium weight GMAW (MIG) gloves, such as Black Stallion Mighty MIG
or Miller MIG glove.

Recommended: Weld 211A-D Wire Feed classes: Medium weight GMAW

(MIG) gloves, such as Black Stallion Mighty MIG or Miller MIG glove.

Recommended: Weld 221A-D OAW (Oxygen-Acetylene or gas welding)

classes: Medium weight GMAW (MIG) gloves, such as Black Stallion
Mighty MIG or Miller MIG glove.

Heavy weight glove for SMAW or FCAW

Medium weight welding glove for OAW, GMAW or SMAW

Tig gloves

 
Breathing Protection

There are many fumes and gases produced from welding and associated
processes. It is highly recommended that a filter mask or a ½-mask respirator
be worn for welding and grinding. FCAW, SMAW and grinding are processes
that produce fumes and particulates.Nuisance filter masks, type N95 with
charcoal, are recommended as minimum protection. The N95 filters 95% of
particles 0.3 micrometers (µm) and larger, while the charcoal filter reduces
ozone (O3) created in the weld process.

For heavy particulate generation and harmful materials (for example,

chromium 6+), a ½-mask respirator with P100 filter with charcoal filter is
highly recommended. A P100 filters 100% of particles 0.3 micrometers (µm)
and larger. P100’s are also called high efficiency particulate absorbing
(HEPA) filters. As with the N95’s, the charcoal filter reduces ozone (O3).

Highly recommended: half-mask Respirator with a P100 filter and

charcoal filter (for example, 3M part number 2097).

Recommended: N95 or N100 mask.

NOTE: if you have respiratory health issues you should consult with your
doctor first before use and read the manufacture instructions regarding use.
Half mask respirator

N95 or N100 mask

 
P100 particulate filter with charcoal

 
Clothing
 

Protective Clothing

Protective Clothing includes welding gloves, coat, sleeves, and leg protection
Personnel exposed to the hazards created by welding, cutting, or
brazing operations shall be protected by personal protective equipment
in accordance with OSHA standards, Subpart I, Personal Protective
Equipment, paragraph 1910.132.

The appropriate protective clothing required for any welding operation

will vary with the size, nature, and location of the work to be performed.

Welders should wear work or shop clothes without openings or gaps to

prevent arc rays from contacting the skin.

Those working close to arc welding should also wear protective

clothing. Clothing should always be kept dry, including gloves.

Woolen clothing should be worn instead of cotton since wool is not

easily burned or damaged by weld spatter and helps to protect the
welder from changes in temperature.

Cotton clothing, if used, should be chemically treated to reduce its

combustibility.

All other clothing, such as jumpers or overalls, should be reasonably

free from oil or grease.

Flameproof aprons or welding jackets made of leather, fire-resistant

material, or other suitable material should be worn for protection
against spatter of molten metal, radiated heat, and sparks.
Capes or shoulder covers made of leather or other suitable materials
should be worn during overhead welding or cutting operations.

Leather skull caps may be worn under helmets to prevent head burns.

Sparks may lodge in rolled-up sleeves, pockets of clothing, or cuffs of

overalls and trousers. Therefore, sleeves and collars should be kept
buttoned and pockets should be eliminated from the front of overalls
and aprons. Alternatively, you should invest in a good pair of welding
sleeves to make sure you are properly protected.
Trousers and overalls should not be turned up on the outside. For
heavy work, fire-resistant leggings, high boots, or other equivalent
means should be used.

In production work welding safety, a sheet metal screen in front of the

worker´s legs can provide further protection against sparks and molten
metal in cutting operations.

Recommended: Natural fiber such as cotton or leather. For FCAW and

SMAW processes, leather or welding-approved jacket is highly
recommended. Leather chaps that cover the legs are also encouraged.

 
Shoes

Proper shoes will protect your feet from hot sparks or falling objects. Here are
some guidelines for buying protective footwear. The protective footwear you
choose should comply with the American Society for Testing and Materials
(ASTM) standard F2413-05, which separates safety footwear into different
categories such as Impact and Compression Resistance.Impact and
compression resistant footwear is constructed with a toe-cap to protect your
foot from falling objects that could crush or break your toes. The new ASTM
F2413-05 standard does not approve of “strap-on” toe-caps. Any protective
toe-cap must be designed and constructed into the shoe during the
manufacturing process and tested as an integral part of the footwear in order
to protect feet.
The ASTM F2413 standard has two classifications for compression ratings. A
rating of 75 has been tested to withstand compressive 2,500 lbs and a rating
of 50 withstands loads up to 1,750 lbs. before the toe-cap will start to crush
or crack.

Also, safety toe shoes/boots are tested to meet one of two units of
measurement for impact rating i.e.75 or 50 foot-pounds. A foot-pound is
determined through a test, which is performed by dropping a steel weight
from a predetermined height at a designated speed. For example, I/75 rated
shoes/boots will protect a worker from an impact of 75 foot-pounds.

You can determine if your footwear complies with the ASTM F2413-05
standard by looking for this type of information on the label.

ASTMF2413-05 or M/I/75/C/75

ASTM F2413-05: The letters F2413 reference the performance requirement

for foot protection. The additional digits following the standard designation
indicate the year of the standard to which the protective footwear complies,
for example: 05 refers to 2005.

M = Footwear designed for a male.

F = Footwear designed for a female.
I/75 = Impact rating of 75 (foot pounds)
C/75 = Compression rating of 75 (2500 lbs. of pressure)

Recommended: Closed-toed shoes are required. Leather shoes are

recommended. Leather high top work boots or metal-toe safety shoes
are highly recommended.

 
Welding Helmet
 

A limited number of welding helmets are provided for use in the laboratory.
SMAW, FCAW, GMAW, GTAW and plasma cutting require a welding helmet
with a welding approved shaded lens. The amperage used during the
welding process determines the lens shade. See Table 1 for
recommendations as specified by the ANSI Z49.1

Recommended: students are encouraged to wait to buy a helmet.

Because there is such a large range of helmet types and prices the
choice is highly dependent on the welding process(es), frequency,
environment and fit.
 

Guide for shade numbers

 

Electrode
size Minimum Suggested
Arc
Operation in protective shade
current
1/32in. shade (comfort)
(mm)
SMAW Less than 3 Less than 7 –
(2.5) 60
3-5 (2.5-4) 60-160 8 10
5-8 (4-6.4) 160-250 10 12
More than 250-550 11 14
8 (6.4)
Less than
GMAW / FCAW 7 –
60
60-160 10 11
160-250 10 12
250-550 10 14
Less than
GTAW 8 10
50
50-150 8 12
150-500 10 14
 Less than
Air Carbon / Arc Cutting Light 10 12
500
Heavy 500-1000 11 14
Less than
Plasma arc welding 6 6 to 8
20
20-100 8 10
100-400 10 12
400-800 11 14
Less than
Plasma arc cutting Light 8 9
300
Medium 300-400 9 12
Heavy 40-800 10 14
Torch brazing 3 or 4
Torch soldering 2
Carbon arc welding 14
 

Face shields

Additional eye protection is required over safety glasses for certain tasks. For
processes that will produce high velocity particles, a full-face shield is required. A
face shield is required for using portable grinders, pedestal grinders, abrasive cut-off
saws, and sanders.
Goggles

Oxy-Fuel welding and cutting requires welding goggles. Goggles protect the eyes
from the intense light and IR (infrared) from the flame. Goggles should have
minimum shade number of 5.

https://laney.edu/welding/ppe/
https://weldguru.com/welding-safety/

CONDITION:

The students/ trainee should be provided with:

 Personal protective equipment (PPE)

- Hard hat
- Safety shoes
- Gloves
- Goggles
- Welder apron

 Instructional materials for:

- Reference book
- Learning modules/manuals
- Safety standards
- Enterprise safety policies/guidelines

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
  Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview

LO3. PERFORM SAFE HANDLING OF TOOLS, EQUIPMENT AND MATERIALS

ASSESSMENT CRITERIA:

1. Pre-use checking and inspection of tools and equipment are conducted in

accordance with industry/ company policies.
2. Safe handling of tools, equipment and materials are properly observed in
accordance with OHS requirements and industry/ company policies.
3. Safety label and tag of tools and equipment are strictly followed in
accordance with industry/ company policies.

CONTENTS:
SAFE HANDLING OF TOOLS, EQUIPMENT AND MATERIALS
EQUIPMENT AND POWER TOOLS ORIENTATION AND
FAMILIARIZATION

PRE-USE INSPECTION AND CHECKING PROCEDURE

Welding Machine
Pre-Start Checklist
Adopting best-practice welding safety procedures is of paramount importance. Incorrect welding practice
can
result in serious injury, including the risk of electric shock, overexposure to fumes and gases, arc
radiation,
fire and explosion. There’s a lot to be aware of to ensure compliance with the various safety practices
outlined
by the relevant Australian and New Zealand Standards. However, with due diligence, it’s possible to weld
with
complete safety, along with optimal efficiency.
Before starting any welding
operation, a complete inspection of
all welding machines and equipment
should be undertaken. All it takes
on the part of the welder is five to
ten minutes before turning on any
machinery—it doesn’t take much to
prevent injury to yourself or to your
co-workers.
This daily inspection and pre-start
checklist contains guidelines on how
to inspect your welding machinery,
as well as the details of the particular
Australian Standard that supports
the practice.
Recommended Welding Machine
Daily Inspection and Pre-Start
Check List
Power Supply
Disconnect and isolate the power
supply to the welding machine prior
to performing these pre-start checks.
Mains Supply Socket & Switch
(AS/NZS3000)
Inspect for any obvious damage
and defects to the switch or socket.
Ensure that the correct size plug is
fitted to the welding machine for the
rated current and duty cycle of the
welding machine.
Plug & Primary Cable Supply to
the Welding Machine
(AS/NZS3100)
Check that the power supply cable is
of the correct rating for the welding
machine, and for any damage to the
plug. Special attention should be
given to any cuts, burns, abrasions,
fraying, or other damage to the
cable insulation, which may result in
exposed live wires.
Ensure the mains supply cable is
located away from welding cables
and connections, and that the
cable is securely anchored onto the
welding machine and plug.
Welding Machine
(AS1966 and AS3195)
Inspect the exterior of the welding
machine for any obvious damage
to the cabinet, power switches,
indicator lights or controls.

Welding Cable Connections

(AS1674.2)
Ensure that the welding cable
connections to the welding machine
are in good condition, and contact
surfaces are clean and properly
tightened. If terminal posts are used,
ensure only brass washers and the
correct insulated type brass nut are
used. Any unused terminal posts
should have an insulated brass nut
in place. Ensure that all connections
are fully insulated and cables are
firmly anchored to fittings.
For a.c. welding machines, check
that electrode and work return
cables are correctly connected to
the welding machine. For d.c. welding machines, check
the polarity and ensure electrode and work cables are
correctly connected for the procedure in use and that any
other d.c. welding machines in the vicinity are connected
with the same polarity.
Welding Cables (Electrode and Work Return Cables)
(AS1995 and AS1674.2)
Examine all cables (leads) for damage, including cuts or
abrasions, burns, damaged insulation, frayed wires, or
any other damage that may expose live wires. Electrode
and work return cables should be of similar length and
of the same current carrying capacity. Additionally, they
should be rated for the maximum current rating and duty
cycle of the welding activity. Building steelwork shall not
be used as a work return path.
Welding Cable Extension Connections
(AS1674.2)
Check that both the male and female connections are
fully insulated with clean contact surfaces, and that all
fittings are tightened properly, and that there are no
exposed conductors.
Welding Hand Pieces
(AS2826)
Check that the welding hand piece is fully insulated and
in good condition. The hand piece must be rated for the
maximum current rating and duty cycle of the welding
activity. Cracked or damaged hand pieces shall be
taken out of service immediately.
Work Return Clamp
(AS1674.2)
Check that the work return clamp or connection is
securely connected to the work return cable and the
job close to the welding activity.
Engine Drive Welding Machines
Check that all exhaust fume emissions are dispersed
away from the work area and any other personnel
working in the immediate vicinity. Do not use in an
enclosed area or building.
Voltage Reduction Device (VRD)
(AS1674.2)
If a voltage reduction device (VRD) is used, ensure
that the indicator lights or voltmeter are functioning
and indicating low voltage. Green indicates safe.
High welding voltage is unsafe, and indicated by a
flashing green or red signal when the welding machine
is operated in a normal welding cycle. This check is
performed with the power switched on.
Electrical Inspection Tag
Check that a current electrical inspection tag,
traceable to your equipment maintenance register, is
attached to the welding machine.
Notes
1. If on completion of this pre-start checklist you are
unsure of the safety of any part of this equipment,
do not use it. Isolate the equipment and notify
your supervisor immediately, in order for remedial
action to be taken.
2. Fumes are generated by hot work. Take adequate
precautions to limit exposure to fumes from
welding consumables or surface coatings and
contaminants.
3. Ensure that you have all necessary Personal
Protective Equipment in place, dry, and in good
order, before turning on the welding power source.

Welding Inspection Procedure / Checklist

This article provides you a general welding inspection proceduer.
 Stage 1 -  Welding Inspection Prior to Welding
Work 

1. Welding symbols and weld sizes clearly specified in drawing and related
documents.
2. Weld joint designs and dimensions clearly specified in drawings and related
documents.
3. Weld maps identify the welding procedure specification (WPS) to be used for
specific weld joints.
4. Dimensions detailed and potential for distortion addressed.
5. Welding consumables specified.
6. Proper handling of consumables, if any, identified.
7. Base material requirements specified (such as the use of impact tested
materials where notch ductility is a requirement in low temperature service).
8. Mechanical properties and required testing identified.
9. Weather protection and wind break requirements defined.
10. Preheat requirements and acceptable preheat methods defined.
11. Post-weld heat treatment (PWHT) requirements and acceptable PWHT
method defined.
12. Inspection hold-points and NDE requirements defined.
13. Additional requirements, such as production weld coupons, clearly specified.
14. Pressure testing requirements, if any, clearly specified
15. Competency of welding organization to perform welding activities in
accordance with codes, standards, and specifications specified
16. Roles and responsibilities of engineers, welding organization, and welding
inspectors defined and appropriate for the work.
17. Independence of the inspection organization from the production organization
is clear and demonstrated.
18. WPS(s) are properly qualified and meet applicable codes, standards and
specifications for the work.
19. Procedure qualification records (PQR) are properly performed and support the
WPS(s).
20. Welder performance qualifications (WPQ) meet requirements for the WPS.
21. NDE examiners are properly certified for the NDE technique.
22. NDE procedures are current and accurate.
23. Calibration of NDE equipment is current.
24. Welding machine calibration is current
25. Instruments such as ammeters, voltmeters, contact pyrometers, have current
calibrations.
26. Storage ovens for welding consumables operate with automatic heat control
and visible temperature indication.
27. Heat treatment procedure is available and appropriate
28. Pressure testing procedures are available and detail test requirements.
29. PWHT equipment calibration is current.
30. Pressure testing equipment and gauges calibrated and meet appropriate test
requirements.
31. Material test certifications are available and items properly marked (including
back-up ring if used ;).
32. Electrode marking, bare wire flag tags, identification on spools of wire, etc. as-
specified.
33. Filler material markings are traceable to a filler material certification.
34. Base metal markings are traceable to a material certification.
35. Recording of filler and base metal traceability information is performed.
36. Base metal stampings are low stress and not detrimental to the component.
37. Paint striping color code is correct for the material of construction.
38. PMI records supplement the material traceability and confirm the material of
construction.
39. Weld preparation surfaces are free of contaminants and base metal defects
such as laminations and cracks.
40. Preheat, if required, applied for thermal cutting c. Hydrogen bake-out heat
treatment, if required, performed to procedure.
41. Weld joint is free from oxide and sulfide scales, hydrocarbon residue, and any
excessive build-up of weld-through primers.
42. Weld joint type, bevel angle, root face and root opening are correct.
43. Alignment and mismatch is correct and acceptable.
44. Dimensions of base materials, filler metal, and weld joint are correct.
45. Piping socket welds have proper gap.
46. Preheat equipment and technique are acceptable.
47. Preheat coverage and temperature are correct.
48. Reheat, if required, applied to thermal cutting operations.  
49. Preheat, if required, applied to remove moisture
50. Filler metal type and size are correct per procedure.
51. Filler metals are being properly handled and stored.
52. Filler metals are clean and free of contaminants.
53. Coating on coated electrodes is neither damaged nor wet.
54. Flux is appropriate for the welding process and being properly handled.
55. Inert gases, if required are appropriate for shielding and purging.
56. Gas composition is correct and meets any purity requirements.
57. Shielding gas and purging manifold systems are periodically bled to prevent
back filling with air.
Stage 2 - Welding Inspection During Welding
1. Welder is responsible for quality craftsmanship of weldments
2. Welder meets qualification requirements
3. Welder understands welding procedure and requirements for the work.
4. Special training and mock-up weldments performed if required.
5. Welder understands the inspection hold-points.
6. Essential variables are being met during welding.
7. Filler material, fluxes, and inert gas composition/flow rate.
8. Purge technique, flow rate, O2 analysis, etc.
9. Rod warmers energized or where rod warmers are not employed, the welder
complies with maximum exposure times out of the electrode oven.
10. Preheating during tack welding and tack welds removed (if required).
11. Welding technique, weld progression, bead overlap, etc.
12. Equipment settings such as amps, volts, and wire feed.
13. Preheat and interpass temperatures.
14. Travel speed (key element in heat input).
15. Heat input (where appropriate).
16. Mock-up weldment, if required, meets requirements with welder and welding
engineer.
17. Welder displays confidence and adheres to good welding practices. 
18. Tack welds to be incorporated in the weld are of acceptable quality.
19. Weld root has adequate penetration and quality.
20. Cleaning between weld passes and of any back-gouged surfaces is
acceptable.
21. Additional NDE performed between weld passes and on back-gouged
surfaces shows acceptable results.
22. In-process rework and defect removal is accomplished.
23. In-process ferrite measurement, if required, is performed and recorded.
24. Final weld reinforcement and fillet weld size meets work specifications and
drawings.

Stage 3 - Welding Inspection Upon Completion Of

Welding
1. Size, length and location of all welds conform to the drawings / specifications /
Code.
2. No welds added without approval.
3. Dimensional and visual checks of the weld don’t identify welding
discontinuities, excessive distortion and poor workmanship.
4. Temporary attachments and attachment welds removed and blended with
base metal.
5. Discontinuities reviewed against acceptance criteria for defect classification.
6. PMI of the weld, if required and examiner’s findings indicate they comply with
the specification.
7. Welder stamping/marking of welds confirmed.
8. Perform field hardness check.
9. Verify NDE is performed at selected locations and review examiner’s findings.
10. Specified locations examined.
11. Specified frequency of examination.
12. NDE performed after final PWHT.
13. Work of each welder included in random examination techniques.
14. RT film quality, IQI placement, IQI visibility, etc. complies with standards.
15. Inspector is in agreement with examiners interpretations and findings.
16. Documentation for all NDE correctly executed
17. Verify post-weld heat treatment is performed to the procedure and produces
acceptable results.
18. Paint marking and other detrimental contamination removed.
19. Temporary attachments removed.
20. Machined surfaces protected from oxidation.
21. Equipment internals, such as valve internals, removed to prevent damage.
22. Equipment supported to prevent distortion.
23. Thermocouples fastened properly.
24. Thermocouples adequately monitor the different temperature zones and
thickest/thinnest parts in the fabrication.
25. Temperature monitoring system calibrated.
26. Local heating bandwidth is adequate.
27. Insulation applied to the component where required for local heating.
28. Temperature and hold time is correct.
29. Heating rate and cooling rate is correct.
30. Distortion is acceptable after completion of the thermal cycle.
31. Hardness indicates an acceptable heat treatment 
32. Verify pressure test is performed to the procedure 
33. Pressure meets test specification.
34. Test duration is as-specified.
35. Metal temperature of component meets minimum and maximum
requirements.
36. Pressure drop or decay is acceptable per procedure.
37. Visual examination does not reveal defects.
38. Perform a final audit of the inspection dossier to identify inaccuracies and
incomplete information.
39. All verifications in the quality plan were properly executed.
40. Inspection reports are complete, accepted and signed by responsible parties.
41. Inspection reports, NDE examiners interpretations and findings are accurate.
We as welding inspection company utilize many instruction, procedures, welding
inspection forms to check above point precisely that refer to inspection after welding
process.

Welding Inspection @ ASME Section IX

Here are some important points in the ASME Section IX that are necessary to be
taken in account for any welding inspection company that conducts welding
inspection on fix equipment, process and power piping and above ground storage
tank.

1. A WPS is a written document that provides direction to the welder or welding

operator for making production weld in accordance code requirement. It must
be check by welding inspection company.
2. The PQR documents what occurred during welding the test coupon and the
result of testing of the coupon. It must be checked by welding inspection
company.
3. Procedure qualifications give suitability of weld for required mechanical
properties (i.e., strength, ductility), while performance qualifications show the
ability of the welder to deposit sound weld. This must be checked by welding
inspection company. 
4. Each manufacturer or contractor shall maintain a record of the result obtained
in welding procedure and welder/operator performance qualifications. The
records shall be certified by manufacturer or contractor and accessible to the
authorized inspector
5. Tension test gives tensile value, while bend test shows ductility and
soundness. Radiography also indicates soundness.
6. Thus, Procedure Qualification: Tension test + Bend test
7. Performance Qualification: Bend test or Radiography
8. Tensile test for procedure qualification is passed if failure is in a)Weld metal at
strength>= Base metal SMTS or b)Base metal at strength>= 95% of base
metal SMTS. This must be checked by welding inspection company. 
9. When the welder or welding operator is qualified by radiography, the minimum
length of coupon to be examined shall be 6 inch and shall include the entire
weld circumference for pipe
10. Production test with some condition is acceptable
11. Bend test crack shall not exceed 1/8” in any direction. Radiography criteria
are stricter than radiography for the job.
12. P-numbers represent parent metal classification of similar composition and
properties, i.e., similar strength and ductility.
13. F-number gives similar usability aspects of filler material.
14. A-number gives similar chem. comp. In“as welded” condition.
15. Essential variables (EV), if changed require new procedure qualification. Non-
essential variables (NEV) may be changed without new procedure
qualification. But the procedure must be revised.
16. Supplementary essential variables (SEV) are considered as (EV) only if there
is impact strength requirement. Otherwise, they are “non-essential” variables.
17. EV and SEV are included in PQR document. EV, SEV, and NEV are included
in WPS document.
 18. PQR document gives data used in PQR test and test results, and cannot be
revised.
19. WPS gives parameters to be used in the production job and must be within
ranges qualified by the PQR test.
20. WPS may be revised within the EVs qualified. The NEVs can always be
revised without affecting the validity of PQR.
21. Only in SMAW, SAW, GTAW, PAW and GMAW (except short-circuiting) or
the combination of them Radiography test can be used for welder
performance qualification test, but there is an exception, except P-No.21
through P-No.25 and P-No.51 through P-No.53 and P-No.61 through P-
No.62, welder making groove welds P-No.21 through P-No.25 and P-No.51
through P-No.53 metals with GTAW process may also be qualified by
radiography.
22. For welder performance qualification when the coupon has failed the visual
examination, and immediate retest is intended to be done, the welder shall
make two test coupon for each position which he has failed. If both test
coupons passed the visual inspection one may be selected by the examiner
for mechanical, in a similar way if mechanical test coupon has failed, two test
coupons shall make by the welder, both test coupon shall pass the test.
23. For welder performance qualification by radiography for immediate retest, two
6 inch plate and pipe examination shall include two pipes for a total of 12 inch
of weld which shall include entire weld circumference
24. When the welder has not welded with a process during  a period of 6 months
or more, his qualification for that process shall expire
25. Article IV should not be read directly, during the study of other articles
specifically “welding variables procedures specifications” (QW-252 through
265 ) should refer to a specific paragraph in this article.
26. For performance, 1G is flat, 2G is horizontal, 3G is vertical, and 4G is the
overhead position. Pipe 5G qualifies 1G, 3G, and 4G, but pipe 6G qualifies all
positions.

https://www.inspection-for-industry.com/welding-inspection.html

CONDITION:

The students/ trainee should be provided with:

 Equipment/accessories
- Hard hat
- Safety shoes
- Gloves
- Goggles
- Welder apron

 Instructional materials:
- Reference book
- Learning modules/manuals
- Safety standards
 - Enterprise safety policies/guidelines

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview

LO4. PERFORM FIRST AID

ASSESSMENT CRITERIA:

1. First aid treatment of injuries are carried out according to recommended

procedures
2. Emergency hotline and proper authority are accessed and contacted in
accordance with workplace procedure.

CONTENTS:

DIFFERENT TYPES OF INJURIES

FIRST AID TREATMENT PROCEDURE And PROPER HANDLING OF
INJURED INDIVIDUAL

Causes of Welding Accidents

This entry was posted on May 7, 2016 by Safety Officer.

Many welding, cutting and brazing accidents result from:

 Inadequately trained personnel.

 Poor housekeeping practices.
 Poor shop layout.
 Inadequate lighting and ventilation.
 Improper storage and movement of compressed gas cylinders.
 Exposure of oxygen cylinders and fittings to oil or grease creating a fire or
explosive hazard.
 Pointing welding or cutting torches at a concrete surface causing spattering and
flying fragments of concrete.
 Electric shock when motors, generators and other electric welding equipment are
not grounded.
 Inhalation of toxic fumes or vapors from welding metals or alloys.
Fires, explosions, and injuries can occur resulting from:
 The proximity of combustible solids, liquids, or dusts.
 The presence or development of possible explosive mixtures of flammable gases
and air.
 The presence or nature of an oxygen-enriched atmosphere in locations where hot 
work is performed.
 

Welder First Aid Kits

Welder's First Aid Kit in

Durable, Sturdy plastic case with a rubber gasket for protection. Welder's Kit includes
1/2 oz. Industrial Eye Drops & 1 Oz. Eye Wash. Industrial strength workers deserve
industrial strength care. Our 114-piece, 16-unit welder's first aid kit focuses on a wide
range of injuries common to welders such as minor cuts, sprains, welder's arc and other
common eye irritations. Products are contained in a sturdy plastic case with gasket.
Welding Safety
Welding Safety - OSHA Safety Training: People have been welding in one form or
another for over 2,000 years. But like many industrial processes, welding can be very
dangerous. Whether an employee is working with the hazardous gases of an
"oxyacetylene" unit... the high voltage of "stick welding"... or the combination of gas and
electricity that powers "MIG" and "TIG" operations... flying sparks, toxic fumes, electric
shock and high temperatures are just some of the things that can make welding a
dangerous proposition.
 Our training products on "Welding Safety" remind
employees that there are indeed a number of hazards associated with welding, and
provide the information they need to work safely when involved with welding operations.
Topics covered in these products include:
 Getting "authorization" for welding operations.
 Sparking and the risk of fire.
 Guards and protective barriers.
 Hazardous fumes and ventilation.
 The use of respirators and other personal
 protective equipment.
 Eye protection (welding helmets, filters, glasses and goggles)
 Inspecting welding equipment.
 Proper welding safety procedures.
 and more.

https://first-aid-store.com/blog/causes-of-welding-accidents/

WELDING ACCIDENT STATISTICS

The Bureau of Labor Statistics reports that over 500,000 workers are
injured annually due to welding accidents. Given the fact that welding
requires a dangerous level of heat and energy, this isn't surprising.
Welding is a very dangerous occupation, with the risk of death being
more than 4 per 1000 over a career.

WHAT ARE THE MOST COMMON

WELDING INJURIES?
 Burns from fire, sparks, or flammable material
 Eye injuries due to excessive heat or the arc eye
 Infrared radiation exposure
 Electrocution
 Skin injuries other than burns
 UV exposure
 Toxic fume inhalation, especially due to working in confined spaces with
little ventilation
 Invisible light exposure
 Hearing loss due to excessively loud noises
 Vision loss due to excessive lighting or injuries to the eyes

Burns from fire, sparks, or flammable material

There are many different causes of serious burns, including sunburn, hot water or other hot
liquids, and those due to fire, electrical contact, or chemicals. All of these can cause
permanent injury and scarring to the skin.

Immediate Treatment Steps for Burns:  

1. As quickly as possible, soak the burn in cool water. Don't hesitate to run cool water
over the burn long enough to cool the area and relieve the pain immediately after the
injury. Do not use ice on a burn. It may delay healing. Also, do not rub a burn; it can
increase blistering.
2. Cool any smoldering clothing immediately by soaking with water, then remove
any clothing from the burned area unless it is stuck firmly to the skin. In that case,
cut away as much clothing as possible.
3. If the injured area is not oozing, cover the burn with a sterile gauze pad or a
clean, dry cloth.
4. If the burn is oozing, cover it lightly with sterile gauze if available and
immediately seek medical attention. If sterile gauze is not available, cover burns
with a clean sheet or towel.
5. Do not put butter, grease, or powder on a burn. All of these so-called home
remedies actually can make the injury worse. For anything more serious than a
superficial burn, or if redness and pain continue for more than a few hours, consult a
physician. All electrical burns and burns of the hands, mouth, or genitals should
receive immediate medical attention. Chemicals that cause burns also may be
absorbed through the skin and cause other symptoms. Call the Poison Help Line.

Under the following circumstances, hospitalization may be

necessary:
 If the burns are third degree.
 If 10% or more of the body is burned.
 If the burn involves the face, hands, feet, or genitals, or involves a moving joint.
 If the child is very young or fussy, and therefore too difficult to treat at home.

For All Burns

1. Stop Burning Immediately
  Put out fire or stop the person's contact with hot liquid, steam, or other material.
 Help the person "stop, drop, and roll"to smother flames.
 Remove smoldering material from the person.
 Remove hot or burned clothing. If clothing sticks to skin, cut or tear around it.

2. Remove Constrictive Clothing Immediately

 Take off jewelry, belts, and tight clothing. Burns can swell quickly.

Then take the following steps:

For First-Degree Burns (Affecting Top Layer of Skin)

1. Cool Burn

 Hold burned skin under cool (not cold) running water or immerse in cool water until
the pain subsides.
 Use compresses if running water isn't available.

2. Protect Burn

 Cover with sterile, non-adhesive bandage or clean cloth.

 Do not apply butter, oil, lotions, or creams (especially if they contain fragrance).
Apply a petroleum-based ointment two to three times per day.

3. Treat Pain

 Give over-the-counter pain reliever such

as acetaminophen (Panadol, Tylenol), ibuprofen (Advil, Motrin, Nuprin),
or naproxen (Aleve, Naprosyn).

4. When to See a Doctor

Seek medical help if:

 You see signs of infection, like increased pain, redness, swelling, fever, or oozing.
 The person needs tetanus or booster shot, depending on date of last injection. Tetanus
booster should be given every 10 years.
 The burn blister is larger than two inches or oozes.
 Redness and pain last more than a few hours.
 The pain gets worse.
 The hands, feet, face, or genitals are burned.

5. Follow Up

 The doctor will examine the burn and may prescribe antibiotics and pain medication.

Eye injuries due to excessive heat or the arc eye

 First aid for eye injuries
Warning
When giving first aid for eye injuries do not:

 touch the eye or any contact lens

 allow patient to rub eye

 try to remove any object which is penetrating the eye

 apply pressure when bandaging the eye.

Managing different types of eye injuries

Burns
1. Open eyelid gently and wash eye with cold flowing water for 20 mins.
2. Place eye pad or light clean dressing over the injured eye only.
3. Ensure ambulance has been called – triple zero (000).

Wounds
1. Lie patient on their back.
2. Place light dressing over injured eye only.
3. Ask the patient to try not to move eye.
4. Ensure ambulance has been called – triple zero (000).

Small object
1. Ask patient to look up.
2. Draw lower eyelid down. If object visible, remove with corner of moist cloth.
3. If not visible, pull upper lid down.
4. If unsuccessful, wash eye with sterile saline or clean water.
5. If still unsuccessful, cover injured eye only and seek medical aid.

Penetrating
1. Place thick pads above and below injured eye or cover object with paper cup.
2. Bandage the pads in place, making sure there is no pressure on eyelids.
3. Cover injured eye only.
4. Ensure ambulance has been called – triple zero (000).

Embedded objects
1. Cover the injured eye only.
2. Seek medical aid.

Smoke
1. Wash eyes with sterile saline or cold tap water.
2. Seek medical aid if necessary.
Infrared radiation exposure

Preventing and Treating Radiation Injuries and Illness

 The health effects of radiation depend on: the amount of radiation

absorbed by the body (the dose), the type of radiation, how the
radioactive material got in or on the body, and the length of time a
person was exposed. More information…
 The best way to prevent radiation injuries and illness is to get inside
as soon as possible, away from the radioactive material outside  and
shower or wash once inside (self-decontamination).

You should not leave your building or place of shelter until officials or
emergency responders have said it is safe, unless you have a life-
threatening condition.

If you have skin burns, nausea, or begin vomiting shortly after radiation
exposure, seek medical attention as soon as it is safe to leave your
building or place of shelter.

 These may be symptoms of acute radiation syndrome (ARS), which is

caused by exposure to large amounts of radiation over a short
period of time.
 Symptoms can appear within minutes to several days after you were
exposed to large amounts of radiation.
 If you were exposed to a small amount of radiation, you will not see
any health effects right away, and may not have any long-term
health effects. Radiation health experts will monitor people affected
by radiation emergencies for any medical issues.
 Emergency officials will be setting up community reception centers
to check people for radiation exposure and contamination. Click here
to find out more information about community reception centers .
 Treat non-radiation related cuts, bruises or injuries with first aid.
Keep cuts and abrasions covered when washing to keep radioactive
material out of the wound.
 For more information on the impact of radiation emergencies on
health, go to Possible Health Effects of Radiation Exposure and
Contamination.
Electrocution

The danger from an electrical shock depends on the type of current, how high the
voltage is, how the current traveled through the body, the person's overall health and
how quickly the person is treated.
An electrical shock may cause burns, or it may leave no visible mark on the skin. In
either case, an electrical current passing through the body can cause internal
damage, cardiac arrest or other injury. Under certain circumstances, even a small
amount of electricity can be fatal.

When to contact your doctor

A person who has been injured by contact with electricity should be seen by a
doctor.

Caution
 Don't touch the injured person if he or she is still in contact with the electrical
current.
 Call 911 or your local emergency number if the source of the burn is a high-
voltage wire or lightning. Don't get near high-voltage wires until the power is
turned off. Overhead power lines usually aren't insulated. Stay at least 20 feet
(about 6 meters) away — farther if wires are jumping and sparking.
 Don't move a person with an electrical injury unless he or she is in immediate
danger.
When to seek emergency care
Call 911 or your local emergency number if the injured person experiences:

 Severe burns
 Confusion
 Difficulty breathing
 Heart rhythm problems (arrhythmias)
 Cardiac arrest
 Muscle pain and contractions
 Seizures
 Loss of consciousness
Take these actions immediately while waiting for medical help:

 Turn off the source of electricity, if possible. If not, move the source away from
you and the person, using a dry, nonconducting object made of cardboard, plastic
or wood.
 Begin CPR if the person shows no signs of circulation, such as breathing,
coughing or movement.
 Try to prevent the injured person from becoming chilled.
  Apply a bandage. Cover any burned areas with a sterile gauze bandage, if
available, or a clean cloth. Don't use a blanket or towel, because loose fibers can
stick to the burns.

https://www.mayoclinic.org/first-aid/first-aid-electrical-shock/basics/art-20056695#:~:text=Turn
%20off%20the%20source%20of,as%20breathing%2C%20coughing%20or%20movement.

UV exposure

Toxic fume inhalation, especially due to working in confined spaces with little
ventilation

Invisible light exposure

Hearing loss due to excessively loud noises

Vision loss due to excessive lighting or injuries to the eyes

CONDITION:

The students/ trainee should be provided with:

 Equipment
- First aid kit (different types)
- Oxygen
- Stretcher
- Medicine

 Learning materials
- Video tape, CD’s, transparencies

 Directory hotline number and offices

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO5. USE FIRE EXTINGUISHER

ASSESSMENT CRITERIA:

1. Fire fighting equipment identified according to types/source of fires.

2. Use of fire fighting equipment demonstrated in accordance with
manufacturer’s instructions.
3. Used fire fighting equipment and accessories are recorded/reported for
replacement/refill in accordance with enterprise approved safety
regulations.

CONTENTS:

 Types of fire fighting equipment

 Types of fire extinguishers
 Fire hoses
 Fire hydrants
 Sources/causes of fires
 Proper use of fire fighting equipment

CONDITION:

The students/ trainee should be provided with:

 Equipment
- Fire extinguishers (different types)
- Fire hydrants
- Video players/monitors

 Learning materials
- Types of fires/sources
- Types of fire fighting equipment and its operations
- Manuals on fire protection regulations
- Video tape, CD’s, transparencies
- Report cards/checklist

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
UNIT OF COMPETENCY : INTERPRET DRAWINGS AND SKETCHES

MODULE TITLE : INTERPRETING DRAWING AND SKETCHES

MODULE DESCRIPTION : This module covers knowledge, skills and attitudes

required to interpret drawing and sketches in
accordance with work plan specifications.

SUGGESTED DURATION : 8 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Identify standard alphabet of lines

LO2. Identify orthographic/ isometric views

LO3. Interpret standard drawing symbols, dimensional tolerances and notations

LO1. IDENTIFY STANDARD ALPHABET OF LINES

ASSESSMENT CRITERIA:

1. Alphabet of lines identified according to ISO.

2. Alphabet of lines are clearly explained according to their use.

CONTENTS:

 Alphabet of lines and applications

 Drawing specifications
 Dimensions
 Scaling

CONDITION:

The students/ trainee should be provided with:

 Equipment/accessories
- OHP/transparencies
- Computer
- Video/multi-media materials

 Training materials
- Reference book,
- Learning modules
- Blueprint (sample)
- Writing instrument
- Drawing instrument

METHODOLOGIES:

 Lecture/demonstrations
 Self-paced instruction
 Presentation

ASSESSMENT METHODS:

 Written
 Direct observation
 Interview/oral
LO2. IDENTIFY ORTHOGRAPHIC/ ISOMETRIC VIEWS

ASSESSMENT CRITERIA:

1. Orthographic and isometric views are clearly explained

2. Orthographic and isometric drawing are identified based on plan

CONTENTS:

 Types of welding joints and symbols

 Welding positions, codes and plan specifications
 Contour symbols
 Drawing technique
o Perspective
o Exploded view
o Hidden view technique
 Projections
o First angle projections
o Third angle projections

CONDITION:

The students/ trainee should be provided with:

 Equipment/accessories
- OHP/transparencies
- Computer
- Video/multi-media materials

 Training materials
- Reference book,
- Learning modules
- Blueprint (sample)
- Writing instrument
- Drawing instrument

METHODOLOGIES:

 Lecture/demonstrations
 Self-paced instruction
 Presentation

ASSESSMENT METHODS:

 Written
 Direct observation
 Interview/oral
LO3. INTERPRET STANDARD DRAWING SYMBOLS, DIMENSIONAL
TOLERANCES
AND NOTATIONS

ASSESSMENT CRITERIA:

1. Drawing symbols are interpreted according to drawing standards

2. Dimensional tolerances, notations are interpreted according to
specifications

CONTENTS:

 Types of welding joints and symbols

 Welding positions, codes and plan specifications
 Contour symbols
 Welding process (abbreviation)

CONDITION:

The students/ trainee should be provided with:

 Equipment/accessories
- OHP/transparencies
- Computer
- Video/multi-media materials

 Training materials
- Reference book,
- Learning modules
- Blueprint (sample)
- Writing instrument
- Drawing instrument

METHODOLOGIES:

 Lecture/demonstrations
 Self-paced instruction
 Presentation

ASSESSMENT METHODS:

 Written
 Direct observation
 Interview/oral
UNIT OF COMPETENCY : PERFORM INDUSTRY CALCULATION

MODULE TITLE : PERFORMING INDUSTRY CALCULATION

MODULE DESCRIPTION : This module covers knowledge, skill and attitude

required to compute/calculate quantity /size/cost of
materials/parts, and convert systems of
measurements using formulas and other methods.
This also includes measuring instruments and its
applications.

SUGGESTED DURATION : 8 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Perform four fundamental operations.

LO2. Perform conversion of units

LO3. Perform calculations on algebraic expressions

LO4. Compute percentage and ratio

LO1. PERFORM FOUR FUNDAMENTAL OPERATION

ASSESSMENT CRITERIA:

1. Simple calculations involving whole numbers, mixed numbers, fraction and

decimal are performed using four fundamental operations

CONTENTS:

 Mathematical operations
o subtraction
o addition
o multiplication
o division
 Industrial mathematics
 Computation formulas finding areas of:
o plane
o circles
o triangles
o other geometrical figures

CONDITION:

The students/ trainee should be provided with:

 Equipment/ accessories
- Calculators

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO2. PERFORM CONVERSION UNIT

ASSESSMENT CRITERIA:

1. Units are converted to the required figure using the given formulae
2. English measurements are converted to metric measurements
according to procedure.

CONTENTS:

 Units
- Fractions
- Mixed numbers
- Decimal
 Conversion of English to metric (vise versa)

CONDITION:

The students/ trainee should be provided with:

 Equipment/ accessories
- Calculators

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO3. PERFORM CALCULATIONS ON ALGEBRAIC EXPRESSIONS

ASSESSMENT CRITERIA:

1. Simple calculations are performed on algebraic expressions using the four

fundamental operations
2. Simple transposition of formulae are carried out to isolate the variable
required, involving the four fundamental operations.
3. Appropriate formula applied and results obtained in accordance with job
specifications.

CONTENTS:

 English and metric system of measurements

 Four fundamental operations
 Method of transposing formulae
 Equation formulation

CONDITION:

The students/ trainee should be provided with:

 Equipment/ accessories
- Calculators

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO4. COMPUTE PERCENTAGE AND RATIO

ASSESSMENT CRITERIA:

1. Percentages are computed using appropriate formula.

2. Ratio and proportion are computed using appropriate formula.

CONTENTS:

 Ratio and proportion

 Calculation
 Percentage and ratio

CONDITION:

The students/ trainee should be provided with:

 Equipment /accessories
- Calculators

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
UNIT OF COMPETENCY : CONTRIBUTE TO QUALITY SYSTEM

MODULE TITLE : CONTRIBUTING TO QUALITY SYSTEM

MODULE DESCRIPTION : This modules covers knowledge, skill and attitude

required to inspect work against specification and
standards and apply quality standards to work.

SUGGESTED DURATION : 4 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Inspect work done.

LO2. Apply quality standards to work

LO3. Protect company property and customer interests

LO1. INSPECT WORK DONE

ASSESSMENT CRITERIA:

1. Appropriate inspections are conducted to ensure company quality systems

and procedures are maintained/ followed.
2. Job specifications/work order and quality standards are identified.
3. Faults/defects are identified and rectified according to company
procedures.

CONTENTS:

 Quality system and procedures

- Work instructions
- Safe work procedures
- Product specifications
- Equipment maintenance schedules
- Technical procedures adopted or specifically prepared standards
- Company/industry rules
 Faults and defects
 Communication/feedback methods-written and verbal

CONDITION:

The students/ trainee should be provided with:

 Inspection record manual

 Job specification
 Workplace/company procedure manual
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO2. APPLY QUALITY STANDARDS TO WORK

ASSESSMENT CRITERIA:

1. Inspections are conducted throughout the manufacturing processes to

ensure quality standards are maintained.
2. Appropriate quality standards are applied throughout the
production/fabrication process.
3. All activities are coordinated throughout the workplace to ensure efficient
quality work outcomes.
4. Records of work quality are maintained according to the company
requirements

CONTENTS:

 Quality standard/ISO
 Work inspection techniques/procedures
 Record maintenance
 Communication process

CONDITION:

The students/ trainee should be provided with:

 Inspection record manual

 Quality standard
 Job specification
 Workplace/company procedure manual
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO3. PROTECT COMPANY PROPERTY AND CUSTOMER INTERESTS

ASSESSMENT CRITERIA:

1. Possible damage to company property is avoided by adherence to

company quality procedures.
2. Quality of work is reviewed to ensure customer requirements and
company standards are met.

CONTENTS:

 Company systems, processes and work quality requirements

 Quality assurance principles
 Safety precautionary measures
 Handling materials, tools and equipment

CONDITION:

The students/ trainee should be provided with:

 Inspection record manual

 Quality standard
 Job specification
 Workplace/company procedure manual
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
UNIT OF COMPETENCY : USE HAND TOOLS

MODULE TITLE : USING HAND TOOLS

MODULE DESCRIPTION : This modules covers knowledge skills and attitude

required to use hand tools

SUGGESTED DURATION : 4 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Select hand tools

LO2. Use hand tools

LO3. Maintain hand tools

LO1. SELECT HAND TOOLS

ASSESSMENT CRITERIA:

1. Hand tools selected are appropriate to the requirements of the task.

2. Unsafe or defective tools are identified and marked for repair according to
procedure

CONTENTS:

 Types and uses of hand tools

 Hand tool defects

CONDITION:

The students/ trainee should be provided with:

 Hand tools
o Hacksaws
o Hammers (ball peen, chipping)
o Punches
o Screwdrivers
o Wrenches
o Scrapers
o Chisels
o Gouges
o Files
o Clamps

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO2. USE HAND TOOLS

ASSESSMENT CRITERIA:

1. Hand tools are used to produce the desired outcomes to job specifications.
2. Task performed in accordance with company or industry safety procedure

CONTENTS:

 Types and uses of hand tools

 Tasks:
o Adjusting
o Dismantling
o Assembling
o Finishing of item or components

CONDITION:

The students/ trainee should be provided with:

 Hand tools
o Hacksaws
o Hammers (ball peen, chipping)
o Punches
o Screwdrivers
o Wrenches
o Scrapers
o Chisels
o Gouges
o Files
o Clamps

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
  Demonstration
LO3. MAINTAIN HAND TOOLS

ASSESSMENT CRITERIA:

1. Routine maintenance of hand tools is undertaken according to standard

operating procedures, principles and techniques.
2. Hand tools are stored in designated location in accordance with
manufacturer’s instruction/standard operating procedure.

CONTENTS:

 Routine maintenance
o Lubricating
o Tightening
o Simple tool repair
o Hand sharpening
o Cleaning
 Proper storage of hand tools

CONDITION:

The students/ trainee should be provided with:

 Hand tools
o Hacksaws
o Hammers (ball peen, chipping)
o Punches
o Screwdrivers
o Wrenches
o Scrapers
o Chisels
o Gouges
o Files
o Clamps

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module

METHODOLOGIES:
 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:
 Written/oral
  Direct observation
 Demonstration

UNIT OF COMPETENCY : PREPARE WELD MATERIALS

MODULE TITLE : PREPARING WELD MATERIALS

MODULE DESCRIPTION : This modules covers knowledge, skills and attitude

required in preparing weld materials.

SUGGESTED DURATION : 8 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Set up cutting equipment

LO2. Cut and prepare edge of materials

LO3. Clean surfaces and edges

LO4. Prepare welding consumables

LO5. Prepare welding safety and protective equipment

LO1. SET UP CUTTING EQUIPMENT

ASSESSMENT CRITERIA:

1. Cutting equipment should be operational and should conform to

acceptable OH&S standards
2. Cutting equipment fittings, connection and power source are checked in
accordance with workplace procedure

CONTENTS:

 Parts and function of cutting equipment

 Procedures in setting–up of cutting equipment
 Procedure in checking cutting equipment functionality.

CONDITION:

The students/ trainee should be provided with:

 Hand tools
 Cutting equipment and accessories
 Gases (oxygen, acetylene, LPG)
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO2. CUT AND PREPARE EDGE OF MATERIALS

ASSESSMENT CRITERIA:

1. Materials are cut to specified dimension/specifications.

2. Task are performed in accordance with company/industry requirement and
safety procedure

CONTENTS:

 Cutting operation procedure

 Cutting material with different process
- Oxy-acetylene gas cutting equipment (manual and automatic)
- Plasma cutting equipment
- Shearing machine
- Disc cutter
- Cutting electrode

CONDITION:

The students/ trainee should be provided with:

 Hand tools
 Cutting equipment and accessories
 Gases (oxygen, acetylene, LPG)
 Air compressor
 Shearing machine
 Disc cutter
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Demonstration
LO3. PREPARE WELDING CONSUMABLES

ASSESSMENT CRITERIA:

1. Consumables, materials, specified and quantity determined in accordance

with job requirements.
2. Correct materials selected in accordance with job requirements.

CONTENTS:

 Consumable materials specifications

 Equipment and tools for preparing plates and pipes edges
 Safe working practices in preparing consumables

CONDITION:

The students/ trainee should be provided with:

 Hand tools
 Cutting equipment and accessories
 Gases (oxygen, acetylene, LPG)
 Air compressor
 Shearing machine
 Disc cutter
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Demonstration
LO4. CLEAN SURFACES AND EDGES

ASSESSMENT CRITERIA:

1. Surfaces are cleaned to required specifications.

2. Task performed in accordance with company or industry requirements and
safety procedure

CONTENTS:

 Procedures and techniques of preparing plates and pipe edges for welding
 Equipment and tools for preparing plates and pipes edges
 Safe working practices

CONDITION:

The students/ trainee should be provided with:

 Hand tools
 Cutting equipment and accessories
 Mild steel
 Carbon steel
 Alloy steel
 Cutting gases
 Gouging electrodes
 Grinding/cutting discs
 Run on/run off, backing plates/ring
 Shearing machine
 Disc cutter
 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Demonstration
LO5. PREPARE WELDING SAFETY AND PROTECTIVE EQUIPMENT

ASSESSMENT CRITERIA:

1. PPE should conform to acceptable OH&S requirement and standards.

2. Welding safety and protective equipment are checked in accordance with
safety procedure

CONTENTS:

 Procedures and techniques in checking protective equipment

 Safe working practices and handling of protective equipment

CONDITION:

The students/ trainee should be provided with:

 Personal protective equipment

 Supplies/materials
- Pencil/paper
- Reference books
- Learning materials/module
- OHP/transparencies
- Video/multi-media materials

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Demonstration
UNIT OF COMPETENCY : SET-UP WELDING EQUIPMENT

MODULE TITLE : SETTING-UP WELDING EQUIPMENT

MODULE DESCRIPTION : This modules covers knowledge, skills and attitude

required in setting up welding equipment.

SUGGESTED DURATION : 4 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Set up welding machine

LO2. Set up welding accessories

LO3. Set up welding positioners, jigs and fixtures

4. Set up pre-heating 4.1 Pre-heating equipment appropriate to the job

tools/equipment as requirement and specifications
required 4.2 Equipment operated in conformance with the
manufacturer’s instructions.
LO1. SET UP WELDING MACHINE

ASSESSMENT CRITERIA:

1. Primary cable attached to welding machine primary cable terminal

2. Primary cable attached to power source.
3. Welding machine checked for functionality.
4. Polarity switch, if any, set to DC reverse.
5. Cable terminals checked for tightness.

CONTENTS:

 Parts and function of welding machine (SMAW)

 Procedures in setting –up of welding machines
 Procedure in checking welding machine functionality.

CONDITION:

The students/ trainee should be provided with:

 Equipment and accessories

- AC/DC Welding machine
- Welding cables
- Ground clamp
- Primary cable
- Power source connectors and outlets
 Tools
- Set of screw driver
- Set of wrenches
 Supplies/materials
- Electrical tape
- Rubber tape
 Instructional materials
- Reference book /modules/ learning guides/ video CDs
- Equipment manual

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO2. SET UP WELDING ACCESSORIES

ASSESSMENT CRITERIA:

1. Electrode cable connected to positive of welding machine.

2. Ground cable connected to negative terminal of welding machine.
3. Ground clamp attached to workpiece/material.
4. Welding cable checked for crack, burns and cuts.
5. Primary cable attached to welding machine primary cable terminal

CONTENTS:

 Parts and function of welding machine accessories and consumables

 Procedures in setting-up of welding accessories
 Procedure in checking welding machine functionality.

CONDITION:

The students/ trainee should be provided with:

 Equipment and accessories

- AC/DC Welding machine
- Welding cables
- Ground clamp
- Primary cable
- Power source connectors and outlets

 Tools
- Set of screw driver
- Set of wrenches

 Supplies/Materials
- Electrical tape
- Rubber tape

 Instructional materials
- Reference book /modules/ learning guides/ video CDs,
- Equipment manual

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO3. SET UP WELDING POSITIONER, JIGS AND FIXTURES

ASSESSMENT CRITERIA:

1. Braces, stiffeners, rails and other jigs are provided and in

conformity with job requirements.
2. Work items/materials are protected from strong winds, drafts
and rainfall

CONTENTS:

 Types of welding positioner, jigs and fixture

 Different kind of jigs and fixture
 Uses and function of welding positioner, jigs and fixture

CONDITION:

The students/ trainee should be provided with:

 Welding positioner
 Jigs and fixture
 Tools
 Supplies/materials
 Instructional materials
- Reference book /modules/ learning guides/ video CDs,
- Equipment manual

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
UNIT OF COMPETENCY : FIT UP WELD MATERIALS

MODULE TITLE : FITTING UP WELD MATERIALS

MODULE DESCRIPTION : This modules covers knowledge, skills and attitude

required in fitting up weld materials.

SUGGESTED DURATION : 4 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Perform tack welding

LO2. Check gap and alignment

3. Set up welding 3.1 Weld specimen positioned and secured according to the
positioner requirements.
LO1. PERFORM TACK WELDING

ASSESSMENT CRITERIA:

1. Tack welding is performed in accordance with the welding

procedure requirements
2. Joints are free from rust, paints, grease and other foreign
materials prior to fit up or tacking.

CONTENTS:

 Kind of tacking
 Welding procedure standard requirement
 Codes and specification

CONDITION:

The students/ trainee should be provided with:

 Welding machine equipment and accessories

 Tools
 Supplies/materials
 Personal protective equipment
 Drawing plan and specification
 Instructional materials
- Reference book/ modules/ learning guides/ video CDs
- Equipment manual

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
LO2. CHECK GAP AND ALIGNMENT

ASSESSMENT CRITERIA:

1. Root gap is prepared/checked in accordance with WPS requirements

2. Alignment of work piece are checked in accordance with welding standard
3. Included angle are checked in accordance with WPS

CONTENTS:

 Fit up tolerances
 Workpiece alignment procedure
 Fit up

CONDITION:

The students/ trainee should be provided with:

 Measuring tools
 Work piece
 Personal protective equipment
 Drawing plan and specification
 Instructional materials
- Reference book /modules/ learning guides/ video CDs,
- Equipment manual

METHODOLOGIES:

 Lecture/demonstrations
 Self pace learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Interview
 Demonstration
UNIT OF COMPETENCY : REPAIR WELD

MODULE TITLE : REPAIRING WELD

MODULE DESCRIPTION : This modules covers knowledge, skills and attitude

required in repairing weld.

SUGGESTED DURATION : 8 hours

SUMMARY OF LEARNING OUTCOMES:

At the completion of the module the trainees/students must be able to:

LO1. Mark/locate weld defects

LO2. Prepare tools and equipment

LO3. Remove defects

LO4. Perform re-welding

LO1. MARK/LOCATE WELD DEFECTS

ASSESSMENT CRITERIA:

1. Location of weld defects identified/determined in accordance with

industry standard.
2. Weld defects marked for repair in accordance with industry standard.
3. Procedures in locating weld defects performed as per approved
procedures.

CONTENTS:

 Types of welding defects

 Procedures in locating weld defects
 Proper uses of NDT equipment or tools

CONDITION:

The students/trainees must be provided with:

 Equipment and accessories

 Tools
- Chipping hammer
- Steel brush

 Supplies/materials
- Carbon steel plates
- Pipe; alloy pipe

 Instructional materials
- Reference book/ modules/ learning guides/ video CDs,
- Welding charts,
- Work plans
- Drawing and specifications relevant to the task

METHODOLOGIES:

 Lecture/ demonstrations
 Self-paced learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Return demonstration
LO2. PREPARE TOOLS AND EQUIPMENT

ASSESSMENT CRITERIA:

1. Tools and equipment are prepared appropriate to the job requirements

2. Tools and equipment are properly checked to the job requirements

CONTENTS:

 Tools and equipment and their uses

 Procedures in checking tools and equipment

CONDITION:

The students/trainees must be provided with:

 Equipment and accessories

 Tools
- Chipping hammer
- Steel brush
- Electric grinders

 Supplies/Materials
- Carbon steel plates
- Cutting/ grinding disk
- Carbon steel plates
- Pipe

 Instructional materials
- Reference book/ modules/ learning guides/ video CDs,
- Welding charts,
- Work plans
- Drawing and specifications relevant to the task

METHODOLOGIES:

 Lecture/ demonstrations
 Self-paced learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Return demonstration
LO3. REMOVE DEFECTS

ASSESSMENT CRITERIA:

1. Weld defects removed/excavated in accordance with welding procedures.

2. Removal of non-defective welds is minimized and cleaned.
3. Visual and dye-penetrant test are performed to verify the extent of removal
of defects

CONTENTS:

 Dye penetrant testing principle and applications.

 Procedures of dye penetrant testing
 Weld defects removal and excavation

CONDITION:

The students/trainees must be provided with:

 Tools
- Chipping hammers
- Steel brush

 Supplies/materials
- Developer
- Penetrant
- Cleaner
- Cloth/ clean rag

 Instructional materials
- Reference book/ modules/ learning guides/ video CDs
- Welding charts
- Work plans
- Drawing and specifications relevant to the task

METHODOLOGIES:

 Lecture/ demonstrations
 Self-paced learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Return demonstration
LO4. PERFORM RE-WELDING

ASSESSMENT CRITERIA:

1. Re-welding performed in accordance with approved repair

procedure.
2. No new weld defects or damages occurred during re-welding.
3. Weld visually checked after re-welding for acceptability

CONTENTS:

 Rectifying weld defects

 Re-welding procedures
 Visual inspection of weld

CONDITION:

The students/trainees must be provided with:

 Equipment and accessories

- Welding machine with complete accessories

 Tools
- Chipping hammers
- Steel brush
- Electric grinders

 Welding supplies/materials
- Carbon steel plates
- Cutting/ grinding disk
- Welding consumables

METHODOLOGIES:

 Lecture/ demonstrations
 Self-paced learning
 Group discussion

ASSESSMENT METHODS:

 Written/oral
 Direct observation
 Return demonstration