SAFETY IN

GAS CUTTING & WELDING

GAS CUTTING
Something to think on……

 Every time you use the oxy-acetylene

equipment, if certain safety guidelines are not
followed, it would be the same as handling
live explosives ready to go off…….

Now let’s talk about the

gases
 What is Oxygen

 Remember, oxygen is not air;

 There is approximately 21% oxygen in normal air;
 Oxygen is found naturally in the atmosphere;
 It is produced industrially by distilling air below it’s freezing point;
 Pure oxygen does not burn or explode;
 Oxygen is an “accelerant” , it causes every thing it comes in
contact with to burn hotter and faster;
 Air has a vapor density of 1.000, Oxygen is heavier than air (1.105)
This means if a oxygen bottle is leaking, the gas will settle in low
areas before diffusing back into the atmosphere;
 30% oxygen in the atmosphere will cause things to burn or
explode 8 times faster.
 Never use oxygen……….

 in pneumatic tools- the oil and the gas pressure friction can
cause a fire or explosion;
 in oil pre-heating burners- these burners are set to burn with
21% oxygen to air ratio;
 to start internal combustion engines- gasoline is flammable
enough with 21% oxygen available;
 to blow out pipelines- Leftover flammable or combustible
vapors may still be present to cause an explosion;
 to dust off clothing or work area- the oxygen will remain present
in the cloth fibers causing them to be more flammable;
 to create pressure;
 for ventilation;
 Remember, oxygen is not air
How Are Oxygen Bottles Constructed

 Usually of steel construction

 244 cu. ft is standard size (K size)
 2000 to 2600 psi
 Hollow in construction
 An electric arc can cause an oxygen bottle to
explode ( the carbon in the steel will atomize into a
fuel )
 The orifice at the top of the bottle is the diameter of
the lead in a pencil ( if the bottle top is damaged, the
bottle can become projectile causing injury or
property damage
 Never allow a tank to go empty (this may allow
acetylene to travel into the oxygen lines or bottle
What is acetylene

 Acetylene is a compound of Carbon and Hydrogen (C2H2) a member of

the hydrocarbon gases;
 Explosive range is 3.0 to 93%;
 Needs only 10% of oxygen to ignite;
 Produced when calcium carbide is mixed with water;
 It is an unstable gas, will violently decompose when in a pure state
above 15 psi;
 Has a burning temperature of 4,600o F, 5,700o F when burned with
oxygen;
 Auto-ignition temperature is 763o - 824o F, this means if acetylene
reaches 30 psi in a free state, it can explode by itself without a spark or
flame being present;
 Remember, acetylene is a very dangerous gas.
 How are acetylene bottles constructed

 Usually are steel construction

 Filled with a porous material to allow the acetone to
dissolve the acetylene, which makes it stable
 Porous filler(8-10%), Acetone(42%)
 Acetylene gas(36%),
 Reserve volume-70o F(10-12%)
 Never allow a tank to go empty. Oxygen may back
pressure into the bottle
 Comes in various sizes
 Must always be stored upright. This prevents the
acetone and acetylene from separating
 Should not be stored below freezing Acetone may
come out instead of acetylene and may clog the
regulators.
 Care & maintenance of the Gas Regulators

The internal working parts of the regulator are precision units. Only
qualified technicians should clean or repair a regulator

High pressure gauge

Low pressure Indicates the
gauge pressure from tank
Indicates the
delivery
pressure to
the hoses &
torch The Inlet Connections
Oxygen are right handed
The Pressure adjusting screw thread / Acetylene are
left handed thread
Turning clockwise allows the gas allows to flow Keep free of oil, grease, &
Turning counterclockwise reduces or stops the dirt
gas flow
Some more info on regulators

Warning - Always keep the regulator free of oil, grease and other
flammable substances

Never use oil or grease on the regulator, cylinder or manifold connection

DO NOT change the inlet connection on a regulator in an attempt to use

the regulator for a different gas service

Never stand in front or behind a

regulator when opening the cylinder
valve
Backfires and Flashbacks

 Backfires occur when the torch flame burns back into the torch
tip and is extinguished with a loud pop.

 They occur either because the torch tip touched the work or
because of insufficient gas pressure.

 They are generally harmless. However, flashbacks are more

serious when the flame front does not extinguish, but burns
back sometimes beyond the mixing chamber, through the
hoses, and even into regulator and supply.
 Check valves

The purpose of an internal check valve is to reduce the possibility of

reverse flow gas.
It is not intended to act as a fire stop!
Ensure that the internal check valves are working properly by testing at
least every six months, more often if the hoses are frequently removed
from the torch.

Spring activated

Gas flow Once flow

pressure
decreases, valve
will closes
preventing back
Flow of gas keeps valve open flow of gas
Flashback arrestors

Flashback arrestors are designed to prevent a flashback from

reaching upstream equipment.

They offer added safety and often include reverseflowcheck valves
in a single unit
The Hoses

 The hoses are usually color coded, but not always

– Oxygen(green)
– Acetylene(red)
– Be careful not to use other hoses, such as air lines, LP gas, etc.
 They are neoprene over braided inner section
– Be careful around sharp objects, they can be cut very easily
 They are constructed of flame retardant materials, but will burn if there is a
flashback or exposed to sustained heat
 Hoses are graded
– Make sure you are using the right hose for the right gas
 Hose

 Keep welding hoses clear of any failing metal, slag or sparks.

 Never allow hoses to become coated with oil, grease or dirt.
Such coatings could conceal damaged areas.
 Examine the hoses before attaching to welding torch handle
or regulators.
 If cuts, burns, worn areas or damaged fittings are found,
replace the hose.
 Completely replace welding hose if it contains multiple
splices or when cracks or severe wear is noticed.
Torch handle

Control valve &

body”Y”

Barrel

Torch head
Torch cutting attachment

There must always be two o-

rings on the cone end. The
absence or damage of either
of these o-rings allows
premixing and leaks of
oxygen and fuel gases. This
can lead to flashback within
the torch handle.
 
 What size cutting-nozzle do I need

Always make sure your equipment is rated for the size nozzle you
have selected.

A nozzle with too much capacity for the equipment can starve or
choke the nozzle. This causes overheating of the head and a flashback
may result.

A damaged seating surface on either the tip or the head can create a
dangerous condition, resulting in a fire or flashback. This may damage
the cutting attachment.

If the seating surface of a nozzle becomes damaged, DO NOT use it.
Discard the damaged tip.

If the head requires repair, take the torch to a qualified repair
technician.
What nozzle sizes do I use for oxy-acetylene welding and what
pressures do I set on my regulators?

nozzle sizes and gas regulator settings are dependent on

the thickness of the material to be welded and the type
torch being used

Always refer to the manufacture’s

supplied cutting chart for the cutting
tips you are using.
Remember, if you do not use the
proper oxygen to acetylene ratio, you
may cause an accident, at the very
least you will waste gas, which costs
$$$$.
 Cutting tips
and nozzles

 Never starve or choke a multi-flame heating nozzle. This causes

overheating of the head and a flashback may result.
 Should a flashback occur (flame disappears and/or a hissing sound is
heard, the flame is burning inside the nozzle), immediately turn off the
oxygen valve on the torch handle. Then, turn off the fuel valve.
 Allow the nozzle to cool before using.
 If a flashback reoccurs, have the apparatus checked by a qualified
technician before using again.
Let’s Finish With Some Final General Safety Tips

 Never allow oxygen to contact oil, grease or other

flammable substances

 Never mix brands

 Purge the lines before and after usage

 Always wear protective clothing

 Use proper eye protection

If flashback occurs, immediately turn off the O2, then the acetylene,
and allow unit to cool

 
Always work in a well ventilated area
Always light the acetylene first
                              

Oxygen cylinders must be opened the whole way

Use an approved striker, never use matches or cigarette lighter


Use the proper regulator for each specific gas
Only qualified technicians should repair a regulator

Keep regulators free of oil, grease and other flammable

General Safety Tips

Keep regulators free of oil, grease and other flammable

substances
Check valves stop reverse gas flow, they do not act as a fire stop
Never starve a tip, this can cause a flashback
Always keep cylinders in an upright position
Never stand in front or behind a regulator when opening the cylinder
valve
Do not open acetylene valve more than 1 1/2 turns
Always make sure area is safe and flammable free
Safety Checklist for Getting Started
What is the necessary safety equipment you need?

•Proper Eye protection

•Appropriate gloves

•Clothing free of grease & oil

•Clean work area

•Proper Task Training

•Fire extinguisher
 Gas cutting
DO` S
Storage structure should
be fire proof with flame proof
lighting and adequate
ventilation
Store well away from blow
pipe flames or any other
combustible materials
Always store and use DA
and Oxygen cylinder in
upright position and secure
DON`T
Do not use tarpaulin
or any other covers in
direct contact with
cylinders as protection
against sun
Do not store cylinder
in the open as cylinder
valve may be weaken by
direct sunrays and
dangerous conditions
might develop
 Gas cutting
DO` S
Store the full and empty
cylinder s in separate
locations with clear bold
indication to avoid confusion
Ventilate storage place at
top for gases lighter than air
(DA) and for heavier than
air(oxygen) ventilate at
bottom
DON`T
Never store DA and
oxygen cylinder together
as these are susceptible
to reaction.
Most cylinders are
provided with steel
protective caps that
screw over the valve.
never should the cap be
removed unless the
cylinder are in
 Gas cutting
DO` S
Use soap solution for test
purpose
Shut cylinder valves when
work has to be stopped.keep
cylinder valves key in
position when cylinder is in
use.
Stand clear of cylinder
valves when clearing outlet
sockets
DON`T
Do not lubricate the
valves any times
Never substitute a
cylinder for another.Do
not get confused
between compressed air
and oxygen.
Do not force
connection that do not fit
on the cylinder valve
 WELDING

Welding is a process, in which two

parts of the same or different metals
are joined by causing the edges to melt
and unite while molten without the aid
of hammer or compression. When cool,
the parts form one piece of metal
 General precautions

Double earth should be provided to welding M/c

Terminals of the welding cables should be provided
with
lugs and kept tight
Joints in the cables should be made with terminals,
kept
tight and well insulated with heat resistant tape
Cable should be free from joints at least for a length
of three meters from electrode holder to avoid shock
hazards
 General
precautions
Other electrical cables,gas cutting hoses,should not
be
laid with welding cables to avoid insulation damage,
For the return lead use only proper cables.use of
fire
reinforcement steel,structural steel members should be
avoided
Never change electrode with bare hands or wet
gloves
Body earthing should be provided to portable ovens
Proper eye protection should be used by helper to
protect against radiation hazards-ARC EYE
 General
precautions
Fixing return lead on bottom of structural steel
structures and welding at elevation should be strictly
provided
Welding m/cs should be kept within the visibility of the
welders
Provide proper working platform for welders to work at
height
Welding bits should not be allowed to drop from
height.provide suitable box to keep the hot welding bits
and should be lowered down on daily basis
 General precautions

Molten slag should be not allowed to fall down.use

suitable
protections like fire blanket/G.I.Sheet etc to arrest the
falling
slag extinguishers should be kept near welding spot
Fire
and keep a fire watch .
Remove combustible materials from the vicinity
before under taking welding job
Use separation barrier screen for multiple work
at same location to protect the person nearby
 General precautions

Ventilate the work area properly

Make sure there are no coated surface within 4
inches of the weld area
Wear personal protective equipment appropriate to
the specific task
Inspect the work area.Ensure that sparks or molten
metal will not contact flammable or combustible
materials
 General precautions

Be sure that all welding leads and hose

are off floors,walkways and stairways
Never perform welding cutting or
burning barrels,tanks pipes or other
vessels that may have contained
combustible or unknown materials
without clearance of safety deptt.
Health Hazards

 Gases and Fumes…

 Welding “Smoke” is a mixture of very fine particles
called fumes and gases
 Welding “Smoke” contains fumes and gases including…
Chromium, nickel, arsenic, asbestos, manganese, silica,
beryllium, cadmium, nitrogen oxides, phosgene,
acrolein, fluorine compounds, carbon monoxide, cobalt,
copper, lead, ozone, selenium, and zinc
Health Hazards…Gases & Fumes

Generally, gases and fumes come from…

 Base material & filler material
 Coatings & paints
 Shielding gases & chemical reactions
 Process & consumables used
 Contaminants in the air
Health Hazards

 Exposure to welding “smoke” may have…

 Short-term effects…
Effects happen at or very soon after exposure
 Long-term effects
 Effects may happen after repeated overexposures
or an extended time after the exposure
Short-term exposures

 Exposure to zinc, magnesium, copper and

copper oxide can cause metal fume fever
 Symptoms of metal fume fever may occur 4 to
12 hours after exposure
Symptoms include…
 Chills, thirst, fever, muscle ache, chest
soreness, coughing, wheezing, fatigue, nausea,
and metallic taste in mouth
Short-term exposures

 Welding “smoke” can irritate the eyes, nose,

chest and respiratory tract
 Welding “smoke” can cause nausea, loss of
appetite, vomiting, cramps, and slow digestion
Short-term exposures

 Exposure to cadmium can be fatal in a short

time
 Ultraviolet radiation can react with oxygen and
nitrogen to form ozone and nitrogen oxides
 These gases are deadly at high concentrations
and can also cause irritation of nose and throat
and cause serious lung disease
Long-term exposures

 Studies of welders, flame cutters, and burners

have shown that welders have an increased risk
of lung cancer…
 and…possibly cancer of the larynx and urinary
tract
 Remember… welding “smoke” can include
cancer causing agents such as…cadmium,
nickel, beryllium, chromium, and arsenic
Long-term exposures

 Welders may experience a variety of chronic

respiratory problems, including…
 Bronchitis, asthma, pneumonia, emphysema,
pneumoconiosis, decreased lung capacity,
silicosis, and siderosis
Other Health Risks…

 Heat exposure…
Heat stress, heat stroke
 burns, eye injuries from hot slag, metal chips,
sparks, and hot electrodes
Other Health Risks…

 Visible light, and ultraviolet and infrared radiation

 Intense light can cause damage to retina
 Infrared radiation may damage the cornea and result in
cataracts
 Invisible UV light can cause “arc eye” or “welders’ flash”
May include sandy or gritty eye, blurred vision, intense pain,
tearing, burning and headache
Other Health Risks…

 Permanent eye damage

 Skin burns
 Skin cancer
 Noise
– Can result in stress, increased blood pressure, may
contribute to heart disease, tiredness, nervousness,
and irritability
Musculoskeletal Injuries

 Back injuries, shoulder pain, tendonitis, reduced

muscle strength, carpal tunnel syndrome, white
finger, and knee joint diseases
 Injuries may be caused by overhead work,
vibration and heavy lifting
 Electrical Hazards

 Even though welding generally uses low

voltage, there is still a danger of electric shock
 Wet work areas, Cramped work spaces
 Falls, fractures and other accidents can result
from electrical exposure
 Even small shock can cause brain damage
 Death can occur from large shocks
Fire and Explosion Hazards

 Intense heat and sparks can cause fires or

explosions if in the vicinity of combustible or
flammable materials
 Welding and cutting should only be performed
in areas free of combustible materials such as
trash, wood, paper, textiles, plastics, chemicals,
and flammable dusts, liquids and gases
Fire and Explosion Hazards

 Never weld or cut on containers that have held

a flammable or combustible material unless
the container is thoroughly cleaned or filled
with an inert gas
 A fire inspection should be performed prior to
leaving a work area and for at least 30 minutes
after the operation is completed
 Fire extinguishers should be nearby, of proper
size, type and number for the hazards involved
Trips and Falls

 To prevent trips and falls…

 keep work areas clear of equipment, machines,
cables, and hoses
 Always properly maintain and use handrails
 Always use and maintain safety lines,
harnesses and lanyards
 Always make sure that scaffolds are properly
assembled and used
Welding Hazards in Confined Space

 A work area with limited access, little or no

airflow, not intended for continuous occupation
May also have dangerous atmospheres, hazardous
configurations, or other hazards
 All employees working in or around confined
space must be trained
Welding Hazards in Confined Space

 Never weld or cut in explosive, flammable,

combustible or other dangerous environments
 Always use all necessary Personal Protective
Equipment (PPE), including, harness and
lanyard, respiratory protection, eye protection,
etc.
 Never work in confined space without a trained
attendant
Welding Hazards in Confined Space

 Always leave gas cylinders and welding power

sources outside the confined space…
 Only take hoses or welding leads into confined
space
 Always removed hoses and/or leads when
leaving confined space for breaks, shift or crew
changes, etc.
Welding Hazards in Confined Space

 No worker should work in an area with less than 19.5%

or more than 23.5% oxygen content
 Never ventilate with oxygen
 Use continuous mechanical ventilation and proper
respiratory protection
 All pipes, ducts, power lines, etc. that are not
necessary for the work should be disconnected/locked
out/tagged out
Compressed Gas Hazards

 Gas welding and cutting use a fuel gas and

oxygen which are stored in high pressure
cylinders
 Most fuel gases are explosive
 Pure oxygen will increase the flammability of
any combustible/flammable material
Engineering Controls and Work
Practices

 Substitute less hazardous materials for

hazardous materials
 Use cadmium-free silver solders
 Use asbestos- free electrodes, gloves, and hot
pads
 Use ventilation to move away or dilute hazards
 Use work area barriers to protect others
working in the same general area
Engineering Controls and Work
Practices

 Welding booths should be painted with dull

finishes so they don’t reflect UV light
 Acoustic shields between the worker and noise
sources can reduce exposures
 Noisy machinery can be totally enclosed
 Thank You all
and
Have a Safe Day