SAFETY DURING GAS

CUTTING & WELDING

 SAFETY IN GAS
CUTTING OPERATION
SAFETY DURING GAS CUTTING WORKS

• Colour code of the Cylinder

Oxygen - Black
Acetylene – Maroon
Nitrogen – Light Blue
STORAGE OF GAS CYLINDERS

Keep minimum
distance of 20 feet
between fuel and
oxygen cylinders
 STORAGE OF GAS CYLINDERS

FUEL GAS CYLINDERS (DA STORE CYLINDERS IN

CYLINDERS) SHOULD BE COOL, DRY AND WELL
STORED SEPERATELY FROM VENTILATED PLACE
OTHER GAS CYLINDERS AWAY FROM HEAT
FULL EMPTY
NO OTHER MATERIALS
SHOULD BE STORED IN
CYLINDER STORAGE
FUEL GAS OXYGEN FUEL GAS OXYGEN
AREA
FUEL GAS EMPTY CYLINDERS AFTER DAY’S WORK,
SHOULD BE STORED REMOVE CYLINDER TO
SEPERATELY SAFE STORAGE PLACE
STORAGE OF GAS CYLINDERS
 HANDLING OF GAS CYLINDERS

KEEP CYLINDERS DO NOT

AWAY FROM THE KEEP ACETYLENE SWEETEN FOUL
SPARK OF THE CYLINDERS ATMOSPHERE
FLAME UPRIGHT WITH OXYGEN

DONOT DONOT USE

LUBRICATE CHAIN ACETYLENE
MAGNETS TO MOVE CYLINDERS UPRIGHT
VALVES GAS CYLINDERS

DONOT USE CLOSE VALVES USE STD KEYS

CYLINDERS AS OF EMPTY FOR OPENING
ROLLERS OR WORK CYLINDERS THE VALVES
SUPPORTS USE TROLLEY FOR CYLINDERS SHIFTING
HAZARDS DURING GAS CUTTING

• BACKFIRE
FIRE & EXPLOSION
• FLASH BACK
 HAZARDS DURING GAS CUTTING

BACKFIRE:
•DURING GAS CUTTING, THE DUST & DIRT COMING FROM
THE CYLINDERS BLOCK THE HOLES OF THE NOZZLE
GRADUALLY.
•OXYGEN, WHICH IS STORED AT HIGHER PRESSURE,
STARTS FLOWING TO ACETYLENE CYLINDER AND FORMS
INFLAMMABLE GAS MIXTURE.
•THIS COULD LEAD TO EXPLOSION WHEN THE TORCH IS
REIGNITED.
 HAZARDS DURING GAS CUTTING

FLASH BACK:

•THIS HAPENS WHEN FLAME VELOCITY EXCEEDS THE GAS

MIXTURE VELOCITY.
•THIS COULD OCCUR WHEN THE PRESSURE INSIDE THE
CYLINDERS IS CONSIDERABLY LESS.
 BACK FIRE / FLASH BACK

INDICATIONS

• HISSING NOISE
• HEAVY BLACK SMOKE
• SPARK COMING OUT OF NOZZLE / TIP
• TORCH HANDLE GETTING HOT
 BACK FIRE / FLASH BACK CAUSES

• FLAME HELD TOO CLOSE TO WORK

• SLAG BLOCKING TIP
• HOT METAL FALLING ON AND BURNING THROUGH HOSE
• FAULTY EQUIPMENT
• WRONG GAS SEQUENCE DURING START- UP
• INSUFFICIENT PURGING TO CLEAN HOSE BEFORE USE.
• GAS HOSES DAMAGED BY PREVIOUS FLASHBACK.
USE OF FLASH BACK ARRESTORS

FLASH BACK
ARRESTORS
ARE ESSENSIAL.
THEY ARE NOT
SUBSTITUTE
FOR SAFE WORK
PRACTICES
 NON COMBUSTIBLE
GENERAL GAS CYL VALVES R H THREADS

INFORMATION COMBUSTIBLE
GAS CYL VALVES L H THREADS

SNIFT VALVE BEFORE

CONNECTING THE REGULATOR
TWO STAGE
REGULATOR

USE APPROPRIATE
REGULATOR AND
BLOW PIPE.
SINGLE
DONOT OPEN CYL. VALVE TOO MUCH. STAGE
REGULATOR
ONE TURNING OPENING IS ENOUGH
 GAS CUTTING HOSE

AVOID DAMAGE TO HOSES

AGAINST SHARP EDGES ETC.

US PE AS
TY ANV
E R H
C

O UB O
NL B SE
Y ER
PR
ES
SU
DONOT ALLOW TRAFFIC TO

R
PASS OVER A HOSE.

E
HOSE CONNECTIONS
FOR ACETYLENE
FOR OXYGEN
THREADED LEFT
THREADED RIGHT HAND HAND NOTCHED
PLAIN FACETS FACETS
 OTHER IMPORTANT POINTS………

1. PRESSURE:
OXYGEN - 1200 psi
ACETYLENE - 200 psi
2. EXPLOSIVE RANGE:
UPPER LOWER
ACETYLENE - 2.5% 82%
LPG - 2.2% 9.5%
 OTHER IMPORTANT POINTS……

3. KEEP THE ACETYLENE CYLINDER ALWAYS

VERTICAL/UPRIGHT. IF NOT,THE LIQUID
ACETYLENE KEPT DISSOLVED INSIDE THE
CYLINDER COULD LEAK THROUGH THREADS OF
THE VALVE FITTING. THE VOLUME OF THE LIQUID
ACETYLENE, WHICH HAS COME OUT, GETS
MULTIPLIED ENORMOUSLY AND FORMS A HUGE
VOLUME OF FLAMMABLE GAS MIXTURE IN THE
 OTHER IMPORTANT POINTS……

4. KEEP THE CYLINDERS ALWAYS PROVIDED WITH

VALVE PROTECTION CAP.
5. USE RAMP FOR UNLOADING CYLINDERS FROM TRUCK
6. USE TROLLEYS FOR MOVING CYLINDERS FROM ONE
PLACE TO THE OTHER AND KEEP THEM CHAINED.
7. ROUGH HANDLING OF THE CYLINDER COULD
DAMAGE THE VALVE. HIGH VELOCITY GAS JET
COMING THROUGH DAMAGED VALVE WOULD MAKE THE
CYLINDER FLY LIKE A MISSILE.
 OTHER IMPORTANT POINTS……

8. WHEN CYLIDERS ARE REQUIRED TO BE TAKEN TO

HEIGHT, DO NOT LIFT THEM WRAPPING SLINGS
AROUND THE CYLINDERS. INSTEAD, KEEP THEM
INSIDE SUITABLY DESIGNED CAGE/CRADDLE AND LIFT
BY USING CRANE.
9. NEVER LUBRICATE THE REGULATOR SET OF OXYGEN
CYLINDERS WITH OILS/GREASE. OIL /GREASE GETS
OXIDISED. HEAT PRODUCED DURING OXIDIZATION
COULD IGNITE OIL /GREASE.
 OTHER IMPORTANT POINTS……

10. KEEP STORE ROOM OF THE GAS CYLINDERS WEL-

VENTILATED AND DO NOT KEEP ANY HEAT SOURCES
LIKE OPEN FLAME, ELECTRIC OVENS ETC.
11. NEVER LUBRICATE THE REGULATOR SET OF OXYGEN
CYLINDERS WITH OILS/GREASE. OIL /GREASE GETS
OXIDISED. HEAT PRODUCED DURING OXIDIZATION
COULD IGNITE OIL /GREASE.
 OTHER IMPORTANT POINTS……

12. WHILE DOING GAS CUTTING IN CONFINED SPACE,

ENSURE NO LEAKAGE IN THE SET. KEEP ALL THE
VALVE CLOSED WHEN THE SET IS NOT USED. WHEN
THE WORK IS OVER IMMEDIATELY TAKE OUT THE
SET.
13. USE 24V HAND LAMP AND PNEUAMATICALLY
OPERATED HAND TOOLS WHILE DOING GAS CUTTING
INSIDE CONFINED SPACE.
 OTHER IMPORTANT POINTS……

14. BEFORE IGNITING THE TORCH ENSURE THE HOSES

ARE PURGED/FLUSHED TO LET OUT THE FLAMMABLE
GAS MIXTURE, IF ANY.
15. KEEP KEYS ON THE CYLINDER ITSELF TO CLOSE THE
VALVE IN CASE OF EMERGENCY
16. USE FLASH BACK ARRESTER
 OTHER IMPORTANT POINTS……

17. WHEN ACETYLENE CYLINDER IS ON FIRE

• CLOSE THE CYLINDER VALVE.

• WHEN IT IS NOT POSSIBLE USE WATER JET OR
DCP/CO2 EXTINGUISHERS
• INFORM NEARBY FIRE STATION WHEN IT IS
UNCONTOLLABLE
SAFETY IN WELDING
OPERATION
ELECTRIC ARC WELDING
 THREE IMPORTANT CONNECTION FOR A
WELDING CIRCUITS

WELDING LEAD:
CARRYING WELDING CURRENT FROM SOURCE OF SUPPLY TO
THE ELECTRODE HOLDER
WELDING RETURN:
CARRYING RETURN CURRENT BETWEEN THE WORK AND
SOURCE OF SUPPLY
WELDING EARTH:
CONNECTION BETWEEN WELDING CIRCUIT AND EARTH
 PERSONAL PROTECTIVE
EQUIPMENT FOR WELDING
PPE FOR WELDING OPERATION

WELDING HELMETS
 LIGHT FILTERS

•REDUCE INTENSITY OF LIGHT FROM THE WELDING ARC AND

ABSORB ULTRA VIOLATE AND INFRA RED REDIATION.

• THEY ARE GRADED IN ACCORDANCE WITH VISUAL DENSITY.

LIGHT FILTERS

WELDINGCURRENT SHADE NO.

UP TO 100 amps 8, 9
100-300 10, 11
300-400 12, 13
over 400 14, 15
Inert gas welding 14, 15, 16, IS 5893-1971
MOBILE WELDING SCREEN
 REACTION OF BODY TO
ELECTRIC SHOCK (100 VOLTS)
WILL CAUSE DEATH

100 MA OR 0.100 AMP

200 MA OR 0.200 AMP
MAY CAUSE MUSCULAR CONTRACTION
15 MA OR 0.015 AMP

20 MA OR 0.020 AMP

MAY CAUSE SOME SENSATION

1 MA OR 0.001 AMP

8 MA OR 0.008 AMP
 SEVERITY OF SHOCK NOT DEPENDS ON
VOLTAGE ALONE BUT…..DEPENDS ON

1 QUANTITY OF CURRENT FLOWING THROUGH THE BODY

2 PATH OF CURRENT FLOWING THROUGH THE BODY

3 LENGTH OF TIME BODY IS IN CURRENT

WELDING AND FIRE SAFETY
FLAMMABLE AND COMBUSTIBLE MATERIAL
MAY BE IGNITED BY

SPARKS
 HOT METAL
CONDUCTED HEAT
FLAME
ELECTRIC ARC
STRAY CURRENT
GAS WELDING TORCH
BACK FIRE IN GAS WELDING EQUIPMENT
 TO PREVENT WELDING FIRES

• REMOVE FLAMMABLE AND COMBUSTIBLE MATERIAL TO A

SAFE DISTANCE

• SUITABLE FIRE EXTINGUISHER SHOULD BE READILIY

AVAILABLE

• ISSUE PERMIT-TO-WORK WHEN SPECIAL PRECAUTIONS ARE

TO BE TAKEN
 TO PREVENT WELDING FIRES

• DO NOT LEAVE ELECTRIC CIRCUIT ON OR BLOW TORCHES

BURNING WHEN WELDER HAS TO BE AWAY

• AFTER THE WORK IS THROUGH DO NOT LEAVE BEHIND ANY

MATERIAL SMOULDERING
 TO PREVENT WELDING FIRES

• PROVIDE SCREENS OR PARTITIONS TO PREVENT WELDING

SPARKS SPREADING AROUND
• COVER COMBUSTIBLE MATERIALS WHICH CAN NOT BE
REMOVED, WITH NON-COMBUSTUBLE COVERINGS
THANK Q