SAFETY DURING GAS

CUTTING & WELDING

 SAFETY IN GAS
CUTTING OPERATION
 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;

• 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;
• 30% oxygen in the atmosphere will cause things to
burn or explode 8 times faster.
 What is acetylene?

 Acetylene is a compound of Carbon and Hydrogen (C 2H2) a member of

the hydrocarbon gases;
 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.
SAFETY DURING GAS CUTTING WORKS

• Colour code of the Cylinder

Oxygen - Black
Acetylene – Maroon
Nitrogen – Light Blue
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 pressure
gauge from tank
Indicates
the delivery
pressure to
the hoses & The Inlet Connections
torch Oxygen are right handed
thread / Acetylene are left
handed thread
The Pressure adjusting screw Keep free of oil, grease,
Turning clockwise allows the gas allows to & dirt
flow
Turning counterclockwise reduces or stops
the gas flow
 The Hoses

• The hoses are usually color coded, but not always

– Oxygen (black / blue)
– Acetylene(red)
– Be careful not to use other hoses, such as air lines, LP gas, etc.
• They are neoprene over braided inner section and ISI marked
– 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 gas 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/gas cutting torch
handle or regulators.
 If cuts, burns, worn areas or damaged fittings are found, replace
the hose.
 Completely replace gas hose if it contains multiple splices or when
cracks or severe wear is noticed.
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 cut / 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 $$$$.
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

ON UB O
LY BE SE
PR R
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 - 200 psi
ACETYLENE - 1200 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 ATMOSPHERE.
 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.
 OTHER IMPORTANT POINTS……

11. WHILE DOING GAS CUTTING IN CONFINED SPACE, ENSURE

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

13. BEFORE IGNITING THE TORCH ENSURE THE HOSES ARE

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

16. 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
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 them
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
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
SAFETY IN WELDING
OPERATION
 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
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
 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, 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, fire etc.
For the return lead use only proper cables. Use of 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 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
Fire extinguishers should be kept near welding spot 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
 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
 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
 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
 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

QUANTITY OF CURRENT FLOWING

1 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
WELDING OF EMPTY DRUMS, TANKS OR CLOSED CONTAINERS
THAT HAVE HELD FLAMMABLE LIQUID OR OTHER
COMBUSTIBLE MATERIALS

THOROUGHLY CLEAN
FILL WITH WATER TO WITHIN AN INCH OR TWO OF THE
PLACE WHERE WELDING IS TO BE DONE.
FILL REST OF THE SPACE WITH NITROGEN OR
CARBONDIOXIDE. IF NOT AVAILABLE FILL WITH WATER.
ANY Q?
THANK Q