Welding, Cutting & Grinding-1

WELDING, CUTTING & GRINDING
1
SAFETY BRIEF
IN CASE OF AN EMERGENCY DURING THE TRAINING DO

NOT GET PANIC AND KINDLY FOLLOW THE TRAINER
INSTRUCTIONS.
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LEARNING OUTCOMES
At the end of this training you will know:
Welding
– Definition and General Overview
– Hazards in Welding
 Health Hazards
 Safety Hazards
– Preventive and protection measures
• Oxy-Fuel Cutting
– Hazards and preventive/protection measures in Oxy-fuel Cutting
• Grinding
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– Hazards and ppreventive/protection measures in Grinding
WELDING
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What is Welding?
Welding is a fabrication process that joints
materials (usually metals or
thermoplastics) by causing coalescence.
This is often done by melting the work

pieces and adding filler material to form a
pool of molten material (the weld pool)
that cools to become a strong joint, with
pressure sometimes used in conjunction
with heat, or by itself, to produce the
weld.
5
Different types of Welding Process
Arc Welding: process using a welding power supply to create
electrical arc between an electrode and the base material to
melt metals at welding points:
– SMAW (Shielded Metal Arc Welding)
– GMAW (Gas Metal Arc Welding)
• MIG (Metal Inert Gas)
• MAG (Metal Active Gas)
– GTAW (Gas Tungsten Arc Welding) or TIG (Tungsten

Inert Gas)
– FCAW (Flux Cored Arc Welding)
– SAW (Submerged Arc Welding)
– Resistance or Spot Welding 6

Different types of Welding Process
Oxy-fuel Gas Welding: welding processes that use fuel gases and
oxygen to weld metals:
 Oxy-acetylene welding
 Oxy-hydrogen torch
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Hazards in Welding
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Health Hazards Hazards in Welding
– Fumes and Gases
– Noise
– Heat
– Visible light, Ultraviolet & Infrared Radiation
– Electromagnetic Fields
– Awkward Positions
Safety Hazards
– Hot surfaces & spatters
– Electricity
– Fire & Explosion
– Confined Space
– Trips and Fall
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Health Hazards in Welding: FUMES
& GASES
• Fumes come from the vaporization of metals and from the formation of oxides; during the welding
process many particles are released and mix with the fumes; the size of the particles can vary from
0,1 to 1mm.
 Composition of fumes depends on:
 type of welding rods;
 base metal;
 coatings present on the base metal or covering the electrode;
 contaminants in the air or on the base metal (i.e. vapors from cleaners
and degreasers)
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Health Hazards in Welding: FUMES & GASES
During the welding process gases are also

released in the surrounding environmet; the
type of released gases depends on:
Shielding gases supplied from cylinders:

 Argon
 Helium
 Oxygen
 Carbon Dioxide
Combustion and temperature:

 Ozone
 Carbon Dioxide
 Carbon Monoxide
 Nitrogen Oxides (Oxidation of atmospheric N2 creates
NO and NO2) 11
FUMES & GASES: Health Effect
Immediate (Acute) Effects
• Metal fumes (i.e. zinc, magnesium, copper, copper oxide, etc.) can cause:
 Metal Fume Fever: chills, thirst, fever,

muscle ache, chest soreness, coughing,
wheezing, fatigue, nausea, and a
metallic taste in the mouth may occur 4
to 12 hours after exposure
 Irritation effects to eyes, nose, chest,
and respiratory tract,
 Respiratory effects: Shortness of breath,
bronchitis, pulmonary edema,
pneumonitis;
 Gastrointestinal effects: Nausea, loss of
appetite, vomiting, cramps, slow
digestion
 Some components of welding fumes (i.e. Chromium VI and Cadmium) can be
fatal in a short time;
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FUMES & GASES: Health Effect
Immediate (Acute) Effects
• Ozone and Nitrogen Oxides (secondary gases given off by the welding process):
 Deadly at high doses
 Irritation of the nose and throat and serious lung disease
• Phosgene gas (reaction between UV rays and chlorinated hydrocarbon solvents):

 Deadly in a very small amount, although early symptoms of exposure - dizziness, chills, and cough usually
take 5 or 6 hours to appear
NOTE: Arc welding should never be performed within 60m of degreasing equipment or solvents; where not
applicable (e.g. on board Vessels), particular R.A. should be issued.
13
FUMES & GAS: Health Effect
Long Term (Chronic) Effects
• Increased risk of various types of cancers and

 Fumes contain large quantity of toxic substances, including
cancer-causing agents (i.e. cadmium, nickel, beryllium,
chromium, and arsenic)
• Chronic respiratory problems:

 Bronchitis, asthma, pneumonia, emphysema,
pneumoconiosis (dust-related diseases) and decreased lung
capacity
 Silicosis (silica exposure)
 Siderosis (caused by iron oxide dust in the lungs)
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FUMES & GAS: Health Effect
Long Term (Chronic) Effects
• Other Health problems:

 heart and skin diseases, hearing loss, chronic gastritis, gastroduodenitis, ulcers of the stomach and small
intestine;
 kidney damage due to exposure to heavy metals such as chromium and nickel
 Leukemia
 Welding or cutting on surfaces covered with

Asbestos insulation can cause:
 asbestosis, lung cancer, mesothelioma,
and other asbestos-related diseases;
NOTE: employees shall be trained and provided with
the proper protective equipment before welding near
asbestos-containing material!
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FUMES & GAS: Preventive and Protective Measures
• Prefer welding techniques which give off less gases and fumes:
 SMAW produces big amount of fumes
 GMAW and GTAW preferable to SMAW
 SAW produces the minor amount of fumes
• Use consumable electrodes which produces less amount of fumes:
Cellulose
(16 mg/s)
Acid
(9 mg/s)
Basic
(7,5 mg/s)
Basic
Rutil
Rutil (5 mg/s)
(3,5 mg/s)
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• Use safer filler materials
• Remove all paint and galvanized coating before welding
 Provide Local Exhaust Ventilation (LEV)
NOTE: unless a detailed and thorough

risk assessment shows that harmful
fumes are not being generated or may
be controlled by general ventilation
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• Not welding near cleaning processes using chlorinated solvents, vapor degreaser or on metal that
has been degreased (10m for most welding - 20m for aluminum)
NOTE: the heat and arc from welding may break down the solvents into harmful substance(s)
• Provide Respiratory PPE
NOTE: only whether control measures are unable to reduce fumes to a safe level
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FUMES & GAS: Preventive and Protection Measures
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FUMES & GAS: Preventive and Protection Measures
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Health Hazards in Welding: NOISE
Welding areas could be a noisy environment due to the presence of:
• Welding machines (i.e. plasma arc cutting, plasma arc gouging or air carbon arc gouging)
• Grinding machines;
• Equipment for local ventilation
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NOISE: Health Effects
Short Term Effect (acute)
• Eardrum rupture
Long Term Effect (chronic)
• Noise-induced hearing loss
• Tinnitus
• Hypertension
• Ischemic heart disease
• Annoyance
• Changes in the immune system and birth defects
• Stress, Headaches, Fatigue, Stomach Ulcers, Constipation, Slackness, Lack of appetite,

Vertigo, Anti-social Behaviours, Aggression
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NOISE: Preventive and Protective Measures
• If control measures (silent equipment, soundproof panels, sound insulation) are unable to reduce
noise to a safe level, Wear Ear Protective Devices or Earplugs.
 Ear Protective devices must be worn during performing plasma arc cutting, plasma arc gouging or air
carbon arc gouging.
NOTE: ear protection can prevent hot spatter from entering the ear; warn others in area of
possible noise hazards
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Health Hazards in Welding - HEAT
Heat
• Welding activities exposes the workers to very hot temperatures:
 Flame temperature during Oxy-fuel welding can reach 3000 °C;
 The Arc Temperature during Arc welding exceeds 3800°C
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HEAT: Health Effects
• Excessive exposure to heat can result in:
 Heat stress
 Heat stroke
• Welders should be aware of the symptoms:
 Fatigue
 Dizziness
 Loss of appetite
 Nausea
 Abdominal pain
 Irritability
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HEAT: Preventive and Protective Measures
• Typical preventive and protective measures against heat-related hazards are:
 Ventilation
 Shielding
 Rest breaks
 Drinking plenty of cool water

Health Hazards in Welding – VISIBLE LIGHT, UV & IR RADIATION
ARC RAYS can burn eyes and skin:
• Wear welding helmet with correct filter
• The high temperatures reached by flames and arcs during welding activities produce electromagnetic
radiations, which cover the following range of the Electromagnetic Spectrum:
 Infrared - IR
 Visible
 Ultraviolet - UV
VISIBLE LIGHT, UV & IR RADIATION: Health Hazard
TARGET: EYES - SKIN
Eyes
(es. retina damage, crystallin lens
blurring…)
Skin (es. burns, phototoxic

ractions…)
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Short term effect (acute)
• Intense visible light can cause damage to retina’s eye
• IR may damage the cornea;
• UV from the arc can cause “arc eye” or “welder’s flash” after even a brief
exposure (less than 1 min)
 the symptoms of arc eye include feeling of sand or grit in the eye,
blurred vision, intense pain, tearing, burning, headache. Usually
occur many hours after exposure
 The arc can reflect off surrounding materials and burn nearby co-workers
 about half of welder’s flash injuries occurs in co-workers who are not welding
 Exposure to UV can cause skin burns similar to sunburn
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Long term effect (acute)
• IR may result in the formation of cataracts;
• Welders and Cutters who continually work around UV without proper protection can suffer permanent eye
damage
 Exposure to UV increase the welder’s risk

of skin cancer.
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VISIBLE, UV & IR RADIATION: Preventive and Protection Measures
General preventive measures against Visible, UV & IR Radiation
• Use welding techniques with less emission of Electromagnetic Radiation
NOTE 1: Arc welding emits Visible, UV and IR radiation

depending on:
 Current intensity
 Arc length
 Temperature
 Temperature distribution in the environment
 MIG and MAG give off more intense radiation than

SMAW because the used current is higher
NOTE 2: Oxy-fuel welding does not give off UV radiation
 Reduce “Exposure Time” to radiation.
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Other safety hazards related to heat in welding
activities: SPATTERS/SPARKS
• The high temperatures reached by the welding processes and the welding process itself can cause:
 Spatters
 Sparks
 Hot surfaces
 Metal Chips
 Hot slag
 The interaction between human body and the

above products of welding process can provoke
 Burns
 Eye injuries
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EM RADIATIONS & SPATTERS/SPARKS: Preventive and Protection Measures
 Shield the welding station with metal or heat resistant shields

NOTE: If not practicable, everyone within about 25m should wear eye protection when welding or cutting is in
progress
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EM RADIATIONS & SPATTERS/SPARKS: Preventive and Protection Measures
Safe work practices to protect from EM Radiations and Spatters

• Wear Protective Clothing such as:
 Heat resistant jackets
 Aprons
 Leggings
NOTE 1: thin cotton clothing is inadequate protection (cotton deteriorates with this type of radiation)
NOTE 2: do not wear clothing that has been stained with oil and grease (it may burn if ignited by the heat of the
arc)
• Wear Cuffless Pants in order to eliminate a dangerous spark-spatter trap
 Pants legs shall overlap shoe tops to prevent spatter from getting into the shoes;
• Wear High Safety Shoes, in order to avoid hot spatter to get inside
 shoes must be fitted with quick release system;
• Wear Ear Protection in order to avoid chance that spatter or sparks could get into your ears;
• Wear a Leather Cap or other protection to protect the head from sparks or spatter;
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EM RADIATIONS & SPATTERS: Preventive and Protection Measures
• Keep your pockets, sleeves and collars buttoned:

 Sparks may lodge in them and cause fires or burns
 Be sure your pockets are emptied of combustibles such as matches and other flammables.
 Wear Safety Glasses with Side Shields

for protection from arc burns and
burns from sparks or spatter;
 be aware that arc gouging spatter can spray a
long distance;
 Wear a Helmet over safety glasses;
 Keep Sleeves rolled down
 Wear Gloves;
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EM RADIATIONS: Preventive and Protection Measures
 Use Correct Lens Shade to prevent eye injury;

NOTE: Observers shall also use proper protection.
Health Hazards in Welding:
ELECTROMAGNETIC FIELDS
• Arc welding activities requires high currents (up to

1000A)
Linear Conductor
Magnetic Field mT
(i.e. welding
cable)
• This generates a very intensive magnetic field
(about 200mT) Source
(i.e. small
NOTE: This field rapidly decrease with the welding machine)
distance from the electric source
Distance (meter)
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ELECTROMAGNETIC FIELDS: Health Hazards
Short Term Effect (Acute)
• Heating is the main biological effect of the EM fields of radiofrequency fields.
• EM Fields may interfere with some pacemakers

NOTE: Welders having pacemakers should consult their physician before welding
Long Term Effects (Chronic)

• Exposure to EMF may have other health effects which are unknown
 Connection between EM fields and cancer is highly controversial, despite many studies. It is clear that if
EM fields do have an effect on cancer, then any increase in risk will be extremely small
 Some individuals report "hypersensitivity" to electric or magnetic fields (aches and pains, headaches,
depression, lethargy, sleeping disorders, and even convulsions and epileptic seizures might be associated
with EM field exposure)
 A number of epidemiological studies suggest small increases in risk of childhood leukemia with exposure
to low frequency magnetic fields
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ELECTROMAGNETIC FIELDS: Preventive and Protection
Measures
Welders should use the following procedures to minimize exposure to EM Fields:
 Route the electrode and work cables together,
secure them with tape when possible;
 Never coil the torch or work cable around your

body;
 Do not place your body between the torch and

work cables, route cables on the same side of
your body;
 Connect the work cable to the workpiece as close as possible to the area being
welded;
 Keep welding power source and cables as far away from your body as possible.
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Health Hazards in Welding – AWKWARD POSITIONS
Awkward positions
The welder must be able to clearly see the workpiece, so it tends to assume awkward postures,
bending, keep the arms above the shoulders ...
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AWKWARD POSITIONS – Health Effects
Awkward positions and the typical welder’s work postures contribute to Musculoskeletal Injuries.
The most frequent muskuloskeletal injuries are:

• Back injuries
• Shoulder pain
• Tendonitis
• Reduced muscle strength
• Carpal tunnel syndrome
• White finger
• Knee joint diseases
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AWKWARD POSITIONS: Preventive and Protective
Measures
Musculoskeletal Injuries caused by awkward positions can be prevented by proper techniques:
• Not working in one position for long periods of time;
• Keeping the work at a comfortable height;
• Using a foot rest when standing for long periods;
• Locating tools and materials conveniently;
• Use mechanical arms to reduce weight of cables
• Minimizing vibration.
42
Safety Hazards in Welding - ELECTRICITY
Sources of Electrical Hazard

in Welding:
• Welding machine
• Work connection/electrical cable
• Electrode holder 43
ELECTRICITY – Safety Hazard
Effects of electricity on human body
• The effects of electricity on human body depend on:
 Potential difference / Voltage of equipment
 Type of current (AC/DC) and its frequency
 Path of the current along the body
 Hand-hand
 Hand-foot
 Chest-Hand
 Skin conditions (wet, dry, integrity)
 Humidity / Environmental Condition
• Effects of electricity, in order of severity, are:

 Local burns
 Tetanization (stiffening of muscles fibers)
 Asphyxiation (due to tetanization of respiratory muscles)
 Ventricular fibrillation (Electric shock)
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ELECTRICITY: Preventive and Protection Measures
Safe work practice to prevent Electric Shock
Electrical equipment and workpiece must be well connected to prevent electric shocks:
a. connect power supply and control cabinet chassis to approved earth ground;
b. connect workpiece to “work” output connection of power supply;
c. connect workpiece OR power supply work terminal (but not both) to approved earth ground;
 “double-grounding” can cause current to occur

in conductors intended only for safety
grounding and can result in destruction of the
safety ground
 the work lead is NOT a ground lead; is to be

used only to complete the welding circuit.
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• Be insulate from workpiece and ground:
 Wear rubber-soled shoes, or stand on a dry board or platform (Moisture and water can conduct
electricity)
• To prevent shocks keep work areas, equipment, and clothing dry at all times
• Fix water leaks immediately
• Keep hoses from touching hot metal
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• Use only the proper equipment if welding must be done in electrically-hazardous conditions
Such conditions include:
 damp or warm locations
 wet clothing
 metal structures such as floors or scaffolds
 cramped positions or wherever there is a high risk of contact with workpiece or ground
In any of these situations use:

 DC MIG welding
 DC manual (stick electrode) welding
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• Make sure electrical connections are tight, clean, and dry
 If not they could heat up, and even melt
 They can also cause bad welds and produce dangerous arcs and sparks
 Do not try to make an electrical connection through paint
 Improper or worn electrical connections can cause electrical shocks
• Do not allow water, grease, or dirt to accumulate on plugs, sockets, or electrical units
• Open-circuit voltage of welding, cutting and gouging power supplies can cause electric shock
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• When several welders are working with arcs of different polarities, or when using multiple alternating
current machines, the open-circuit voltages can be additive:
 The added voltages increase the severity of the shock hazard.
• Remove metal jewelry (rings, watches, necklaces and other metallic items )
 Accidental contact of jewelry with welding power can cause metal to become hot or even melt, as well
as increase the possibility of a fatal shock.
49
Safety Hazards in Welding – FIRE
AND EXPLOSIONS
Fire and Explosion Hazard

• performing welding in undesignated hot work area
• performing welding in near proximity to highly combustible and explosive material
50
FIRE AND EXPLOSIONS: Safety
Effects
Safety Effects of Fire and Explosion
• Damage to human body:
 Burns
 Ear drum rupture
 Lung damages
 Other severe injuries
• Damage to properties
• Environmental contamination
• Escalation effects
51
FIRE AND EXPLOSIONS: Preventive and
Protection Measures
• Maintain a Safe Workplace:
 if possible move the material to be welded or cut to a specific safe location;
 areas for welding and cutting must be kept clear and free combustible solids (i.e. paper, packing
material, wood), flammable liquids and flammable gases.
• Provide Fire Barriers:

 if welding or cutting cannot be performed in a designated location or away from combustible
materials, provide metal sheets or fire-resistant blankets.
• Be alert for cracks or crevices and look for holes or openings in the floor:
 sparks and slag can travel long distances; so they can start a fire at a location not apparent to the
welder;
 crevices around pipes and other openings can hide smoldering fire.
• Provide proper Fire Extinguishing Equipment ( their use and type depend on the quantity and type of
combustible material):
 be prepared to put out fires;
 serviceable fire extinguishers, fire hoses, or sand buckets should be on hand.
52
Protection Measures
• Always consider the need for a fire watcher:
 welders may not become aware of a fire starting while welding because their vision is hampered by
the welding helmet and dark lenses;
 depending upon the welding location, it may be advisable to have a fire watcher to man an
extinguisher and sound a fire alarm in case of a fire.
• Know the local fire codes for welding and cutting (i.e. NFPA 51B).
• Inspect the work area after completing operation:

 make sure there are no hot sparks or hot metal which could start a fire later.
• Use a “Hot Work” Permit System:

 before welding or cutting begins in a new or unauthorized location the location shall be inspected;
the inspector should authorize the work before you begin.
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HOT WORK PERMIT Protection Measures
Verify, where necessary, that for the

welding activities a specific Work Permit
has been issued before the
commencement of the activities
Verify that permit requirements are met

during the course of operations
54
Safety Hazards in Welding – WELDING and
CUTTING of CONTAINERS
55
Safety Hazards in Welding – SHIELDING
GASES
SHIELDING GASES
Electric welding and cutting processes need the use of Shielding Gases, such as:
 Argon
 Helium
 Carbon dioxide
 Nitrogen
56
SHIELDING GASES: Safety Effects
SUFFOCATION
• Shielding gases used in welding and cutting activities are:
 Inert
 Colorless
 Odorless
 Tasteless gases
• They cannot be detected by the human senses and can displace the oxygen required for normal
breathing.
NOTE: Shielding gases are heavier or lighter than air and may displace breathing air in treat pits, tank
bottoms, ceilings, etc.
• An atmosphere with less that 19% oxygen can cause:

 Dizziness
 Unconsciousness
 or even Death
NOTE: this can happen without any warning signs!!!
57
SHIELDING GASES: Preventive and
Protective Measures
• Before entering a confined area:
 perform a check with an Oxygen analyzer to be sure it contains a life supporting atmosphere;
 make sure it is well ventilated, otherwise wear an Air Supplied Respirator;
 a second person (Standby Man), similarly equipped, shall be standing by:
 Monitoring oxygen level throughout operation;
 Activate the emergency procedure (if needed).
• Do not bring cylinders of shielding gas into confined areas.
• Do not leave shielding gas equipment in confined areas when not in use.
• Hydrogen, in addition to be a flammable gas, is a colorless, odorless and tasteless gas which can act as a
asphyxiant.
 Being lighter than air, hydrogen can accumulate in upper portions of confined areas
58
Safety Hazards in Welding – GAS
CYLINDERS
• Gases required by welding activities are stored in Cylinders.
• Gas cylinders shall be constructed and maintained in accordance with local and international
regulations
59
GAS CYLINDERS: Safety Effects
• Gases are compressed to 2000 to 5000 psig in high pressure cylinders
• Liquefied gases can be as cold as -267°C
Sudden rupture of CYLINDER VALVE or RELIEF DEVICE

can
INJURE
or
KILL
and can cause
PROPERTY DAMAGE (ROCKETING EFFECT)
60
GAS CYLINDERS: Preventive and Protection Measures
• Cylinders must be clearly labeled with the name of the gas to identify the contents;
 if does not bear a label, or if it is not legible: DO NOT USE THE CYLINDER!!!
NOTE: do not assume the identity of the gas by the cylinder paint color or other means but return the
cylinder to the supplier for identification or cylinder replacement
• Handle, store, use cylinders in an upright and secured position

• Secure cylinders by chain or strap to suitable carts, benches, wall, post, or racks
61
• If transporting cylinders in vehicles such as pick-up trucks, secure

other cargo as well so it cannot roll, slide or skid damaging the
cylinders
 never transport cylinders in the trunk of a car.
 Valve must be closed and cap in place

 unless in use, cylinder valves must be kept closed at all times
 when manually lifted do not raise them by the valve-protection cap (the cap may
accidently and suddenly come loose)
 Do not store cylinders in confined unventilated spaces such as closets, drawers,

cabinets or work boxes
62
• Use suitable hand trucks or racks for moving cylinders
• Properly capped cylinders may be moved for short distances by rolling them on their base
 do not roll cylinders on a wet or steel dock plate
NOTE: care must be taken to prevent the cylinder from rolling or sliding out of control
• Do not slide or drag or bump cylinders
• Do not allow cylinders to drop or tip over
• Never use slings or electro-magnets for lifting and transporting cylinders
• Use a cradle or suitable platform when transporting by crane or derrick
63
GAS CYLINDERS: Preventive and
Protection Measures
64
• Never tamper with safety-relief devices!

NOTE: they are provided to vent the contents to relieve excessive pressure within the cylinders if exposed to
fire or excess temperatures
• Cylinders must not be placed where they might become part of an electrical circuit
• Cylinders must never be used as a grounding connection
• Store high-pressure and liquefied-gas cylinders in a separate, dry, well-ventilated room
• Do not let full or empty cylinders stand around and clutter up work areas
65
• Never use any gas from cylinder except through an approved Pressure-reducing Regulator (designed for
reducing the high pressure in the cylinder to a constant, controllable working pressure for the equipment
in use)
 a single approved regulator may be connected to the outlet of manifolded cylinders supplying one or
more use points;
 use the proper gas pressures recommended for the equipment as furnished by the equipment
manufacturer;
 do not adapt a regulator to use it with a gas for which it was not designed.
NOTE: a regulator must be approved for the particular gas being handled
66
GAS CYLINDERS: Preventive and Protection
Measures
• Never transfer any gas from one cylinder to another or attempt to mix any gases in a cylinder
NOTE: it could result in a cylinder rupture or explosion
• Cylinders must not be exposed to

 welding and cutting work
 falling objects
 moving machinery
 vehicular traffic
• Storage areas should be located where cylinders will not likely get knocked over
67
Protection Measures
• Full and empty cylinders must be stored separately
• Storage location shall be arranged so that the old stock of cylinders can be removed first
• Cylinders should not be exposed to continuous dampness, stored near salt water or corrosive chemicals or
fumes
 corrosion can weaken the cylinder, eventually leading to a sudden rupture or explosion
68
Protection Measures
• Store cylinders at least 10m from any combustible materials
• Do not subject cylinders to temperatures above 50°C
• Flammable-gas cylinder storage areas should meet the design requirements of NFPA Standard 51 or 58
• Smoking, open flames, and other sources of ignition must be prohibited in areas where flammable gases
are stored
69
Protection Measures
 CYLINDERS MUST BE
GROUPED BY TYPES OF GAS
Where gases of different types are stored at the

same location:
 Oxygen cylinders must be separated from
flammable-gas cylinders at a minimum
distance of 5m or,
 a non-combustible barrier at least 1,5m high
having a fire-resistance rating of at least 1
hour
70
Protection Measures
ARC BURNS
• Prevent Arc-Burns on cylinders:
 accidental arcing could cause a brittle local defect
(arc-burn) which could lead to eventual cylinder
rupture
 it can be caused by arc current passing through a

grounded cylinder
 it can happen quickly and in a number of ways
REMEMBER: keep the torch, arc, and any source of

current away from compressed gas cylinders, with a
little care while operating!
71
Protection Measures
• Arc-burn damage can be eliminated by following these precautionary steps:
 Never strike an arc on a cylinder, when you want to test the system operation
 use a piece of grounded scrap metal
 Be sure that shielding-gas cylinders are never grounded:

 Cylinders, fittings, and supports should be electrically insulated from metallic building
structures or fixtures to which they are secured
 Do not fasten cylinders to work tables or fixtures that may become part of the work circuit
 Use insulating shields to electrically isolate cylinders that cannot be removed
 Be careful of where and how the work is grounded so that the ground connections will
never touch the cylinder
 Do not hang the torch or any electrode holder on the cylinder

 use a nearby hook and not the regulator or the flowmeter
 Make sure all electrical wiring is in good condition and repair or replace defective,
frayed or exposed sections immediately
72
Protection Measures
73
Measures
CONNECTING AND ADJUSTING SHIELDING GAS SUPPLY
A series of step and things to check are required during hook up cylinders in order to prevent injury or death
as well as prevent equipment and property damage:
• Fasten the cylinders to be used in an upright position;
 if cylinders are not on a suitable cylinder cart, they should be securely chained or
strapped to a workbench, wall, or post so that they cannot be accidentally
knocked or pulled over
• “Crack” the cylinder valve: stand at one side or rear of the cylinder outlet, open the cylinder valve slightly
for an instant and then close it.
NOTE 1: this will clean the valve of dust or dirt which may have accumulated during
storage (dirt can damage critical parts of a regulator!)
NOTE 2: valves on flammable-gas cylinders should NOT be “cracked” near welding or cutting work in
progress or near sparks, flame or other possible sources of ignition
74
Measures
75
Measures
• Always attach a Regulator to the gas supply (and a Flowmeter when required), when a single cylinder is
used
 A pressure-reducing regulator must be connected at the cylinder valve
 Normally a combination regulator-flowmeter is used
NOTE: make certain that the regulator is proper for the particular gas, service
pressure, and flow requirements
• If the shielding gas is supplied at the proper working pressure through a piping system that is regulated
from a large storage unit or bank of manifolded cylinders, a flowmeter may be connected at the work
station
• When using adaptors the instructions of manufacturer must be followed

 the various Compressed Gas Association (CGA) designated connections are
designed for your protection!
76
Protection Measures
• Never force connections not properly fitting ( this can strip the threads on fittings
resulting in leaky connections)
• To prevent leakage be sure the regulator nut is pulled up wrench-tight, not merely hand-tight;
NOTE: do not tighten the connections excessively
• Do not use lubricants or pipe fitting compound for making connections

 Oil or grease in lubricants and compounds tends to gum up regulating equipment
and torches;
 lubricants and compounds can also contaminate the shielding gas, and in the case
of oxygen service they can cause a catastrophic fire and personal injury
NOTE: connections in apparatus are designed so that they can be made up clean and
leak tight
77
Protection Measures
• Make sure the regulator pressure-adjusting screw is released by rotating it counterclockwise until it turns
freely
 this closes the regulator valve and prevents a sudden surge of pressure from
possibly damaging components in the system
 if regulator is equipped with a flowmeter, be certain the flow control valve is
closed by turning the knob all the way in (clockwise)
 Stand to one side of the regulator or

regulator/flowmeter away from gauge face
 Slowly open the cylinder valve
 Never open a cylinder valve suddenly,

sudden surge of high pressure gas can
weaken or damage critical components in
the regulator
78
Protection Measures
• Check all connections and joints for leaks
 use suitable leak test solution for every connection and joint from cylinder to
torch
• After making all connections, close torch or downstream valve and then turn the regulator pressure-
adjusting screw to the desired operating pressure (or just open the flowmeter valve).
• Never tighten a leaky connection between a regulator and cylinder when under pressure
NOTE: Close the cylinder valve, allow the trapped gas to leak out and then tighten
the connection!
79
Measures
• Always be sure you are using the correct gas pressure and gas flow
 refer to the manufacturer’s instructions for the torch or apparatus being used
NOTE: if operated properly, the regulator maintains pressure as set; the required flow
rate will of course vary according to the type of job
• As soon as you have finished working or if you are going to disconnect the regulator or regulator-
flowmeter combination, do the following:
1) close the cylinder valve
2) open the flowmeter and torch valves to release all pressure from the hose and
regulator
3) when the gauge pressure drops to zero, close the flowmeter valve
NOTE: this will prevent the occurrence of an accident caused by someone removing
the regulator with the cylinder valve open
4. double check by observing the inlet gauge
80
CONFINED SPACES in Welding Activities
CONFINED SPACES
Introduction/definition
Many different places require welding, cutting,

and heating work and some of these lack of
space, becoming a “confined space”
Confined spaces have the following

characteristics:
• Limited space, entry, or exit
• Poor ventilation
 lack of safe breathing air and
possible buildup of hazardous
gases, fumes, and particles
81
Examples of Confined Spaces
 small rooms  degreasers
 process vessels  boilers
 pits  furnaces
 tunnels  silos
 sewers  compartments of ships
 underground utility vaults  ventilation and exhaust ducts
 unventilated corner of a room  storage tanks
 pipelines  reactor vessels
Reasons for deaths and serious injuries from welding in confined

spaces
fire – explosion – asphyxiation – electric shock – exposure to
hazardous air contaminants 82
Actions required before start of work in a confined space
– Only trained personnel shall enter into a confined space
– Obtain the necessary permits
– A specific JSA must be done before starting the job and discussed with workforce
involved
– Open all covers and secure them from closing
– Test confined space atmosphere for:
1) suitable oxygen content
2) no combustibles or reactives
3) no toxics
NOTE: testing requires specific trainings
83
Actions required before start of work in a confined space
 Isolate lines by capping or double
valving and venting
 if feasible-keep vents open and
valves leak-free
 Lock out all systems not required during

welding, cutting, or heating
 Provide means for readily turning off

power, gas, and other supplies from
outside the confined space
–Protect or remove any hazardous materials or materials which

may become a physical or health risk when heated or exposed to
an arc
84
Required actions during work in a confined space

– continuously ventilate and monitor confined space atmosphere to ensure that fumes and gases do not
exceed safe exposure limits
– use proper Breathing Devices (SCBA) as required by code, instruction/good practice
– do not bring (at all) gas cylinder into confined space and do not leave gas equipment in confined areas
when not in use
– keep unnecessary persons and equipment out of and away from the confined space
– do not allow equipment to block exit or possible rescue efforts
– do not go into a confined space unless a Watchperson (Standby man), properly equipped and trained for
rescue, is outside and maintaining continuous communications with worker inside and the emergency
team informed
– provide means for turning off power, gases, and fuel from inside the confined space if feasible
 especially whether outside turn-off means are not provided, feasible, or certain
85
Oxy-Fuel Cutting
Oxy-fuel cutting is a processes that use fuel
gases and oxygen to cut metals.
In oxy-fuel cutting, a torch is used to heat

metal to its kindling temperature.
A stream of oxygen is then trained on the

metal, burning it into a metal oxide that
flows out of the kerf as slag
86
Hazards in Oxy-Fuel Cutting
Health Hazards
– Fumes and Gases
– Heat
– Visible light & Infrared Radiation
– Awkward Positions
Safety Hazards
– Hot surfaces & Spatters
– Fire & Explosion
– Confined Space
– Trips and Fall
87
GASES in Gas Cutting: Safety Hazards and
Mitigative Measures
OXYGEN (O2)
O2 causes fire to burn more rapidly
Anything that burns in air burns violently in O 2
– Do not use oil! Keep regulators, hoses, torches and other oxy-fuel gas equipment free of grease, oil, coal
dust, lubricants and other combustibles
 this and similar combustibles once ignited burns violently in the presence of O 2
and may cause serious burns or explosions
 connections are designed for seating leak tight without sealants or lubricants
– Never substitute oxygen for compressed air: O2 shall never be called air
 O2 should never be used in pneumatic tools, in oil preheating burners, to start
internal combustion engines, to blow out pipelines, to dust clothing or work, for
pressure tests of any kind or for ventilation
 Using oxygen as air may result in serious burns or explosions
– Never allow O2 or O2-rich air to saturate your clothing
NOTE: materials that can be ignited in air have lower ignition temperatures in O 2
88
FUEL GASES
Mitigative Measures
Fuel gas can explode in air or O2 if ignited by flame, spark, or other ignition source
Fuel gas can cause rapid suffocation without warning
– Acetylene, natural gas and liquefied petroleum gases (i.e. Propane, Butane, Propylene) are the
commonly used gas in welding, cutting, and heating processes.
– Remember that these gases can displace O 2 and create an atmosphere with less than 19% O 2, causing
rapid dizziness, unconsciousness, or even death.
NOTE: call fuel gases by their proper names, not just “gas”; fuel gases differ from each
other in heat contents, flammability limits, handling characteristics and safe handling
requirements, therefore be specific when refer to a particular fuel gas
89
Mitigative Measures
The following table compares the relative vapor density of fuel gases with that of air:
– NOTE 1: Acetylene and natural gas are lighter than air. They will rise and can collect in high places as
well as in closed areas
 be sure to provide enough ventilation to disperse the light vapors
– NOTE 2: Propylene, Butane, Propane, and MAPP are heavier than air, so they may spread to poorly
ventilated areas along the floors or beneath equipment. Also, they tend to diffuse in air slowly,
increasing the hazards of accumulation
 forced ventilation and exhaust duct at floor level may thus be desirable to
protect against unexpected release of the heavier fuel gases
90
*methylacetylene-propadiene propane
Mitigative Measures
– Fuel gases must never be released near:
 other welding or cutting work
 sparks or flame caused by other means
 in confined spaces
NOTE: Sparks from circuit breakers, thermostats, etc. can also cause ignition
– If strictly necessary, release it outdoors, choosing a place where they are not likely to be a significant hazard
and where the flammable gas will soon dissipate
 keep in mind the density considerations mentioned on previous slide
NOTE: some gases like acetylene have natural smell and leaking can be detected, other gases
like propane have not natural smell and odorizer (e. g. mercaptane), must be added
– Fuel gases should be considered flammable within the following ranges of concentration when mixed with
air:
Natural gas between 2.8% and 17.5% NOTE: Such concentrations in
Acetylene between 2.2% and 85% air, given a source of ignition,
Propylene between 2.0% and 11.1%
will burn or, if confined, will
Propane between 2.1% and 9.5%
Butane between 1.8% and 8.5% explode
Hydrogen between 4.0% and 75%
91
Mitigative Measures
NEVER use Acetylene at pressures above 103Kpa (│30│psi): it is contrary to insurance regulations and
prohibited by law in many places.
 Free gaseous Acetylene, depending upon confinement conditions, is potentially unstable
at pressures above 103Kpa;
 Some conditions can cause the Acetylene to decompose with explosive violence;
 Experience indicates 103Kpa generally acceptable as a safe upper pressure limit;
 The │30│psi limit is intended to prevent unsafe use of Acetylene in pressurized

chambers such as caissons, underground excavations, and tunnel construction
NOTE 1: Absolute pressure (PATA) is equal to gauge pressure plus P ATM, which at sea level
averages 101,3Kpa (14.7psi). Thus at sea level a gauge pressure reading of 103,4Kpa
(15psi) is equal to an absolute pressure of 204,7Kpa (29.7psi)
NOTE 2: under no flow conditions some regulators will indicate up to 24psig on its delivery
pressure gauge, but as soon as the gas valve is turned on, the delivery pressure will
return to 15psig or less: this is an acceptable condition
92
Typical Oxy-Fuel Gas Cutting Equipment
93
Acetylene Regulator
94
Oxygen Regulator
95
Typical Oxy-Fuel Gas Cutting Equipment:
Oxygen Regulator
 There are many different types of O2 regulators.
 They are designed to reduce the high pressure of the O 2 coming from the cylinder to the proper
pressure needed for cutting and welding;
 O2 regulators can be damaged, and even burnout with explosive forces that can destroy the regulator
when used improperly;
 O2 regulator fires (ORF) can violently release the full cylinder pressure and contents
 NOTE: this release of contents and the accompanying O 2 enriched fire can cause
injury or death to you and other workers, as well as damage to equipment and
property!
96
Cutting Torch
Flashback Reverse Flow

Arrestor Check Valve
97
Setting up and operating oxy-fuel gas
systems
– To prevent leakage, all seating surfaces should be clean and smooth
– Be sure the regulator and hose nuts are pulled up wrench-tight, not merely hand-tight.
– Do not tighten the connections excessively but use a proper regulator wrench
 do not use vise grips or pipe wrench
 if the connection still leaks after reasonable torque has been used in tightening
the nuts, stop and repair or change the connection.
– Only use hoses fitted with connections made especially for oxy-fuel gas equipment
 Oxygen hose is usually GREEN with right-hand threaded connections
 RED hose with left-hand threaded connections (indicated by a groove-about the
nut) is used with any fuel gas
NOTE: they are designed to prevent improper connections between the regulators
and the torch
98
RED = FUEL
GREEN = OXYGEN
99
systems
– The hoses must be free of oil and grease, in good condition and free of cuts and heavy abrasions
– Support hose out of traffic path so that fork lift trucks and other vehicles do not run over them.
– Always make sure there is enough oxygen and fuel gas available in the cylinders to complete your
welding, cutting, or heating work
 if you run out of one gas while operating and you must change cylinders, it is
imperative that the hose lines be thoroughly purged, for several seconds at least,
before an attempt is made to relight the torch;
 never allow the oxygen cylinder pressure to fall below 100-125psig
100
systems
101
systems
– Reverse flow check valves are available for mounting on torch hose connections
NOTE 1: They are designed to provide a certain amount of protection against the
back flow of one gas into the hose of the other in the event of sudden loss of
pressure of the one gas
NOTE 2: These check valves are designed to prevent a reverse flow of gas, they are
NOT designed for stopping flashbacks
– Careless use, abuse or accumulated dirt can shorten check valve service considerably
 They should be checked regularly for back flow leakage, as directed by the valve
manufacturer
NOTE: check valves will restrict flow and should not be used with large heating
heads
102
systems
– Do not use matches for lighting torches
 Hand burns may result from this practice
– Use friction lighters or stationary pilot flames

– Never relight on hot work in a pocket or small confined space
NOTE: the gases do not always ignite instantly and ignition may be violent if it is
delayed for even a second
103
systems
FLASHBACK
– FLASHBACK is a phenomenon in which the flame goes out and burns back within the torch, producing a
pronounced hissing or squealing noise.
 Usually, a flashback indicates a malfunction or incorrect operation of the torch;
– In case of flashback, IMMEDIATELY shut off the torch, otherwise the flame will burn through the torch and
may cause injury
– After a flashback, allow the torch to cool and recheck the operating pressures
– Before relighting, allow oxygen (NOT fuel gas) to flow through the torch for several seconds to clear out
soot that may have accumulated in the torch;
 if another flashback occurs or the torch repetitively backfires, remove torch from
service and send it along with tip or nozzle in use to an authorized repair station.
104
systems
BACKFIRE
– BACKFIRE is a phenomenon in which a flame may go out with a loud snap or pop
 Backfire should not be confused with Flashback
– After a backfire a torch can be relight immediately;

 a backfire may be caused by touching the tip or nozzle to work, an overheated tip
or nozzle, a loosely connected tip or nozzle, dirt on the seat, but most likely by
incorrect operating pressures.
105
systems
As soon as you have finished working, or if you are going to disconnect the regulator, do the following for
one gas at a time:
1. Close the cylinder valve;
2. Open the torch valve to release all

pressure from the hose and regulator;
3. When the inlet gauge pressure drops to 0,

turn out the pressure-adjusting screw;
4. Check inlet gauge to make sure the

cylinder is shut off, this will prevent the
release of gas and a possible accident
caused by someone removing the regulator
with the cylinder valve open.
106
Grinding
107
Grinding Safety
DEFINITION
A grinding machine, often shortened to grinder,

is a machine tool used for grinding, which is a
type of machining using an abrasive wheel as
the cutting tool; each grain of abrasive on the
wheel's surface cuts a small chip from the
workpiece via shear deformation
108
Grinding Safety
HAZARDS
 Eyes & face injury, cut & scratches, legs & fits injury
 Sparks can cause burn
 Fire and explosion
 Irritation of skin
 Dust
 Vibration
 White finger
 Noise
 Electric shock
109
Grinding Safety
 Employers are responsible for the safe condition of machines
 Eye and finger loss is a common result of improper abrasive wheel
machine usage
 Rotating or flying objects injure and even kill daily
 Abrasive wheel machines are often downplayed in the workplace
110
Grinding Safety
SAFETY MEASURES
• A fire blanket or similar means must be

used to ensure sparks do not fall on
areas below
• A fire extinguisher (foam or powder)
must be available
• Sparks must be contained to protect
other operatives
• Eye protection must be worn
111
Grinding Safety
size of disk designed for CHECKING THE GRINDER
spindle speed rating of the

machine
CE standard
“deadman” switch
automatically returns to OFF
double insulated emblem
no cracks in the casing
casing screws intact
grip handle is secure

no more than
150° exposure
of the wheel
guard secure
112
Grinding Safety
THE ANGLE GRINDER

locking spigot to be
direction of rotation used for locking
guard adjusted so that fingers mechanism when
cannot be caught in the changing wheel
rotating wheel
air vents for

cooling must be
clear
“t” bar to be used for all
operations failure to use this
may result in loss of control of
the machine
threaded hole for “t” bar may be

used for power brushing
113
Grinding Safety
domestic 3 pin plugs are not to be used,

plug tops are to be of the industrial locking
variety
inspection colour coding
a spindle flange spanner is to be used to loosen

and tighten the flange; hammer and punch must
never be used; the flange is not to be
overtightened but to be tightened to a firm
tightness by hand
114
Grinding Safety
trade mark
dimensions in mm referring
normative
speed
manufacturing
or expiring date
115
Grinding Safety
INFORMATION
all this information must
be clearly reported on the
face of the grinding
wheel, in case they are
not, report immediately
to the supervisor and HSE;
anyway do not use it
116
Grinding Safety
NEVER, NEVER and NEVER use an abrasive disc as a cutting disc,

it may explode!!!
CONSEQUENCES for YOU and/or COLLEAGUES could be OUT OF SCALE!
117
Grinding Safety
CONSEQUENCES
118
Grinding Safety
cutting disk is thinner grinding disk is thicker
119
Grinding Safety
TESTING A DISK FOR DEFECT
Before using any disks a visual inspection must be

done.
disk is supported on a wooden spindle and

tapped lightly with a wooden striker a dull
sound is indicative that the disk is flawed or
damaged and may shatter when used
120
Grinding Safety
1 2 3 4 5
order of nature of grain size grade structure nature of

marking abrasive bond
A-C 36 L 5 V
Aluminium oxide coarse medium fine very fine spacing from the V: vitrified
closest to open S: silicate
abrasive - A 8 30 70 220 R: Rubber
10 36 80 240 0 5 10 B: resinoid
Silicon carbide 12 45 90 280 1 6 11 (synthetic resin)
abrasive - C 14 54 100 320 2 7 12 BF: resinoid
16 60 120 400 3 8 13 (reinforced
20 150 500 4 9 14 synthetic resin)
24 180 600 RF: rubber reinforced
E: shellac
M: magnesia
SOFT MEDIUM HARD

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z
121
Grinding Safety
REMEMBER
 Never operate a grinder before have compared the speed rating of the machine
to that one on the disk, the rated speed of the disk is not to be less than the
spindle rating of the grinding machine
 When not in use electrical tools are to be isolated from the power source
 Cutting disks are not to be used for grinding under any circumstance
 Feed the disk into the cut slowly allowing the weight of the grinder to do the work, never force the
grinder into a cut!
 Every few minutes of operation dress the disk
 When stopping the grinder make sure the disk has come to a complete stand before putting the
grinder down
 Changing the disk place the plug in the pocket in order there can be no accidental energisation of
the machine
On board Vessels and any other Offshore realities it is matter

of common sense to use air powered portable tools or at least
48V electrical portable tools!
IF IN DOUBT, ASK!
122
Safety Hazards in WELDING, CUTTING and
GRINDING:
Preventive and Precaution measures
GOOD HOUSEKEEPING
Good housekeeping, especially the removal of combustible materials, is essential
VERIFY THAT THE AREA IS CLEAR OF COMBUSTIBLE MATERIALS
RAGS
CARDBOARD
PAPER
GREASE LIQUID FUELS OILS
123
Conclusions and clarifications
Any question?
Learning evaluation test

124
Hot Work and Fire Safety
Provision of Fire Point Proper PPE
Gas leaking - All Damaged/Worn Out

Gas Leak Check prior to Work
Hoses to be Change Immediately
125
125
Handling of Gas Cylinders
Proper storage of gas cylinders in

Improper storage of gas
rack / trolley
cylinders 126
126
Storage of Gas Cylinder
Improper storage Proper storage of Gas Cylinders

127
127
Inspection on Gas Cylinder
Pressure Gauges Chuck Key
2 Ear Crimp Clip

Jubilee Clip
2 nos. of 2 Condition
Ear Clip 2 Ear Clip Flashback Arrestor
of Hose 128
128
Hot Work and Fire Safety
Use Spark Gun, Matches or Cigarette Use Ear Clip Clamp/Crimping Tool
lighters are NOT allowed
129
129
Wheel Example
Cutting Blade
Max RPM
Size of Disk
Type of Material
can be used on
130
130
131
131

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WELDING, CUTTING & GRINDING

IN CASE OF AN EMERGENCY DURING THE TRAINING DO

At the end of this training you will know:

– Preventive and protection measures

– Hazards and preventive/protection measures in Oxy-fuel Cutting

This is often done by melting the work

– SMAW (Shielded Metal Arc Welding)

– GMAW (Gas Metal Arc Welding)

• MIG (Metal Inert Gas)

• MAG (Metal Active Gas)

– GTAW (Gas Tungsten Arc Welding) or TIG (Tungsten

– FCAW (Flux Cored Arc Welding)

– SAW (Submerged Arc Welding)

– Resistance or Spot Welding 6

During the welding process gases are also

Shielding gases supplied from cylinders:

Combustion and temperature:

 Metal Fume Fever: chills, thirst, fever,

• Phosgene gas (reaction between UV rays and chlorinated hydrocarbon solvents):

• Increased risk of various types of cancers and

• Chronic respiratory problems:

• Other Health problems:

 Welding or cutting on surfaces covered with

 SMAW produces big amount of fumes

 GMAW and GTAW preferable to SMAW

 SAW produces the minor amount of fumes

• Use consumable electrodes which produces less amount of fumes:

• Remove all paint and galvanized coating before welding

 Provide Local Exhaust Ventilation (LEV)

NOTE: unless a detailed and thorough

• Provide Respiratory PPE

Welding areas could be a noisy environment due to the presence of:

• Equipment for local ventilation

• Noise-induced hearing loss

• Ischemic heart disease

• Changes in the immune system and birth defects

• Stress, Headaches, Fatigue, Stomach Ulcers, Constipation, Slackness, Lack of appetite,

• Welding activities exposes the workers to very hot temperatures:

 Flame temperature during Oxy-fuel welding can reach 3000 °C;

 The Arc Temperature during Arc welding exceeds 3800°C

• Welders should be aware of the symptoms:

 Drinking plenty of cool water

ARC RAYS can burn eyes and skin:

• Wear welding helmet with correct filter

TARGET: EYES - SKIN

Skin (es. burns, phototoxic

Short term effect (acute)

• Intense visible light can cause damage to retina’s eye

• IR may damage the cornea;

 Exposure to UV can cause skin burns similar to sunburn

• IR may result in the formation of cataracts;

 Exposure to UV increase the welder’s risk

General preventive measures against Visible, UV & IR Radiation

• Use welding techniques with less emission of Electromagnetic Radiation

NOTE 1: Arc welding emits Visible, UV and IR radiation

 Temperature distribution in the environment

 MIG and MAG give off more intense radiation than

NOTE 2: Oxy-fuel welding does not give off UV radiation

 Reduce “Exposure Time” to radiation.

 The interaction between human body and the

 Shield the welding station with metal or heat resistant shields

Safe work practices to protect from EM Radiations and Spatters

• Keep your pockets, sleeves and collars buttoned:

 Wear Safety Glasses with Side Shields

Welding, Cutting & Grinding-1

Welding, Cutting & Grinding-1