Welding and Cutting are common industrial operations. The associated hazards are Fire and Explosion, Electric Shock, Burns, Exposure to Radiation and Toxic Fumes and Gases. Operations are required to be fully conversent with all safe practices.

Safe Practices

OXY-ACETYLENEWELDING/CUTTING:

Equipment Check

• Ensure that the tip of the torch is free from dirt metal and

• Move out any leaking cylinder immediately.

• Check leaks around regulators, hoses/fittings & nozzle with soap solution.  Faulty equipment should be changed immediately.

Equipment Set-up

• Use trolley for oxygen & acetylene cylinder and chain them.

• Arrange hoses to avoid tripping hazards.

• Always use red hose for acetylene and other fuel gases and black for oxygen and exure that both are in equal length.

• Before attaching regulator to the cylinder, it is necessary to shift the valve to blow out foreign particles from the valve seat.

• Never use copper fittings on acetylene lines.

• Attach flashback arresters to each regulator.

• Select the proper welding/cutting nozzles.

• Non-return valve should be installed in fuel gas line.

Precautions

• Always stand back from the regulator when opening the cylinder valve. Turn valve slowly to avoid bursting the regulator.

• Leave key wrenches on cylinders in use, so they can be closed quickly.

• Do not use an acetylene pressure greater than 9 p.s.i.g.

• Use only a friction/spark lighter to light the torch. Never use matches, hot metal or welding arc.

• When leaving a confined space (even if it is only for a break or lunch), shut off the gas supply.

• If you run out of gas, extinguish the flame and connect the hose to the new cylinder. Purge the line before reigniting the torch.

• Purge regulators after welding work is over and then turn off.

Electrical Arc Welding: Equipment check

• Make sure that splices are atleast 3m away from the holder

• Regularly inspect insulation on electrode holder, cables and accessories, replace worn & damaged cables immediatly.

• Ensure cable and power source are free from dirt/grease. Equipment Set-up

• Ground the work piece separately from the welding return connection. Never attach the ground cable to pipes containing flammable liquids or gases.

• Arrange cables so that they do not create tripping hazards.

• Cover the lug terminals to prevent shorting out by a metal object.

Precautions

• Use the current for which the cable is designed.

• Place electrode stubs in containers.

• Burn electrodes to not less than 38 to 50 mm in length. Burning them further damages the electrode holder.

• When job is finished, disconnect the welding machine from the power source and remove the electrode from its holder. Store the electrode holder in a safe place.

General

• Remove combustible materials from work area or cover them with fire-resistant blankets, before starting the welding operations.

• For work in a confined space, fasten cylinders/welding machine securely outside and provide proper ventilation.

• Use welder's screen of correct specification.

• Use all necessary personal protective equipment.