Mandatory Welding & Cutting Safety Practices in Metal Working | Digital Dialogue
Watch this exclusive episode on Mandatory Welding & Cutting Safety Practices in Metal Working. In this episode, you’ll delve into the world of crucial welding and cutting safety practices. These practices are essential not only for ensuring the well-being of workers but also for maintaining the integrity of equipment and enhancing the overall productivity of metalworking operations.
E𝐱𝐩𝐞𝐫𝐭 S𝐩𝐞𝐚𝐤𝐞𝐫𝐬: ~ Arun Jain, Oxyfuel Business Head, Messer Cutting Systems India ~ Sankha Das, Manager Sales – Skill Development, Messer Cutting Systems India.
Whether you’re an experienced professional or just starting out, there’s something for everyone to learn and explore.
When asked to share more details on the importance of safety in welding and cutting in the context of metalworking, Sankha Das, Manager Sales – Skill Development, Messer Cutting Systems India, said: We’re discussing essential safety measures in metalworking. Metalworking involves shaping and reshaping metals to create useful objects, parts, assemblies, and large structures. Common metalworking processes in workshops, factories, garages, and work areas include grinding, welding, oxyfuel cutting, and plasma cutting where oxyfuel cutting is not feasible.
Only trained and competent individuals should operate portable grinders. Novices should not be given access to operate portable grinders. Individuals tasked with using grinders must undergo safety training before operating the machine due to the challenges associated with handling the heavy equipment during grinding operations.
SAFETY PRECAUTIONS:
- Personnel operating grinding machines must wear appropriate PPE, including double eye protection (goggles under a shatter-resistant face shield), an inhalation mask (like a dust mask), and leather gloves.
- Workpieces being processed must be securely clamped; holding the workpiece by hand during grinding is strictly forbidden.
- All handheld grinding machines must have a handle or ‘T’ Bar, and removing the handle during use is strictly prohibited.
- Every grinding machine should have its correct guard provided by the manufacturer, covering a minimum of 70% of the rotating disc’s circumference.
- Grinding and cutting discs are manufactured for different purposes and must only be used for their intended functions. Cutting wheels are strictly for cutting and should not be used for grinding to prevent breakage. Discs should be stored separately and clearly identified to prevent selection errors.
- When changing the grinding disc, isolate the power source and physically remove the plug.
- The power source must be isolated, and the plug physically removed when the grinder is not in operation.
PRECAUTIONS TO PREVENT ELECTRICAL WELDING HAZARDS
- Refrain from touching the metallic parts of the electrode holder, especially if your skin or clothing is damp.
- Welders must wear dry gloves in good condition.
- Ensure the provision of rubber mats or other insulation for welders.
- Conduct a thorough inspection of welding equipment and the electrode holder before starting work.
- Exercise additional safety precautions when working in humid environments, on metal structures, and in confined spaces.
- Use HOFR cables of the proper size by IS9857 to prevent electrical and heat-related accidents.
PRECAUTIONS TO PREVENT FIRE HAZARDS IN WELDING
The following measures can help prevent fire during welding:
- Keep a fire extinguisher accessible.
- Keep the working space free of clutter.
- Store combustible substances, such as gasoline, wood, cardboard, and flammable chemicals, away from the working space.
- If flammable materials cannot be moved, use fire-resistant shields.
- Be cautious when welding in dusty locations, as the high concentration of fine particles can unexpectedly oxidize, leading to a potential flash fire or explosion.
WELDING HAZARD – RADIATION
Welding arcs emit radiation covering a broad range of wavelengths, spanning from 200 nm (nanometers) to 1,400 nm (or 0.2 to 1.4 mm, micrometers). These include ultraviolet (UV) radiation (200 to 400 nm), visible light (400 to 700 nm), and infrared (IR) radiation (700 to 1,400 nm).
Specific types of UV radiation can cause injuries to the eye’s surface and mucous membrane, leading to conditions like “arc eye,” “welders’ eye,” or “arc flash.”
Prolonged exposure to UV light may result in cataracts. Exposure to infrared light can heat the eye’s lens, potentially causing cataracts over the long term.
Visible light from welding processes is intense and can overpower the iris’s ability to close quickly enough, leading to temporary binding and fatigue.
Extended exposure to UV radiation can contribute to the development of skin cancer.
PRECAUTIONS TO PREVENT RADIATION HAZARDS IN WELDING
Eye Protection:
– Welders must use welding helmets with the correct DIN shade appropriate for various welding processes.
– Employ welding curtains to shield the welding area, preventing other workers from being affected by welding radiation.
– Ensure complete coverage of the welder’s face with the welding helmet.
– Utilize neck protection for the welder’s safety.
Hand Protection: Welder’s gloves must offer thermal insulation and block UV and visible light frequencies. They should cover the hands and wrists, overlapping the sleeves for proper protection.
Protection for welder’s helpers: Anyone working regularly within 2 meters of a welding arc must be protected against skin and eye exposure. Therefore, the welding area should be guarded with welding curtains.
SAFETY MEASURES FROM WELDING FUME HAZARDS
- se substitute materials such as water-based cleaners or high flash point solvents.
- Consider using a lower fume-generating or less toxic process or material
- Do not weld on surfaces that are still wet with a degreasing solvent.
- Safely remove coatings before welding.
- Have adequate ventilation in a workplace to prevent the displacement or enrichment of oxygen and to prevent the accumulation of hazardous substances and flammable atmospheres.
- Use local exhaust ventilation systems positioned close to the welding source to remove fumes and gases from the welder’s breathing zone
- Wear appropriate respiratory protective equipment
- Following safe work procedures, such as workers positioning themselves to avoid breathing welding fumes and gases
WELDING ACCESSORIES FOR SAFE WELDING PRACTICE
- Utilize trolleys for transporting gas cylinders; avoid rolling cylinders on the ground.
- Employ calibrated and certified welding electrode heating ovens for appropriately heating electrodes.
- Avoid using a cutting torch head or electrode holder for slag removal; use a chipping hammer with the correct weight.
- Do not use your gloved hand to clean the weld bead; use a wire brush.
- Never use a cigarette lighter or matchstick to ignite a flame for cutting or welding; use industrial gas regulators.
- Always use properly insulated and appropriately rated MIG welding torches.
When asked about the unique safety considerations for oxyfuel welding and cutting methods, Arun Jain, Oxyfuel Business Head, Messer Cutting Systems India said: The oxyfuel process is widely employed, particularly in welding where cutting is integral. The screen caption highlights potential hazards when using oxyfuel systems without proper knowledge or equipment, leading to disastrous consequences, such as regulator, hose, or cylinder bursts.
Unsafe conditions, flashbacks, or flashback occurrences could result in hazardous situations depicted on the screen. Inadequate regulators, poorly clamped hoses, or damaged equipment pose risks in the work area. Adhering to safe practices is crucial to prevent accidents.
Understanding the gases used in oxyfuel operations is the initial step. Oxygen, acetylene, and LPG are commonly utilized, with LPG being denser than air. Oxyfuel cutting involves a preheat flame to reach the metal’s ignition temperature, followed by oxygen streaming through a central hole for cutting.
The safety concern arises with two-pipe torches mixing oxygen and fuel gas in a potentially explosive manner, leading to torch explosions during flashbacks. Three-pipe torches, where gases mix in the nozzle, are recommended for better safety.
Incorrect nozzle selection, such as using a single-piece nozzle for oxyacetylene, can lead to damage. Different nozzles are required for varying gas combinations, like the PNME nozzle for oxy LPG or oxy bmcg oxynano gas.
Implementing flashback arrestors at strategic points, like after the regulator and before the torch, is crucial for safety. Gas regulators play a pivotal role in an oxyfuel system, converting cylinder pressure to working pressure. Using the right regulator for each gas application is essential for safety.
Proper gas hose maintenance, avoiding damaged hoses, and immediate replacement of cracked hoses contribute to safety. Gas manifolds enhance safety by keeping cylinders outside the work area and transporting gases through an overhead pipeline.
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