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General Safety

General Safety. Eyes. Safety glasses must be worn at all times Welding goggles (shade 5) when using Oxy-acetylene equipment, (shade 12) when welding or using plasma Never watch the arc with the naked eye. Ears. Plugs are cheapest form of protection

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General Safety

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  1. General Safety

  2. Eyes • Safety glasses must be worn at all times • Welding goggles (shade 5) when using Oxy-acetylene equipment, (shade 12) when welding or using plasma • Never watch the arc with the naked eye

  3. Ears • Plugs are cheapest form of protection • Ear muffs block out more noise and protect better

  4. Head • Caps made from non-flammable material to protect from hot sparks • Helmets to protect face from exposure to arc. • Long hair must be tied back • No dangling earrings • No necklaces • Jewelry may become entangled in spinning or rotating machinery

  5. Arms and Hands • No exposed skin • Arc is like the sun, severe sunburn can result from exposure. • No loose sleeves or cuffs • May become entangled or trap hot sparks • Gloves must be worn while welding • Non-flammable material • Protect from exposure • Remove gloves when grinding. • May become entangled in spinning machinery

  6. Torso • Welding jacket or coveralls • Protect from exposure • Non-flammable material, leather is best, cotton is fine • No synthetics, melt to your skin • Must be buttoned or zipped to the top • No open pockets

  7. Legs and Feet • No shorts allowed!! • Legs must be covered at all times. • No cuffs • Hot sparks may become trapped • No open toed shoes • Protect toes and the foot • Non slip sole is best, rubber is good • No leather soles, slippery

  8. Housekeeping • Floors and workbenches should be kept clean of dirt, scrap metals, excess tools, and anything flammable. • Aisles must be kept clear of hoses and cables, which can cause tripping hazards • Everyone has a responsibility to keep the shop clean and clear and report any hazards

  9. Fire hazards • Paint, oil, cleaning chemicals, other combustibles must be kept in metal container away from sparks. • Fire exits, fire blankets, and extinguishers must be clearly marked. • Equipment must be shut down before evacuating

  10. Electrical Hazards • All electrical devices are hazardous, but some use extremely high and dangerous voltages. • All equipment and areas where 220 volts or more are used must be well-marked.

  11. Lifting • Always lift with your legs • Keep back straight • Ask for help with heavy loads

  12. Machinery general safety • Never operate until properly trained • Ask for help if you are unsure • All safety guards must be installed • Turn power off and unplug it before making adjustments • Check for loose parts before operating • Check cords for frays or cracking • Report any defective equipment to teacher immediately

  13. Pedestal grinder • Probably one of the most dangerous pieces of equipment in the shop • Adjust tool rests as close as possible to wheel • Never grind on the side of the wheel • Don’t push against the wheel or attempt to grind downward. • If the wheel slows down stop pushing against it • Your thumb may become caught resulting in severe injury. • Never operate at speeds exceeding those marked on the wheel itself. • May result in wheel exploding

  14. Handheld angle grinder • Always operate with guard in place • always operate with handle in place. • Check cord for fraying or cracking • Inspect grinding wheel to ensure it is securely tightened • Always grind in the 12 to 3 area of the wheel • Ensure sparks are away from others. • Always place grinder upside down when not in use. • Exercise caution so as not to grind through cable.

  15. Drill Press • Secure work to work bench with clamps • Use cutting oil to help remove metal burrs and reduce heat from friction • Always center punch the hole to be drilled • This helps keep the bit from wandering • Always tighten the bit in all three key holes with the chuck • Never force the bit • This will result in the bit shattering

  16. Iron worker • Make sure all guards are in place while operating • Only the operator may be around the ironworker while it is on • Keep fingers away from all sharp edges. • Only cut metal of the recommended thickness. • Tighten all clamps on work before operating the shear.

  17. Bench brake and shear • Only bend or cut metal of the recommended thickness • Always operate with all guards and shields in place. • Only the operator activates the foot treadle. • Keep feet from under the treadle as they may become trapped • Beware of freshly cut metal. Edges are razor sharp.

  18. Power saws • Keep all guards in place. • Secure work to saw or bench before beginning your cut. • Inspect saw blade for damage • Aim sparks away from others.

  19. Hand tools • Always pull wrenches towards your body • If wrench slips you will fall away from the machine • Use tools for their intended use • Always clean and return tools when finished.

  20. Safety in Welding shops

  21. Designated areas • All welding and cutting should be done in designated areas. • Areas kept clear of any flammable materials. • Welding screens must be closed before striking an arc

  22. ventilation • Exhaust fans must be turned on to remove toxic fumes produced by welding. • High ceilings and opening doors ensures a movement of air in the shop • Respirators must be used when welding aluminum or galvanized steel

  23. Hot and Sharp Metal • All metal in a welding shop is hot until you yourself make it cool. • Chip off all slag before cooling your metal in the quench tank • Use tongs to pick up hot metal • Do not drop the metal into the tank • The tank water is above boiling use caution • Do not get the leather gloves wet. This ruins them

  24. Freshly cut metal has a razors edge. • Metal that has been cut by a torch has a temperature above 6000 F. • Always wear gloves in the welding shop

  25. Oxy-Acetylene Outfits • All cylinders must be chained to the wall or cart to prevent them from tipping over. • When not in use all cylinders must have a protective cap in place. • This helps prevent the “rocket effect” • An unprotected tank has the capability of smashing through a concrete wall. • All hoses must be inspected for leaks using soapy water. • Flash back arrestors are in place to prevent fire from reaching the tanks.

  26. Tanks that are green are non-flammable • Therefore they are safe and have normal threads • Righty tighty, lefty loosey. • Tanks that are red or black are highly flammable!! • Therefore they have left-handed threads to prevent any untrained person for properly attaching them.

  27. Tank Regulators • Inspect the butterfly valves to make sure they are not under pressure before opening the tank. • Upon opening the cylinders the valve may be under such tremendous pressure that the valve will shoot off. • Always crack the cylinder to clear it of any debris • Never oil the connections. • This may cause a dangerous chemical reaction resulting in explosion

  28. Opening the tanks • Oxygen • Open the main valve on the tank completely. • Acetylene • Only open the main valve on the tank ¼ to ½ a turn. • This is referred to as “cracking” the cylinder. • In case of emergency you want to be able to close this tank quickly.

  29. Set Working pressures • Slowly turn in butter fly valve on both regulators • 10 psi max for Oxygen • 5 psi max for Acetylene • Never exceed 15 psi with Acetylene. • The tank becomes unstable at this point and may spontaneously combust.

  30. Lighting the torch • Ignite the torch away from yourself, others, and anything flammable. • Always use a flint igniter never matches or a butane lighter. • Always crack the valves until a flame is established then open them to obtain a neutral flame.

  31. 1. Open the Oxygen torch valve completely. No gas will flow through the torch yet because the mixing valve is closed. 2. Open the Acetylene torch valve ¼ of a turn and light the torch. 3. Slowly open the Acetylene torch valve more until the black smoke disappears from your flame.

  32. 4. Slowly turn the mixing valve located at the top of the torch away from you. • The flame will change from orange to a bright blue. • Continue opening the mixing valve until the bright blue color of the flame forms a tight cone near the torch tip. • 5. This is the neutral flame.

  33. Acetylene Safety • Never exceed 15 psi with Acetylene!!!! • The tank becomes unstable at this point and may spontaneously combust.

  34. Bleeding off • Pressure in the lines must be released safely • Begin by shutting off the torch itself. • 1. Mixing valve • 2. Acetylene • 3. Oxygen • Close both cylinder tank valves • First Acetylene then Oxygen • Open torch valves • Wait until all gauges read zero • Close torch valves

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