SAFETY IN WELDING

PURPOSE
This course will provide you with a basic understanding of the Welding and Cutting Safety requirements.

INTRODUCTION
A safe job is no accident; it takes work to make the job safe. Each person working must do what it takes to keep the job safe.

The most important components of an effective safety and health program are leadership, support, and direction.
Management must clearly state objectives and show its commitment to safety and health by consistent support of safe practices.

You must approach new job with your safety in mind. Your safety is your own responsibility, and you must take that responsibility.

BURNS
Burns are one of the most common and painful injuries that occur in the welding shop. Burns can be caused by ultraviolet light rays as well as by contact with hot welding material. The chance of infection is high with burns because of the dead tissue. Burns are divided into three classifications, depending upon the degree of severity. The three classifications include first-degree, second-degree, and third-degree burns.

First-degree Burns
First-degree burns have occurred when the surface of the skin is reddish in color, tender, and painful and do not involve any broken skin. The first step in treating a firstdegree burn is to immediately put the burned area under cold water or apply cold water compresses (clean towel, washcloth, or handkerchief soaked in hot water) until the pain decreases.

Then cover the area with nonfluffy sterile or clean bandages.

Do not apply butter or grease.

Second-degree Burns
Second-degree burns have occurred when the surface of the skin is severely damaged, resulting in the formation of blisters and possible breaks in the skin.

Again, the most important first step in treating a second-degree burn is to put the area under cold water or apply cold water compresses until the pain decreases.
Gently put the area dry with a clean towel, and cover the area with a sterile bandage or clean cloth to prevent infection. Seek medical attention. Note: any cold liquid you drink- for example, water, cold tea, soft drinks, or milk shake- can be poured on a burn. The purpose is to reduce the skin temperature as quickly as possible to reduce tissue damage.

Third-degree Burns
Third-degree burns have occurred when the surface of the skin and possibly the tissue below the skin appear white or charred. Do not remove any clothes that are stuck to the burn. Do not put ice water or ice on the burns; this could intensify the shock reaction. Do not apply ointments, sprays, antiseptics, or home remedies to burns. Place a cold cloth or cool (not iced) water on burns of the face, hands, or feet to cool the burned areas.

Call for an ambulance immediately; people with even small third-degree burns need to consult a doctor.

EYE AND EAR PROTECTION

ELECTRICAL SAFETY

ELECTRICAL SAFETY
Most electric shocks in the welding industry does not occur from contact with welding electrode holders, but as a result of accidental contact with bare or poorly insulated conductors. Injuries and even death can be caused by electric shock unless proper precautions are taken. Most electrical equipment in a welding shop is powered by alternating-current (ac) sources having input voltages ranging from 115 volts to 460 volts. However, fatalities have occurred when working with equipment operating at less than 80 volts. The workpiece being welded, and the frame or chassis of all electrically powered machines, must be connected to a good electrical ground. Cable connectors for lengthening leads must be insulated. Cables must be checked periodically to be sure that they have not become frayed, and, if they have, they must be replaced immediately.

SPECIAL PROTECTIVE CLOTHING

HANDLING AND STORING CYLINDERS

Cylinders equipped with a valve protection cap must have the cap in place unless the cylinder is in use. The protection cap prevents the valve from being broken off if the cylinder is knocked over. If the valve of a full high-pressure cylinder (argon, oxygen, CO2, and mixed gases) is broken off, the cylinder valve can fly around the shop like a missile if it has not been secured properly. Never lift a cylinder by the safety cap or the valve. The valve can easily break off or be damaged. The cylinders must never be dropped or handled roughly.

Acetylene cylinders that have been lying on their sides must stand upright for 15 minutes or more before they are used.

FIRE PROTECTION
Fire is a constant danger at welding shop. The possibilities of fires cannot always be removed, but they should be minimized.

Highly combustible materials should be 10.7 m or more away from any welding.
When it is necessary to weld within 10.7 m of combustible materials, when sparks can reach materials farther than 10.7 m away, or when anything more than a minor fire might start, a fire watch is needed. A fire watch can be provided by any person who knows how to sound the alarm and use a fire extinguisher. The fire extinguisher must be the type required to put out a fire of the type of combustible materials near the welding. The four types of fire extinguishers are type A, type B, type C, and type D. Using the wrong type of fire extinguisher can cause the fire to spread, cause electrical shock, or cause an explosion.

Type A Extinguishers
Type A extinguishers are used for combustible solids (articles that burn), such as paper, wood, and cloth. The symbol for a type A extinguisher is a green triangle with the letter A in the center.

Type B Extinguishers
Type B extinguishers are used for combustible liquids, such as oil, gas, and paint thinner. The symbol for a type B extinguisher is a red square with the letter B in the center.

Type C Extinguishers
Type C extinguishers are used for electrical fires. For example, they are used on fires involving motors, fuse boxes, and welding machines. The symbol for a type C extinguisher is a blue circle with the letter C in the center.

Type D Extinguishers
Type D extinguishers are used on fires involving combustible metals, such as zinc, magnesium, and titanium. The symbol for a type D extinguisher is a yellow star with the letter D in the center.

Location of Fire Extinguishers

Fire extinguishers should be of a type that can be used on the types of combustible materials located nearby.

Location of Fire Extinguishers

They should also be placed at a level low enough to be easily lifted off the mounting

Location of Fire Extinguishers

The location of fire extinguishers should be marked with red paint and signs, high enough so that their location can be seen from a distance over people and equipment. The extinguishers should also be marked near the floor so that they can be found even if a room is full of smoke

MATERIAL HANDLING
Improper work habits can cause serious personal injury as well as cause damage to equipment and materials.

If it is necessary to pull a load, use a rope. It is advisable to stand to one side of ropes, chains, and cables that are being used to move or lift a load. If they break and snap back, they will miss you.

VENTILATION
The actual welding area should be well ventilated. Excessive fumes, ozone, or smoke may collect in the welding area; ventilation should be provided for their removal. Natural ventilation is best, but forced ventilation may be required. Areas that have 283 cubic meters or more per welder, or that have ceilings 4.9 meters high or higher may not require forced ventilation unless fumes or smoke begin to collect.

General room ventilation must be at a rate of 2,000 cu ft (56 m3) or more per person welding. Localized exhaust pickups must have a suction strong enough to provide 100 linear feet (30.5 m) per minute velocity of welding fumes away from the welder.
Small shops or shops with large numbers of welders require forced ventilation. Forced ventilation can be general or localized using fixed or flexible exhaust pickups.

SAFETY FIRST
Usually manufacturers have a safety department with one individual in charge of plant safety. The safety officer's job is to make sure that all welders comply with safety rules during production. The proper clothing, shoes, and eye protection to be worn is emphasized in these plants. Any worker who does not follow established safety rules is subject to dismissal. Equipment is periodically checked to be sure that it is safe and in proper working condition. Maintenance workers are employed to see that the equipment is in proper working condition at all times.

SAFETY FIRST
If an accident does occur, it is important that appropriate and immediate first aid steps be taken. You should take time to learn the proper procedure for accident response and reporting before you need to respond in an emergency. After the situation has been properly taken care of, you should fill out an accident report.

INDONESIAN REGULATIONS REGARDING HEALTH & SAFETY OF EMPLOYEES

Undang-Undang No.1 tahun 1970 tentang Keselamatan Kerja Undang No.3 tahun 1992 tentang Jaminan Sosial Tenaga Kerja Undang-Undang No.25 tahun 1997 tentang Ketenagakerjaan Pasal 108

SUMMARY
General hazards
- fire and explosion - hot metal - mechanical

Welding hazards
- electrical shock - arcs - fumes and gases - enclosed spaces

Cutting and burning

- safety requirements - storage