For ARC WELDING, CUTTING & GOUGING
WARNINGF-52-529December, 2009Protect yourself and others.Read and understand this booklet.Precautions and Safe PracticesforARC WELDING,CUTTING & GOUGINGBe sure this information reaches theoperator.Keep this booklet available for reference at all times. You can get extracopies through your supplier.ESAB Welding &Cutting Products
FOREWORDThe “Occupational Safety and Health Act of 1970” (OSHA) was enacted “to assure safeand healthful working conditions for working men and women.”.As duties under Section 5 of this Act, each employer shall;1.2.Furnish to each of his employees employment and a place of employment whichare free from recognized hazards that are causing or are likely to cause death orserious physical harm to his employees.Comply with occupational safety and health standards promulgated under this act.Each employee shall comply with occupational safety and health standards and allrules, regulations, and orders issued pursuant to this Act which are applicable to hisown actions and conduct.This booklet provides employers and employees with safety and health information onelectric welding products and processes. If an employee has language difficulties orcannot be expected to read and understand this booklet, the employer should provideadditional training and help to the individual.Precautions and safe practices outlined in this booklet cover arc welding and cuttingprocesses such as the following:1.2.3.4.5.6.7.8.9.Gas metal arc welding (GMAW), commonly known as “MIG” weldingGas tungsten arc welding (GTAW), commonly referred to as “TIG” weldingShielded metal arc welding (SMAW), commonly called “stick” weldingSubmerged arc welding (SAW)Air carbon arc gouging and cutting (AAC)Flux cored wire welding (FCAW)Plasma arc welding (PAW)Plasma arc cutting (PAC)Plasma arc gouging (PAG)This booklet contains guidelines on the safe handling and operation of electric weldingand cutting equipment. The American Welding Society and the American National Standards Institute also publish specifications and standards on welding and cutting safety.You should be familiar with the information in this booklet as well as “Safety in Weldingand Cutting” - ANSI Z49.1, which is published by the American Welding Society, P.O. Box351040, Miami, Florida, 33135. Material Safety Data Sheets (MSDS’s) on various products, such as rods, wires, and fluxes also provide helpful safety and health information.In addition, you should also read the manufacturers’ operating instructions for the apparatus you use. You should be familiar with the proper operation of all equipment before you start to work. ALWAYS READ AND UNDERSTAND THE MANUFACTURER’S OPERATING INSTRUCTIONS AND YOUR EMPLOYER’S SAFETY PRACTICES BEFORE OPERATINGAND MAINTAINING ELECTRIC WELDING AND CUTTING EQUIPMENT.2
-AlsoALWAYS READ AND UNDERSTAND ALL PRECAUTIONARY LABELS AND INSTRUCTIONSBEFORE USING EQUIPMENT OR MATERIALS. A typical precautionary label is shown below. This booklet supplements information on the label.This booklet is intended for beginners and skilled operators. The Appendix, which discusses the health hazards, is intended for use by persons trained in first aid, as well asmedical professionals. It will help you do the best job possible. Additional copies of thisbooklet (F-52-529) may be obtained from your nearest distributor.For safety and health information covering oxy-fuel gas operations, obtain a copy ofForm 2035, “Precautions and Safe Practices for Gas Welding, Cutting, and Heating”.Additional safety information, including material on video cassettes, is developed fromtime to time as well.3
TABLE OF CONTENTSFOREWORD .2DESCRIPTION OF MAJOR HAZARDS ANDPRECAUTIONS .5Fumes and Gases. .5Electric Shock .7Arc Rays and Spatter.9Noise; Electric and Magnetic Fields EMF) .11OTHER PRECAUTIONARY MEASURES .12Prevent Fires .12Welding and Cutting of Containers .13Shielding Gases.13Handling, Storage, and Use of Cylinders. .14Prevent Arc Burns on Cylinders .16Connecting and Adjusting Shielding Gas Supply .18MAINTENANCE AND TROUBLESHOOTING PRECAUTIONS .21APPENDIX .23Chemical Substances and Potential Health Hazards in the Welding and CuttingEnvironment .23RECOMMENDED REFERENCES .32EMERGENCY AND FIRST-AID PROCEDURES .Back Cover PageESAB Welding & Cutting ProductsP.O. Box 100545Florence, SC 29501-0545(803) 669-4411DISTRIBUTORS IN PRINCIPAL CITIESCopyright 1995ESAB Welding & Cutting ProductsPrevious printings: 1966, 1972,1973,1975,1977,1980,1984, 1986, 1988, 1991, 1994, and 19954
DESCRIPTION OF MAJORHAZARDS AND PRECAUTIONSFUMES and GASES can be hazardous toyour health.Keep your head out of the fumes. Do not breathe fumes and gases caused by thearc. Use enough ventilation. The type and the amount of fumes and gases dependon the equipment and supplies used. Air samples can be used to find out whatrespiratory protection is needed.Provide enough ventilation wherever welding and cutting are performed. Proper ventilation will protect the operator from the evolving noxious fumes and gases. The degreeand type of ventilation will depend on the specific welding and cutting operation. It varies with the size of work area; on the number of operators; and on the types of materialsto be welded or cut. Potentially hazardous materials may exist in certain fluxes, coatings,and filler metals. They can be released into (lie atmosphere during welding and cutting.In some cases, general natural-draft ventilation may be adequate. Other operations mayrequire forced-draft ventilation, local exhaust hoods or booths, or personal filter respirators or air-supplied masks. Welding inside tanks, boilers, or other confined spacesrequire special procedures, such as the use of an air supplied hood or hose mask.DO NOT BREATHE FUMES ANDGASES CAUSED BY THE ARC.KEEP YOUR HEAD OUT OF FUMES.USE ENOUGH VENTILATION.5
Check the welding atmosphere and ventilation system if workers develop unusualsymptoms or complaints. Measurements may be needed to determine whether adequate ventilation is being provided. A qualified person, such as an industrial hygienist,should survey the welding operations and environment. Follow their recommendationsfor improving the ventilation of the work area.Do not weld on dirty plate or plate contaminated with unknown material. The fumesand gases which are formed could be hazardous to your health. Remove all paint andgalvanized coatings before welding. All fumes and gases should be considered as potentially hazardous.Do not weld near vapor degreasers or on metal that has been just degreased. The decomposition of chlorinated hydrocarbons used in vapor degreasers can form into a poisonous gas.Additional information on various fumes and gases that can harm your health is located in the Appendix of this booklet. More complete information on health protectionand ventilation recommendations for general welding and cutting can be found in theAmerican National Standard Z49.1, “Safety in Welding and Cutting”.TYPICAL METHODS FOR VENTILATIONAND RESPIRATORY PROTECTION.BOOTHSFORCED DRAFTVENTILATIONLOCAL EXHAUSTHOODSAIR SUPPLIED MASK6
ELECTRIC SHOCK can kill you.Do not touch live electrical parts.Live electrical parts can include the power supply, the power and work cables, the torchand the work itself (if the work is not connected to earth ground.)Electric shock can be avoided. Follow the recommended practices listed below. Faultyinstallation, improper grounding, and incorrect operation and maintenance of electricalequipment are always sources of danger.1.Connect electrical equipment and workpiece correctly. Prevent electrical shock.(A.) Connect power supply and control cabinet chassis to approved earth ground.(B.) Connect workpiece to “work” output connection of power supply. (C.) Connectworkpiece (as illustrated below) OR power supply work terminal (but not both) toapproved earth ground. “Double-grounding” can cause welding/cutting current tooccur in conductors intended only for safety grounding and can result in destruction of the safety ground. NOTE: The work lead is NOT a ground lead; the worklead is to be used only to complete the welding circuit.MAKE PROPER WORKAND GROUND CONNECTIONS(B) Work connectionWork TablePower SourceWork(C) Either work terminal or workpieceto approved earth groundTorch(A) Chassis to approvedearth ground2.Make good electrical connections of the work lead to the power supply workterminal and to the workpiece. A missing or poorly-connected work lead cancause a fatal shock. Make sure the work lead is always in good condition.3.Use the correct cable size. Sustained overloading will cause cable failure and result in possible electrical shock or fire hazard. Work cable should be the same ratingas the torch cable.7
4.Make sure all electrical connections are tight, clean, and dry. Poor electrical connections can heat up, and even melt. They can also cause bad welds andproduce dangerous arcs and sparks. Do not try to make an electrical connectionthrough paint. Do not allow water, grease, or dirt to accumulate on plugs, sockets,or electrical units.5.Insulate yourself from workpiece and ground. Moisture and water can conductelectricity. To prevent shock, it is advisable to keep work areas, equipment, andclothing dry at all times. Fix water leaks immediately. Keep hoses from touchinghot metal. Do not exceed recommended water pressures. Make sure that you arewell insulated. Wear dry insulated gloves, rubber-soled shoes, or stand on a dryboard or platform.6.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 whereverthere is a high risk of contact with workpiece or ground. In any of these situationsuse:* DC MIG welding* DC manual (stick electrode) welding* AC welder with reduced open-circuit voltage control7.Keep cables and connectors in good condition. Improper or worn electrical connections can increase the chance of an electrical shock. Do not use worn, damagedor bare cables.8.Avoid open-circuit voltage. Open circuit voltage of welding, cutting and gougingpower supplies can cause electric shock. When several welders are working witharcs of different polarities, or when using multiple alternating current machines,the open-circuit voltages can be additive. The added voltages increase the severityof the shock hazard.9.Remove metal jewelry. It is recommended that rings, watches, necklaces, andother metallic items be removed before welding or cutting. Accidental contact ofjewelry with welding power can cause metal to become hot or even melt. It canalso increase the possibility of a fatal shock.10. Follow recognized safety standards. Follow the recommendations in American National Standard Z49.1, “Safety in Welding and Cutting,” available from theAmerican Welding Society, P. 0. Box 351040, Miami, FL 33135, and also the NationalElectrical Code, NFPA No. 70, which is available from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269.8
ARC RAYS and SPATTER can injure eyes andburn skin.Wear correct eye, ear, and body protection.Electric arcs emit both ultraviolet and infrared rays. They can bum eyes and skin thesame way as strong sunlight. However, it can happen a lot faster and with greater intensity. Operators and others in the welding area may receive eye and skin bums after briefexposures to arc rays. Reddening of the skin by ultraviolet rays becomes apparent sevenor eight hours later. Long exposures may cause severe skin bum. Eyes may be severelyburned by both ultraviolet and infrared rays. Hot welding spatter can cause painful skinbums and permanent eye damage.To be sure you are fully protected from arc radiation and spatter, follow these precautions:1.Cover all skin surfaces and wear safety glasses with side shields for protectionfrom arc burns and burns from sparks or spatter. Keep sleeves rolled down andwear gloves. Wear a helmet over safety glasses. Use correct lens shade to preventeye injury. Choose the correct shade from the table below. Observers should alsouse proper protection. Be aware that arc gouging spatter can spray a long distance.FILTER RECOMMENDATIONS (adapted from ANSI Safety Standard Z49.1)ApplicationLens Shade No.*Mig (Gas Metal and Fluxed Cored Arc)60 to 160 amps .11160 to 250 amps .12250 to 500 amps .14Tig (Gas Tungsten Arc)up to 50 amps .1050 to 150 amps .12150 to 500 amps .14Arc Gouging and Pad Washingless than 500 amps .12500 to 1000 amps .14Plasma Arc Weldingup to 100 amps .10100 to 400 amps .12400 to 800 amps .14Plasma Arc Cuttingup to 300 amps .9300 to 400 amps .12400 to 800 amps .14Stick (Shielded Metal Arc)under 5’32-in. (under 4 mm) electrodes, up to 160 amps .105-’32- to 1 4-in. (4 to 6 mm) electrodes, 160 to 250 amps .12Over 1 4-in. (over 6 mm) electrodes, 250 to 550 amps .14* As a rule of thumb, start with a shade that is too dark to see the arc zone. Then go to a lightershade which gives sufficient view of the arc zone without exerting a strain on your eyes.9
2.Protect against arc flashes, mechanical injury, or other mishaps. Wear spectacles or goggles with No. 2 shade filter lens and side shields inside the weldinghelmet or hand shield. Helpers and observers should wear similar protection-Besure “lift front” welding helmet has plastic plate inside and safety glass cover on theoutside.3.Wear protective clothing such as heat resistant jackets, aprons, and leggings.Exposure to prolonged or intense arc radiation can cause injury. Thin cotton clothing is inadequate protection. Cotton deteriorates with this type of radiation.4.Wear high, snug fitting shoes. Avoid wearing low or loose shoes which wouldallow hot spatter to get inside.5.Wear cuffless pants. By wearing pants with no cuffs, you eliminate a dangerousspark and spatter trap- Pants legs should overlap shoe tops to prevent spatter fromgetting into your shoes.6.Wear clean clothes. Do not wear clothing that has been stained with oil andgrease. It may burn if ignited by the heat of the arc.7.Wear ear protection, not only where there is noise, but where there is a chancethat spatter or sparks could get into your ears.8.Wear a leather cap or other protection to protect the head from sparks or spatter.9.Protect neighboring workers from exposure to arc radiation. Shield your station with metal or heat resistant shields. If your station cannot be shielded, everyone within about 75 ft. should wear eye protection when welding or cutting is inprogress.10. Keep your pockets, sleeves and collars buttoned. Sparks may lodge in them andcause fires or bums. Be sure your pockets are emptied of combustibles such asmatches and other AFETYSHOESNO CUFFS10
PROTECT YOUR NEIGHBORS FROMSPATTER AND ARC RAYSPORTABLE HEATRESISTANT SCREENSSPATTERSHIELDSNOISE can damage hearing.Wear correct ear protection.Wear ear protective devices or earplugs when plasma arc cutting, plasma arc gouging or air carbon arc gouging is being performed, or in noisy welding areas. In addition,ear protection can prevent hot spatter from entering the ear. Warn others in area ofpossible noise hazards.ELECTRIC AND MAGNETIC FIELDS-May be dangerous. Electric current flowing through any conductor causes localizedElectric and Magnetic Fields (EMF). Welding and cuttingcurrent creates EMF around welding cables and weldingmachines. Therefore:1.Welders having pacemakers should consult their physician before welding. EMFmay interfere with some pacemakers.2.Exposure to EMF may have other health effects which are unknown.3.Welders should use the following procedures to minimize exposure to EMF:A. Route the electrode and work cables together. Secure them with tape whenpossible.B. Never coil the torch or work cable around your body.C. Do not place your body between the torch and work cables. Route cables onthe same side of your body.D. Connect the work cable to the workpiece as close as possible to the area beingwelded.E. Keep welding power source and cables as far away from your body as
Precautions and safe practices outlined in this booklet cover arc welding and cutting processes such as the following: 1. Gas metal arc welding (GMAW), commonly known as “MIG” welding 2. Gas tungsten arc welding (GTAW), commonly referred to as “TIG” welding 3. Shielded metal arc welding (S
the welding processes most often used in today's industry including plasma arc cutting, oxyfuel gas cutting and welding, Gas Metal Arc Welding (GMAW), Flux-Cored Arc Welding (FCAW), Shielded Metal Arc Welding (SMAW), and Gas Tungsten Arc Welding (GTAW). Flat welding positions and basic joints will be practiced. Pipe and tube welding
Air carbon-arc gouging began in the 1940s, evolving from the existing carbon-arc cutting process. Myron Stepath, a welding engineer, developed air carbon-arc gouging to remove several hundred feet of flat, cracked, stainless steel weld. Previously, carbon-arc cutting remov
Apr 30, 2008 · Carbon Arc Cutting/PACCarbon Arc Cutting/PAC 16 16 Hardfacing 10 Wee d g ( ot de ed & ed)lding (not defined & mixed) 21 . GTAW Gas-Tungsten Arc Welding (TIG) GMAW Gas-Metal Arc Welding (MIG) SMAW Shielded Metal Arc Welding (Stick or Manual Arc Welding) FCAW Flux Core Arc Welding. Step 2: Filler Metal/Base Metal .
HMP presents a wide range of AR -200 or MMA-200 of 200 AMP single phase inverter welding machine. These ARC Welding machines are available in various model ranges. HMP have a wide range of 200A ARC inverter welding machine with all standard accessories. HMP have 200A models of Welding as ARC-200N, ARC-200G, ARC-200MOS, ARC-200L, ARC-
Jun 30, 2013 · Air carbon-arc gouging began in the 1940s, evolving from the existing carbon-arc cutting process. Myron Stepath, a welding engineer, developed air carbon-arc gouging to remove several hundred feet of flat, cracked, stainless steel weld. Previously, carbon-arc cutting removed overhead and vertical defective welds and rivet heads.File Size: 920KBPage Count: 44
The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away. While the goal of plasma arc cutting is the separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.
The Arcair brand is home of products such as carbon arc gouging systems, exothermic arc cutting systems, underwater cutting torches, welding electrodes and more! Arcair provides a complete line of air-carbon arc products for the wide-ranging gouging
Mental health in primary care A briefing for Clinical Commissioning Groups 5 One in four of us will experience a mental health problem in any given year, but most of us don’t get professional help. Of those of us who do get treatment, the majority are treated within primary care.10 This is why good mental health support in primary care is so important. Local GPs and other primary care staff .
