Welding, Cutting and Brazing

NOAA Web based training

http://www.labtrain.noaa.gov/default.htm
Introduction
Welding, cutting, and brazing are exceptionally dangerous.
Compressed gases are often used to create an extremely hot
flame. Different welding techniques can cause other hazards.
The welder can be injured or cause damage to the work area in
numerous ways including fire, explosion, gas, and fume hazards.
Good work practices must be followed in all welding, cutting, and
brazing techniques to prevent injuries, fires, and explosions.
This module covers the following sections:

 Compressed Gases
 General Requirements
 Oxygen-Fuel Gas Welding and Cutting
 Arc Welding and Cutting
 Resistance Welding.
Introduction - Objectives
At the end of this Welding, Cutting, and Brazing module, you should
be able to:

 Understand the general requirements concerning

compressed gases
 Identify the general safety requirements for all types of welding
 Understand the general characteristics for the various types of
welding
 Identify the specific safety requirements for:

 Oxygen-fuel gas welding and cutting

 Arc welding and cutting
 Resistance welding.
Compressed Gases -
Introduction
Many welding and cutting operations
require the use of compressed gases. To
understand these hazards, we must
understand that compressed gases are
stores of potential energy. It takes energy to
compress and confine the gas. That energy
is stored until purposely released to perform
useful work or until accidentally released by
container failure or other causes.
Some compressed gases, acetylene for
example, have high flammability
characteristics. Flammable compressed
gases, therefore, have additional stored
energy besides simple compression-
release energy. Other compressed gases,
such as nitrogen, have simple asphyxiating
properties. Some compressed gases, such
as oxygen, can augment or compound fire
hazards.
Compressed Gases -
Introduction
Compressed gases are regulated by many standards.
Two primary standards are:

29 CFR 1910 Subpart Q – Welding, Cutting, and

Brazing – covers the handling, storage, and use of
compressed gases, such as oxygen- fuel gas, when
they are consumed in the welding process.

29 CFR 1910 Subpart H – Hazardous Materials,

1910.101 - 1910.105 – covers the general
requirements for the handling, storage, and use of
compressed gases other than those consumed in the
welding process. The General Requirements section of
1910.101 is concerned with:

 Cylinder inspection to include required markings

 Handling, storage, and utilization
 Installation and maintenance of safety relief
devices
Compressed Gases – General
Requirements
In addition to the Occupational Safety and Health
Administration (OSHA) regulations found in Subparts Q
and H of 29 CFR 1910 there are other applicable
regulations and information. These include the
Department of Transportation (DOT) regulations, and the
Compressed Gas Association (CGA) pamphlets. These
sources provide the requirements for the general
category of compressed gases and certain specific
compressed gases.
An important aspect of these regulations is the safety of
compressed gas storage containers. Specific
requirements are made of employers for the inspection of
the compressed gas cylinders. Visual inspections are
required to ensure that the cylinders are safe. The next
page will go into more detail regarding visual
examinations of compressed gas storage containers and
the safety of these containers.
Compressed Gases – General
Requirements
Employees shall determine that compressed gas cylinders under their
control are in a safe condition to the extent that this can be determined by
visual inspection. Visual and "other" inspections are required, but "other"
inspections are not defined. These inspections must be conducted as
prescribed in the Hazardous Materials Regulations of the DOT contained in
49 CFR Parts 171-179 and 14 CFR Part 103. Where these regulations are
not applicable, these inspections shall be conducted in accordance with
CGA Pamphlets C-6 and C-8.
According to DOT regulations: "A cylinder that leaks, is bulged, has
defective valves or safety devices, bears evidence of physical abuse, fire or
heat damage, or detrimental rusting or corrosion, must not be used unless it
is properly repaired and requalified as prescribed in these regulations."
The term "cylinder" is defined as a pressure vessel designed for pressures
higher than 40 psia (pounds per square inch absolute) and having a circular
cross section. It does not include a portable tank, multi-unit tank car tank,
cargo tank, or tank car.
DOT Marking Requirements
Each DOT marking identified on this page must appear on all cylinders
and must be maintained so that it is legible.
The circled numbers on the graphic correspond to the numbered
definitions provided below.

1. ICC or DOT marking may appear:

"ICC": Pre-existing marking – "ICC 3AA2015"
"3AA" - specification from 49 CFR 178.37
"2015" - marked service pressure.
"DOT": new manufacture marking must read "DOT. 49 CFR 171.14."
2. "A35798641": Serial number - no duplications permitted with any
particular symbol- serial number combinations.
3. "PST": Symbol of manufacturer, user, or purchaser.
4. "6 56": date of manufacture. Month and year. " Ø ": disinterested
inspector's official mark.
5. "+": indicates cylinder may be 10% overcharged per 49 CFR 173.302(c).
6. "5-61" and "5-66": Retest dates.
7. "*" (5 pointed star 0: indicates ten year retest interval.
See 49 CFR 173.34(e)(15).
Compressed Gases – General
Requirements
In addition to the guidance in the OSHA regulations,
Compressed Gas Association (CGA) pamphlets
determine requirements for handling, storing, and
using compressed gases in cylinders, portable tanks,
rail tankcars, and motor vehicle cargo tanks. They also
identify how to install and maintain required pressure
relief valves on these containers.
The in-plant handling, storage, and utilization of all
compressed gases in cylinders, portable tanks, rail
tankcars, and motor vehicle cargo tanks shall be in
accordance with CGA Pamphlet P-1.
Compressed gas cylinders, portable tanks, and cargo
tanks shall have pressure relief devices installed and
maintained in accordance with CGA Pamphlets S-1.1
and S-1.2.
Compressed Gases – Specific
Gases
The OSHA regulations contain some sections
regulating specific compressed gases, including:

 Acetylene
 Hydrogen
 Oxygen
 Nitrous oxide
 Anhydrous ammonia
 Liquefied petroleum gases.

Other compressed gases are in common use

and fall under regulation Subpart H, 1910.101.
Examples include chlorine, vinyl chloride, sulfur
dioxide, methyl chloride, hydrogen sulfide,
ethane, compressed air, and nitrogen.
General Requirements - Introduction
The General Requirements section,
1910.252 provides information about
protecting individuals during welding,
cutting, or brazing operations. This section
contains the three topics listed on the left.
Protection of the individual includes
measures taken to:

 Prevent fires from occurring

 Eliminate fires if they occur
 Protect personnel by providing appropriate
clothing and equipment
 Protect personnel when welding or cutting
containers
 Protect personnel working in confined
spaces.
General Requirements – Fire
Prevention and Protection
Fire prevention and protection include basic
precautions, special precautions, and safety
precautions for the unique situations involving
welding and cutting containers, and welding in
confined spaces.
The basic precautions for fire prevention in welding,
cutting, and brazing focus on removal of fire
hazards. They include the following:

 If the object to be welded or cut cannot readily be

moved, all movable fire hazards in the vicinity shall
be taken to a safe place
 If the object to be welded or cut cannot be moved
and if all the fire hazards cannot be removed, then
guards shall be used to confine the heat, sparks,
and slag, and to protect the immovable fire hazards
 If the above requirements cannot be met, then
welding and cutting shall not be performed.
General Requirements – Fire
Prevention and Protection
Complying with the basic precautions for prevention of fires in welding is not
enough. Special precautions must also be taken. These include having the
proper fire extinguishing equipment available and having fire watchers
present, if needed.
Suitable fire extinguishing equipment shall be maintained in a state of
readiness for instant use. Such equipment may consist of pails of water,
buckets of sand, hoses, or portable extinguishers depending upon the nature
and quantity of the combustible material exposed.
Fire watchers are required whenever welding or cutting is performed in
locations where more than a minor fire might develop, or where any of the
following conditions exist:
 Appreciable combustible materials, in building construction or contents,
closer than 35 feet to the point of operation
 Appreciable combustible materials more than 35 feet away, but are easily
ignited by sparks.
A fire watch shall be maintained for at least a half hour after completion of
welding or cutting operations to detect and extinguish possible smoldering
fires.
General Requirements – Fire
Prevention and Protection
Even if all of the special precautions have been taken, there are
still certain situations in which welding, cutting, or brazing are not
allowed.
Cutting or welding shall not be permitted in:

 Areas not authorized by management

 Buildings with impaired sprinkler systems
 The presence of explosive atmospheres (mixtures of flammable
gases, vapors, liquids, or dusts with air)
 Locations where explosive atmospheres may develop, such as:
 Inside unclean or improperly prepared tanks or equipment which
have previously contained such materials (flammable gasses,
vapors, liquids, or dusts)
 Areas with an accumulation of combustible dusts.
General Requirements – Fire
Prevention and Protection
Welding and cutting certain containers may
constitute a special situation that requires
additional safety precautions beyond basic and
special precautions.
No welding, cutting, or other hot work shall be
performed on used drums, barrels, tanks, or other
containers until they have been thoroughly
cleaned.
Cleaning must remove all flammable materials
present or any substances such as greases, tars,
acids, or other materials which might produce
flammable or toxic vapors when subjected to heat.
Any pipeline or connections to the drum or vessel
being welded shall be disconnected or blanked.
General Requirements – Fire
Prevention and Protection
Working in confined spaces involves additional safety
precautions beyond the basic and special
precautions.
A confined space is defined in 29 CFR 1910.252 as a
relatively small or restricted space such as a tank,
boiler, pressure vessel, or small compartment of a
ship.
Adequate ventilation is a prerequisite to work in
confined spaces.
When welding or cutting is being performed in any
confined space, the gas cylinders and welding
machines shall be left on the outside. When arc
welding is to be suspended for any substantial period
of time, such as during lunch or overnight, all
electrodes shall be removed from the holders. The
holders shall be carefully located so that accidental
contact cannot occur and the machine shall be
disconnected from the power source.
General Requirements – Fire
Prevention and Protection
When suspending gas welding or cutting operations,
eliminate the possibility of gas escaping through the
nozzle by closing the torch valves. The gas supply to
the torch must be positively shut off at some point
outside the confined area whenever the torch is not
to be used for a substantial period of time, such as
during lunch hour or overnight. Where practicable,
the torch and hose shall also be removed from the
confined space.
Where welders must enter a confined space through
a manhole or other small opening, means shall be
provided for quickly removing them in case of
emergency. An attendant with a pre-planned rescue
procedure shall be stationed outside to observe the
welder at all times and shall be capable of putting
rescue operations into effect.
General Requirements – Protection
of Personnel
Protection of personnel focuses on protecting
the welder from hazards other than general
fire protection. Protection of personnel in
welding or cutting operations can involve fall
protection, eye protection, and protective
clothing.
When working at heights, a welder or helper
working on platforms, scaffolds, or runways
shall be protected against falling through the
use of:

 Railings
 Safety belts
 Life lines
 Some equally effective safeguards.
General Requirements – Protection
of Personnel
Welding, cutting, or brazing operations conducted without proper eye
protection create a serious eye injury hazard.
Helmets and hand shields shall be arranged to protect the face, neck,
and ears from direct radiant energy from the arc. They shall be used
during all arc welding or arc cutting operations, excluding submerged arc
welding. helpers or attendants shall be provided with proper eye
protection.
Helmets and hand shields shall be made of a material which is an
insulator for heat and electricity. Helmets, shields, and goggles shall not
be readily flammable and shall be capable of withstanding sterilization.
Where the work permits, the welder should be enclosed in an individual
booth or in a non-combustible screen painted with a finish of low
reflectivity such as zinc oxide (an important factor for absorbing ultra-
violet radiation) and lamp black. Booths and screens shall permit
circulation of air at floor level. People adjacent to the welding areas shall
be protected from the rays by non-combustible or flameproof screens or
shields or shall be required to wear appropriate goggles.
General Requirements – Protection
of Personnel
Because of the danger of burns and clothing catching fire,
employees exposed to the hazards created by welding,
cutting, or brazing operations shall be protected by
personal protective equipment in accordance with the
requirements of 29 CFR 1910.132.
Appropriate protective clothing required for any welding
operation will vary with the size, nature, and location of the
work to be performed. Welders should always select
clothing materials which will provide maximum protection
from sparks and hot metal.
The shirt should have full sleeves, no pockets, and should
be worn outside the trousers with collar buttoned. The
trousers should have no cuffs and should extend well
down to the safety shoes. Safety shoes and fire-resistant
gauntlet gloves are also needed.
General Requirements – Health
Protections and Ventilation
Regardless of the precautionary measures taken, some materials
require special ventilation because they are particularly
hazardous. Mechanical ventilation and other specific control
measures are required when welding or cutting is done with the
following materials:

 Fluorine compounds
 Zinc
 Lead
 Beryllium
 Cadmium
 Mercury
 Cleaning compounds
 Stainless steel
Oxygen-Fuel Gas Welding and
Cutting - Introduction
In this Welding, Cutting, and Brazing module,
three specific types of welding are covered.
These are listed below:
Oxygen-fuel gas welding and cutting
Arc welding and cutting
Resistance welding.

This section deals specifically with oxygen-fuel

gas welding and cutting. The Oxygen-Fuel Gas
Welding and Cutting section is based on 29 CFR
1910.253. This section provides information
about the five topic areas that are listed to the left.
Each topic is presented with guidance information
so that you will be able to prevent accidents and
promote work safety when welding or cutting.
Oxygen-Fuel Gas Welding and
Cutting - Introduction
General Requirements of Oxygen-Fuel Gas Welding and
Cutting, 29 CFR 1910.253, focuses on using acetylene safely.
Under no conditions shall acetylene be generated, piped
(except in approved cylinder manifolds), or utilized at a
pressure in excess of 15 pounds per square inch gauge (psig)
or 30 pounds per square inch absolute (psia). The 30 psia limit
is intended to prevent unsafe use of acetylene in pressurized
chambers such as caissons, underground excavations, or
tunnel construction.
Absolute pressure is equal to gauge pressure plus
atmospheric pressure, which at sea level averages 14.7
pounds per square inch (psi). Thus, at sea level, a gauge
pressure reading of 15 psi is equal to an absolute pressure of
29.7 psi.
This requirement is not intended to apply to storage of
acetylene dissolved in a suitable solvent in cylinders
manufactured and maintained according to DOT requirements,
or to acetylene for chemical use.
Oxygen-Fuel Gas Welding and
Cutting - Introduction
When using acetylene, experience indicates that 15
psig is generally acceptable as a safe upper pressure
limit. Using acetylene at pressures in excess of 15
psig pressure (or about 30 psia pressure) is a
hazardous practice.

Free gaseous acetylene is potentially unstable at

pressures above 15 psig and could decompose with
explosive violence.

The decomposition characteristics of acetylene gas

are avoided by keeping the gas in liquid solution and
storing it in cylinders of unique construction
Oxygen-Fuel Gas Welding and
Cutting - Introduction
Internally, acetylene cylinders are not designed
like other kinds of compressed gas cylinders.
Acetylene cylinders are never hollow. These
cylinders contain a porous, calcium silicate filler
and a suitable solvent, usually acetone, because,
under pressure, acetylene by itself is unstable.
Acetone is used because it has the ability to
absorb over 400 times its own volume of
acetylene at 70º F.
Calcium Silicate
Millions of microscopic pores make up the calcium
silicate filler. Although it appears to fill the steel shell,
approximately 90 percent of the filler's volume
consists of "pore space" for holding and evenly
distributing the acetylene/acetone solution.
When absorbed in this filler, the acetylene is divided
into such small units that, should acetylene
decomposition take place in one pore, the heat
released is not enough to raise the temperature of
the acetylene in surrounding pores to the point
where it, too, will decompose.
Acetylene is usually supplied in cylinders which
have a capacity of up to 300 cubic feet of dissolved
gas under pressure of 250 psig at 70º F.
Oxygen-Fuel Gas Welding and
Cutting - Cylinders
Regardless of the interior construction of the cylinders, all
portable cylinders used for the storage and shipment of
compressed gases shall be constructed and maintained in
accordance with the regulations of the U.S. Department of
Transportation, 49 CFR Parts 171-179.
When using or handling cylinders and containers, it is
important to know about:
Cylinder approval and marking
Storage of cylinders
Operating procedures.

Compressed gas cylinders shall be legibly marked, for the

purpose of identifying the gas content, with either the
chemical or trade name of the gas. Such marking shall be
by means of stenciling, stamping, or labeling, and shall
not be readily removable. Whenever practical, the marking
shall be located on the shoulder of the cylinder.
Oxygen-Fuel Gas Welding and
Cutting - Cylinders
Appropriate marking not only enables proper use, but also assists in proper
storage. The following information generally applies to all cylinders:

Cylinders shall be kept away from radiators and other sources of heat
Inside of buildings, cylinders shall be stored in a well-protected, well-
ventilated, dry location, at least 20 feet (6.1 m) from highly combustible
materials. Cylinders should be stored in assigned places away from
elevators, stairs, or gangways, or other areas where they might be knocked
over or damaged by passing or falling objects, or subject to tampering
Empty cylinders shall have their valves closed
Valve protection caps, where the cylinder is designed to accept a cap, shall
always be in place, hand-tight, except when cylinders are in use or
connected for use. The valve protection cap is designed to take the blow in
case the cylinder falls.

Additional requirements exist for the storage of fuel gas and oxygen
cylinders.
Fuel Gas Cylinders - Storage
Requirements
Inside a building, stored cylinders shall be
limited to a total gas capacity of 2,000 cubic
feet (56 m3) or 300 pounds of liquefied
petroleum gas. This limitation does not apply to
cylinders that are in actual use or are attached
ready for use.

Acetylene cylinders shall be stored valve end

up. If the cylinder is on its side, acetone may
leak out and create a dangerous condition.
Oxygen Cylinders
Oxygen cylinders in storage shall be separated from fuel-gas
cylinders or combustible materials (especially oil or grease), a
minimum distance of 20 feet (6.1 m) or by a non-combustible barrier
at least 5 feet (1.5 m) high having a fire-resistance rating of at least
one-half hour.

This requirement is intended to reduce the possibility of any fire

support when a fire occurs among the fuel gas storage.
Oxygen-Fuel Gas Welding and
Cutting - Cylinders
The potential dangers related to cylinders containing
compressed gases require that cylinders be stored and
operated properly. Operation must emphasize the absence of
oily or greasy substances. Follow these rules of operation:

 Cylinders, cylinder valves, couplings, regulators, hose, and

apparatus shall be kept free from oily or greasy substances
 Oxygen cylinders or apparatus shall not be handled with oily
hands or gloves
 A jet of oxygen must never be permitted to strike an oily
surface, greasy clothes, or enter a fuel oil or other storage
tank.
Oxygen-Fuel Gas Welding and
Cutting - Cylinders
The valve outlet and regulator are two critical
components of compressed gas cylinders that
must be used properly.
Valve protection caps protect the valve from
damage and oil and grease. The valve-protection
cap shall not be used for lifting cylinders from one
vertical position to another. The cap may
accidentally and suddenly come loose.
Should a cylinder without a cap fall or be knocked
over, the valve may be damaged or sheared off,
causing a sudden release of pressure.
If the valve outlet of a cylinder becomes clogged
with ice, thaw with warm – not boiling – water.
Oxygen-Fuel Gas Welding and
Cutting - Cylinders
Like the valve outlet, the regulator must be carefully
protected.
Unless cylinders are secured on a special truck,
regulators shall be removed and valve-protection
caps, when provided for, shall be put in place before
cylinders are moved.
Cylinders not having fixed hand wheels shall have
keys, handles, or non-adjustable wrenches on valve
stems while these cylinders are in service.
Unless connected to a manifold, always attach a
regulator to the compressed gas cylinder before use.
Make certain that the regulator is compatible for the
particular gas and service pressure.
Make sure the regulator is clean and has a clean filter
installed in the inlet nipple.
Oxygen-Fuel Gas Welding and
Cutting - Cylinders
Before attaching the regulator, remove the protective
cap from the cylinder. Stand to one side of the cylinder.
Open the cylinder valve slightly for an instant, and then
close it. This "cracking" of the cylinder valve will clean
the valve of dust or dirt which may have accumulated
during storage. Dirt can damage critical parts of a
regulator, and may cause a fire or explosion.
Before a regulator is removed from a cylinder valve,
the valve shall be closed and the gas released from the
regulator.
An acetylene cylinder valve shall not be opened more
than one and one-half turns of the spindle. This permits
adequate flow of acetylene and allows ready closing of
the valve in an emergency situation.
Oxygen-Fuel Gas Welding and
Cutting - Manifolding of Cylinders
Sometimes when welding, a portable cylinder is not used as
the source of gas. A service pipe system can be used to
provide a manifolding effect. Manifolding is the gathering of
multiple-line fluid inputs into a single intake chamber. In
other words, the combining of gases needed for welding.
This can be accomplished through the use of portable outlet
headers. Each header will control the flow of a particular
gas. Portable outlet headers (shown in purple) consist of the
nozzle and hoses that can be connected to a portable
cylinder or a service pipe.
Portable outlet headers shall not be used indoors except for
temporary service where the conditions preclude a direct
supply from outlets located on the service piping system.
Each outlet on the service piping from which oxygen or fuel
gas is withdrawn to supply a portable outlet header shall be
equipped with a readily accessible shut-off valve (shown in
red in the figure).
Oxygen-Fuel Gas Welding and
Cutting - Manifolding of Cylinders
Each service outlet on portable outlet headers
shall be provided with a valve assembly that
includes a detachable outlet seal cap (shown in
yellow), chained or otherwise attached to the
body of the valve.
The primary reasons for using a seal cap are to
protect the outlet pipe thread from damage and
to prevent the deposit of oil or grease on the
threads.
Many times the caps are not used. Failure to
use the seal cap can result in damage to
threads and ground seals. This can cause leaky
connections
Oxygen-Fuel Gas Welding and
Cutting - Service Pipe Systems
Service piping systems must meet all design and
installation safety requirements.
Pipe shall be at least Schedule 40 and fittings shall be
at least standard weight in sizes up to and including 6-
inch nominal. Schedule 40 pipe is standard black iron
pipe which has a working pressure of up to 125 psi and
is always tested before use. Problems might arise when
line extensions are made with other types of pipe or
aluminum tubing. Therefore, a close inspection is
necessary.
There are special requirements for service pipe
systems when using oxygen or acetylene.

Oxygen

Acetylene or Acetylene Compounds

 Oxygen When oxygen is supplied to a service piping system
from a low pressure oxygen manifold without an intervening
pressure regulating device, the piping system shall have a
minimum design pressure of 250 psig. A pressure regulating
device shall be used at each station outlet when the connected
equipment is for use at pressures less than 250 psig.

 Acetylene or Acetylene Compounds Piping for acetylene or

acetylenic compounds shall be steel or wrought iron. Unalloyed
copper shall not be used for acetylene or acetylenic compounds
except in listed equipment. Under certain conditions, acetylene
forms explosive compounds with copper (as well as silver and
mercury).
Oxygen-Fuel Gas Welding and
Cutting - Service Pipe Systems
Now that we understand material and design
requirements, let’s consider the installation of a
service pipe system.
All piping shall be run as directly as practical. It
will be protected against physical damage with
proper allowance for expansion, contraction,
jarring, and vibration.
Pipe laid underground in earth shall be located
below the frost line and protected against
corrosion.
After assembly, piping shall be thoroughly blown
out with air, nitrogen, or carbon dioxide to
remove foreign materials. For oxygen piping,
only oil-free air, oil-free nitrogen, or oil-free
carbon dioxide shall be used
Oxygen-Fuel Gas Welding and
Cutting - Service Pipe Systems
Low points in piping carrying moist gas shall be drained into drip
pots constructed so as to permit pumping or draining out the
condensate at necessary intervals. Drain valves for this purpose
shall have outlets closed with screw caps or plugs.
Piping from overhead lines shall have drip pots at each station.
These drip pots either have a plug or petcock on the bottom.
Underground installations have no draining system.
Open end valves or petcocks shall be used. However, drip pots
located out of doors, underground, and not readily accessible, may
be controlled by valves if they are equipped with a means to
secure them in the closed position.
Pipes leading to the surface of the ground shall be cased or
jacketed where necessary to prevent loosening or breaking. Pipes
leading to the surface from underground lines have to be secured
to prevent breaking or to avoid other damage to them.
Oxygen-Fuel Gas Welding and
Cutting - Service Pipe Systems
Another important consideration for underground
piping is protection against corrosion.
Underground pipe and tubing and outdoor ferrous
pipe and tubing shall be covered or painted with a
suitable material for protection against corrosion.
Once installation is completed, piping systems
shall be tested and proved gas tight at 1½ times
the maximum operating pressure, and shall be
thoroughly purged of air before being placed in
service.
The material used for testing oxygen shall be oil
free and non-combustible. Flames shall not be
used to detect leaks.
Oxygen-Fuel Gas Welding and
Cutting - Pipe System Protection
The entire service pipe system
must be protected against build-up
of excessive pressure and leaks.
This protection is accomplished
with:
Protectiveequipment
Regulators
Proper hose and hose
connections.
Oxygen-Fuel Gas Welding and
Cutting - Pipe System Protection
Protective equipment is divided
into the two categories listed
here.
Pressure Relief Devices
Piping Protective Equipment
Pressure Relief Devices
Service piping systems shall be protected by
pressure relief devices set to function at not
more than the design pressure of the
systems. In addition, the pressure relief
device should discharge upwards to a safe
location.
Pressure relief valves are required in fuel-gas
piping systems to prevent excessive pressure
build up within the system.
Relief valves will vent automatically at preset
pressures or may be manually operated to
relieve pressure in the system.
Piping Protective Equipment
Approved protective equipment shall be installed in fuel-gas piping
to prevent:

Backflow of oxygen into the fuel-gas supply system

Passage of a flash back into the fuel-gas supply system
Excessive back pressure of oxygen in the fuel-gas supply system.

The three functions of the protective equipment may be combined

in one device or may be provided by separate devices.
The protective equipment in fuel-gas piping systems shall be
located either at the main supply line, at the head of each branch
line, or at each location where fuel-gas is withdrawn. Protective
equipment placed at the main supply provides the best protection.
Go to the next page to see a visual comparison of the three
locations for safety devices.
Piping Protective Equipment
Protective equipment can
be located in the main
supply line with one check
valve installed before each
outlet for the greatest
protection, as in Figure 1,
or at the head of each
branch line plus check
valves at each outlet, as in
Figure 2, or at each
location where fuel-gas is
withdrawn with check
valves at each outlet, as in
Figure 3.
Oxygen-Fuel Gas Welding and
Cutting - Pipe System Protection
Another method of controlling pressure involves the use of
pressure-reducing regulators. Pressure-reducing regulators shall be
used only for the gas and pressures for which they are intended.
When regulators or parts of regulators, including gages, need repair,
the work shall be performed by skilled mechanics who have been
properly instructed. Most production shops do not have the proper
equipment to make repairs. For any equipment repairs or if there
are questions about performance reliability, contact the
manufacturer.
Gages on oxygen regulators shall be marked "USE NO OIL."
Oxygen-Fuel Gas Welding and
Cutting - Pipe System Protection
In addition to using release devices, the system must be designed, using
proper hoses, to protect against leaks. The Oxygen hose is green and has
a right-hand threaded nut for connecting to the torch. The Acetylene fuel
gas hose is usually red (sometimes black) and has a left-hand threaded
nut for connecting to the torch.
Hose and hose connections shall be clamped or otherwise securely
fastened in a manner that will withstand, without leakage, twice the
pressure to which they are normally subjected in service, but in no case
less than a pressure of 300 psi. Oil-free air or an oil-free inert gas shall be
used for the test.
Hoses showing leaks, burns, worn places, or other defects rendering it
unfit for service shall be repaired or replaced. When inspecting hoses, look
for charred sections close to the torch. These may have been caused by
flash-back. Also check that hoses are not taped up to cover leaks.
Arc Welding and Cutting -
Introduction
The second specific type of welding
discussed in this module is Arc Welding
and Cutting. This Arc Welding and Cutting
section provides information about the
three topic areas that are listed to the left.

The information presented here will

prevent accidents and promote work
safety when undertaking arc welding or
cutting operations.
Arc Welding and Cutting -
Introduction
In the arc welding process, an electric current passing through the
welding rod or electrode is forced to jump or arc across a gap. The
resulting arc produces the intense heat necessary for the welding or
cutting operation.
Arc welding is used to fabricate nearly all types of carbon or alloy
steels, the common nonferrous metals, and is indispensable in the
repair and reclamation of metallic machine parts.
Arc cutting is primarily used for rough cuts or for scrapping because
of the uneven cut that results. It has also been used for underwater
cutting in salvaging operations.
While most precautions and safe practices are common to oxy-fuel
gas welding, there are some that are unique to either gas or arc
welding.
Arc Welding and Cutting -
Introduction
Shielding is one of the unique requirements of
arc welding.
Experience has shown that welds will have
better chemical and physical properties if the air
can be kept away from the weld puddle. Such
gases as oxygen, hydrogen, and nitrogen, along
with water vapor (moisture) all tend to reduce the
quality of the weld. Dirt, dust, and metal oxides
(contaminants) also reduce the weld quality.
Shielding of the arc preserves the integrity of the
weld joint. Shielding is provided either by:

Decomposition of the electrode covering,

known as flux
A gas (or gas mixture) which may or may not be
inert.
Arc Welding and Cutting -
Introduction
Arc welding and cutting involves a variety of processes. Some of the
more common processes are listed below.

 Shielded Metal-Arc Welding (SMAW)

 Gas Metal Arc Welding (GMAW)
 Gas Tungsten Arc Welding (GTAW)
 Flux Cored Arc Welding (FCAW)
 Submerged Arc Welding (SAW)
 Arc Cutting
 Plasma Arc Cutting (PAC)
 Air Carbon-Arc Cutting (AAC)
 Arc Gouging
Shielded Metal-Arc Welding
(SMAW)
Shielded metal-arc welding is the most widely
used type of arc welding, commonly referred to
as "stick" welding. In this process, coalescence
is achieved by heating with an electric arc
between a covered (or coated) electrode and the
work surface. Shielding is provided by
decomposition of the electrode covering, known
as the flux, while filler metal is obtained from the
electrode's metal core.
Gas Metal Arc Welding (GMAW)

Gas metal arc welding is commonly known as

"MIG" welding. In the gas metal arc welding
process, coalescence is achieved by the heat of
an electric arc maintained between the end of an
electrode and the work surface. Shielding of the
arc is provided by a gas (or gas mixture) which
may or may not be inert. The electrode is fed
continuously to the weld where it is melted in the
intense heat of the arc and deposited as weld
metal.
Gas Tungsten Arc Welding
(GTAW)
Gas tungsten arc welding is commonly
known as "TIG" welding. In gas tungsten
arc welding, coalescence is achieved by
the arc and electrode method except that
the tungsten electrode is not consumed.
Shielding is provided by an inert gas. This
process produces high precision welds.
Flux Cored Arc Welding (FCAW)

Flux cored arc welding is a process which

produces coalescence by means of an arc
between a continuous consumable
electrode and the work surface. Shielding
is provided by flux contained within the
tubular electrode. Additional shielding may
be obtained from a gas or gas mixture.
Submerged Arc Welding (SAW)

In submerged arc welding, coalescence is produced by

the heat of an arc between a bare metal electrode and
the work surface. The arc is shielded by a blanket of
granular, fusible flux. The tip of the electrode and the
welding zone are surrounded and shielded by the molten
flux and a layer of unused flux in the granular state. In
this process, there is no visible evidence of the passage
of current between the electrode and the work surface.
This eliminates the sparks, spatter, and smoke ordinarily
seen in other arc welding processes. Fumes are still
produced, but not in quantities generated by other
processes.
Arc Cutting

Arc cutting is the general process in which

the cutting or removal of metals is done by
melting with the heat of an arc between an
electrode and the base metal.
Plasma Arc Cutting (PAC)

In plasma arc cutting, the metal is cut by

melting a localized area with a constricted
arc and removing the molten material with
a high velocity jet of hot, ionized gas.
Air Carbon-Arc Cutting (AAC)

Air carbon-arc cutting is a type of arc

cutting in which the metal is cut by melting
with the heat of an arc, with use of an air
stream to facilitate cutting.
Arc Gouging

Arc gouging is an application of arc cutting

used to produce a groove or bevel in the
metal surface.
Arc Welding and Cutting -
Application
When arc welding, either alternating or direct current is
used. The AC and DC limits shown below shall not be
exceeded.
Alternating Direct
Current (AC) Current (DC)
Manual 80 Volts 100 Volts
Automatic 100 Volts 100 Volts
For AC welding under wet conditions or warm
surroundings where perspiration is a factor, the use of
reliable automatic controls for reducing no-load voltage is
recommended to reduce the shock hazard. Some of the
older AC machines do not have an automatic control and
are on load all the time. It is easy to receive an electric
shock when the equipment is not handled properly.
Arc Welding and Cutting -
Installation
Arc welding requires proper installation of equipment. A critical part
of installation is ensuring that proper grounding is completed. The
frame or case of the welding machine (except engine-driven
machines) shall be grounded under the conditions and according to
the methods prescribed in Subpart S, Electrical.
Conduits containing electrical conductors shall not be used for
completing a work-lead circuit. Pipelines shall not be used as a
permanent part of a work-lead circuit, but may be used during
construction, extension, or repair providing current is not carried
through threaded joints, flanged bolted joints, or caulked joints and
that special precautions are used to avoid sparking at connection of
the work-lead cable.
Arc Welding and Cutting -
Operation and Maintenance
Before starting operations, all connections to the machine shall be
checked to make certain that they are properly made. The work lead
shall be firmly attached to the work. Magnetic work clamps shall be
free from adherent metal particles of spatter on contact surfaces.
Coiled welding cable shall be spread out before use to avoid serious
overheating and damage to insulation.
During welding operations, cables with splices within 10 feet (3m) of
the holder shall not be used. Welders should not coil or loop welding
electrode cable around parts of their body.
Cables with damaged insulation or exposed bare conductors shall
be replaced. Joining lengths of work and electrode cables shall be
done by the use of connecting means specifically intended for that
purpose. The connecting means shall have insulation adequate for
the service conditions.
Resistance Welding
The third welding process covered in this module is resistance welding.
Resistance welding utilizes pressure and heat that is generated in the
pieces to be welded by resistance to an electric current.
When conducting resistance welding, all equipment shall be installed by a
qualified electrician in conformance with Subpart S, Electrical. If spot and
seam welding machines are used, the following precautions must be taken:

All doors and access panels of all resistance welding machines and control
panels shall be kept locked and interlocked to prevent access to live
portions of the equipment by unauthorized persons.

In all press welding operations, if there is a possibility of the operator's

fingers being under the point of operation, effective guards must be used.
Examples of effective guards include an electronic eye safety circuit, two
hand controls, or protection similar to that prescribed for punch press
operations.
Resistance Welding
The hazard of flying sparks shall be, wherever practical, eliminated by
installing a shield guard of safety glass or suitable fire-resistant plastic at the
point of operation. Additional shields or curtains shall be installed as
necessary to protect passing persons from flying sparks.
All foot switches shall be guarded to prevent accidental operation of the
machine.
Two or more safety emergency stop buttons shall be provided on all special
multi-spot welding machines, including 2-post and 4-post weld presses.
Additionally, all portable welding guns, transformers and related equipment
suspended from overhead structures, eye beams, trolleys, etc., shall be
equipped with safety chains or cables. Safety chains or cables shall be
capable of supporting the total shock load in the event of failure of any
component of the supporting system.