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SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
INTRODUCTION
We learn by experience. Learning safety through per-
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of
others teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re-
search, development, and field experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The rea-
son for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause seri-
ous injury or death. When safety becomes a habit, the
equipment can be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut-
ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
are also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2.
GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in
this manual, be sure to consult flux and electrode
manufacturers
Material
(MSDSs) for specific technical data and precaution-
ary measures concerning their material.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
Safety
Data
Sheets
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im-
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan-
dard Z49.1 listed in Standards Index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium-bear-
ing and similar materials, when welded (or cut) may pro-
duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each person
in the area as well as the operator must wear an air-sup-
plied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is re-
moved from the work surface, the area is well ventilated
and, if necessary, while wearing an air-supplied respira-
tor.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira-
tor.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod-
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
OM-877 Page 1
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