Increasing productivity and safety
June 1st 2008 When managing welding processes, prioritising health and safety needn't be a dampener on productivity and profit, explains welding expert ESAB
All welding processes can be hazardous if correct operating parameters and lprocedures are ignored. Companies are legally obliged to use safe systems of work and for personnel to exercise special care and attention to 'ensure that the health and safety of those involved with a task and those who might be affected by the process are kept safe from injuries and/or health probems.' Although hazards such as arc flash, hot metal, sharp metal edges, noise, vibration, dust and fumes are ever present in welding and cutting, most risks arises from: The unsafe handling of work pieces and welding equipment- especially gas cylinders (which should only be re-located using dedicated trolleys or wall securing stations)
The inhalation of harmful welding fumes
The noise produced during plasma arc welding, gouging operations Radiation from ultra violet and infrared sources Vibration during grinding for weld preparation The discomfort produced by excessive heat and uncomfortable working positions.
Problems associated with manual arc welding can include: a poorly insulated electrode holder, a dirty visor, the lack of a local isolating switch, poor extraction equipment, poor condition of a work piece earth clamp, the need for an insulated box for the electrode holder (resting an electrode holder on the face shield clothing or a pile of rags is not recommended) and poor cable connections.
It is vital that welding ventilation and protective equipment is maintained and inspected on a regular basis.
Local exhaust ventilation should be examined and tested by a competent person every fourteen months, respiratory protective equipment needs a thorough test on a monthly timetable, with air fed equipment being checked at the same interval, to measure the volume and quality of breathing air being supplied.
Flexible gas and oxygen hoses need to be examined daily and any physically damaged items immediately replaced. It is recommended that pressure regulators, blowpipes and flashback arrestors are leak tested every time they are used with an appropriate proprietary leak test fluid. Further a major check of correct function should be made each year and it is recommended that regulators and reset flashback arrestors are replaced after five years in service.
The reason for this is that the elastomeric parts deteriorate with time regardless of service conditions.
On a personal level, arc welders are recommended not to wear jewellery, rings or watchstraps and must be trained to exchange electrodes in a safe manner.
Full and empty gas cylinders should be stored in a safe and well-ventilated place and preferably outside the building. Cylinders need to be protected from damage and unstable cylinders chained in rack or on its trolley. Oxy fuel gas systems should be closed down at the cylinder when not in use and the hoses drained of gas. This is an essential precaution in case of a workshop fire. Grease, oil or other lubricants should never be applied to oxygen fittings as they can form explosive compounds.
While some individuals in the work place still see health safety as an unwanted overhead and a damper on productivity and profit, the truth is that establishing better health and safety practices can pay dividends through higher productivity and a reduction in scrap and re-work.
Take for example automatic-darkening helmets. They can be more user-friendly than passive ones and save valuable time. Five minutes a day is equal to nineteen hours a year and if the welder is working with short welds the daily saving can exceed five minutes. Using economical low specification helmets can be a false economy. Reaction time for an auto-darkening lens is faster at higher amperage.
While many low-cost helmets justifiably meet the EN 379 requirements and carry an 0.0001 sec switch time specification this might well be for an ambient temperature of 55C, hardly typical of an UK working environment.
WIN A WELDING HELMET AND RESPIRATORY SYSTEM
To mark the launch of its new helmets and respiratory systems, ESAB is offering two prizes to HSM readers worth a total of £1,300.
First prize: ESAB Eyetech II 5/13 with an Air 200 respiratory system
Second prize: ESAB Eyetech II 9/13 with an Air 200 respiratory system
To be in with a chance of winning, just send your name, address and contact details to:
Cheron Robinson
ESAB
Hanover House,
Queensgate Britannia Road,
Waltham Cross,
Hertfordshire,
EN8 7TF
cheron.robinson@esab.co.uk
Entires to be marked "HSM Prize Draw." Competition closes 31st July 2008 More articles from ESAB Group UK Limited: | 
