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MARITIME ACADEMY OF ASIA & THE PACIFIC Department of AcademicsWeldingWeldingWeldingWelding(ffort) book e #1HazardsHazardsHazardsHazards Safety&in Welding Workshop
02General overview of the self-guided learning module This self-guided learning module is created by the developer for welding course as an additional learning material (other than MAAP LMS and on-line synchronous instructions), whose main goal is to support quality education and training as provided for MAAP midshipmen. This module is intended to be used whenever the internet connection is down and/or not readily accessible, so as to avoid unnecessary class disruption. This is not developed for the purpose of limiting the interaction between the instructor and cadets; instead, it is to supplement the synchronous sessions (screen time) based from the recommendations of the Commission on Higher Education (CHED), aligned with the result of studies relating to it. Both the CHED and the president of MAAP VADM. Eduardo Ma. R. Santos, AFP (Ret.) already mentioned that online instruction (flexible learning) is here to stay even after the pandemic that we are currently experiencing is over. Now, since we can not guarantee the reliability of the internet connection, it is a matter of foresight to think of something that will bridge the gap and alleviate the situation. This teacher-made instructional material is made following the minimum standard required by CHED. The developer added some subtopics that will widen the knowledge of cadets relating to the course and maritime field as well. This material will work best if used alongside the workbook manual (with MAAP LMS, CBT, VideoTel, and other online materials related to the course), likewise done by the developer. Note that this material is still on the pilot testing stage. Any suggestion(s) and recommendation(s) will definitely help ensure the success of this module. Self-Learning Module Developer, Dr. Ronaldo B. Rearte SME ACROSS 1. Creator 2. Planet Earth 3. Unit of language DOWN 4. Word puzzle
ICONMEANINGUSESLearning outcome iconThis section enumerates the intended learning outcomes in each topic. These learning outcomes are the specific areas that need to be assessed at the end of the lesson reflected in the workbook.New topic or sub topic introductory iconThis section presents the new topics and sub-topics. This part of the module contains the “need-to-know” information/lecture. It discusses the learning outcomes in detail.Safety instruction iconThis icon reminds the midshipmen to stop for a while and understand the hazard in the work to be performed. The section further discusses the recommended precautionary measures to employ, in order to prevent occurrence of such hazard.‘Think green’ instruction iconThis section gives recommendations about sustainability of certain processes by recycling, utilization of renewable energy, etc. The objective is to promote greening of workshop activities.Formative assessment iconThis icon represents formative evaluation of the midshipmen within the identified enabling outcomes of every topic, which will satisfy the learning and course outcomes in the end.Practical exercise/ activity iconThe icon is shown whenever there are suggested practical exercises or activities to be performed. The activities are typically done in the workshop lab, but the instructions and procedures are enumerated in this section.Recapitulation/ Reflection iconThis section discusses the summary of the topic. This is given prior to formative assessment or whenever there is a need to recall certain information to link with the new one.Enrichment Good-to-know iconEnrichment icon recommends additional learning materials like ebooks, YouTube tutorials, MAAP LMS, and the like. This portion widens and relates the topic into maritime field.0203www.millerweld.comwww.millerweld.comSAFETYwww.millerweld.comwww.millerweld.comwww.millerweld.comwww.millerweld.comwww.millerweld.comwww.millerweld.com How to use this module? Hi, I’m Ronnie. You will always see me in this module to guide you are while reading. Before we proceed to module #1, I will first explain how to use this learning material. Let me start by informing you that this module is organized according to the topic arrangement specified in the course manual prepared by CHED. Content is modified by the subject matter expert in such a way that the learning process is easily followed by the users (students and teachers). Following are specific icons seen in this module, and their corresponding meanings and uses to guide the user(s) accordingly.
04CONTENT PAGE NO. MODULE OVERVIEW ……………………………………………………………….........… 5 BRIEF HISTORY AND DEVELOPMENT OF WELDING PROCESS …….......... 6 MAJOR HAZARDS IN WELDING …………………………………………………........… 17 ELECTRIC SHOCK .………………………………………………………………........….…... 17 ARC RAYS/ARC RADIATIONS …………………………………………………….......….…. 20 OVER EXPOSURE TO FUMES AND GASES ……………………………………............ 22 TYPES OF VENTILATION SYSTEM USED IN WELDIN ………………........……… 23 FIRE AND EXPLOSION ....…………………………………………………….........…..…… 26 BURN ........……..………………………………………………………………..........……...… 27 ADDRESSING HAZARDS IN THE WORKPLACE …………………………..........…….. 30 FIVE (5) STEPS TO RISK ASSESSMENT ………………………………….........…….……. 31 WHAT IS HIERARCHY OF CONTROLS? ……………………………………........……….. 32 REVIEW OF THE TOPICS ……………………………………………………………..................... 38 FORMATIVE ASSESSMENTS ……………………………………………………………............... 40 QUIZ # 1.1: COMMON TERMINOLOGIES USED PERTAINING TO HAZARDS AND SAFETY IN THE WELDING WORKSHOP ……......... 41 QUIZ # 1.2: COMPARE AND CONTRAST THE MAJOR HAZARDS IN WELDING .. 43 QUIZ # 1.3: DIFFERENT SAFETY PRECAUTIONARY ACTIONS TO EMPLOY ON GIVEN WELDING HAZARDS ……………………………………............….... 44 QUIZ # 1.4: SAFETY AND HAZARDS IN WELDING …………………….....……….........…. 47 QUIZ # 1.5: STEPS IN RISK ASSESSMENT ………………………………….....……................ 48 QUIZ # 1.6: SOLVE PROBLEMS ABOUT WELDING SAFETY ……….....……….....…… 49 REFERENCES/ENRICHMENT/MAAP LMS/THINK GREEN……………………….......…… 51 FEEDBACK AND REFLECTION……………………………………………………….........................…. 52 SPECIAL REMINDER ……………………….……………………………………………............................... 53
www.millerweld.com02Module no.1 Hazards & Safety in Welding Workshop CO1: Don PPE and ensure safe working conditions and environment prior to the use of electric arc or gas welding equipment. LO1: Discuss safe practices in the workshop in reference to Code of Safe Working Practice. This module will discuss the following: basic terms relating to hazards and safety in welding; major hazards in welding; different safety precautionary actions to employ when such hazards occur; safe practices in the workshop in reference to Code of Safe Working Practice; steps then explain the process of risk assessment; and perform simple risk assessment inside the welding workshop using the instructor-made material. importance of keeping all the tools and welding equipment in good order and shape to avoid accidents and to ensure safety of life; Definition of terms Safety is the ongoing state of being protected from harm, injury, or damage to property. In a welding shop, safety isn't a static rulebook; it is the active practice of controlling your environment like ensuring proper ventilation, wearing correct PPE, and maintaining your machinery to keep everyone unhurt. Accident is an unplanned, undesired event that results in actual injury, illness, death, or property damage. It is the worst-case realization of a risk. Risk is the likelihood or probability that a specific hazard will actually cause harm, combined with how severe that harm would be. While a hazard is the "what," the risk is the "how likely and how bad." Hazards is anything with the potential to cause harm, injury, or damage. Hazards are the static dangers inherent to the job. Incident is a broader term for any unexpected event that disrupts standard operations. All accidents are incidents, but not all incidents are accidents. An incident might cause damage to equipment or a brief halt in production without necessarily hurting a human being.05
Did you know that there are five major hazards in welding? Let me discuss it one by one for you. Near miss (sometimes called a "close call") is an unplanned event that had the potential to cause injury or damage but didn't, purely by luck or split-second timing. Toolbox meeting (or toolbox talk) is a brief, informal safety meeting conducted with the crew right before a shift or specific task begins. Usually lasting 5 to 15 minutes, it focuses on the specific hazards of the day's work, proper tool handling, and safety reminders. Risk assessment is a systematic process of identifying hazards, evaluating the risks associated with them, and implementing specific control measures to eliminate or minimize those dangers before work ever begins. It answers three questions: What can go wrong? How likely is it? How do we stop it? Safety culture is the shared values, beliefs, attitudes, and behaviors regarding safety within a workplace or team. It is "the way we do things around here." In a strong safety culture, workers actively look out for one another, speak up about hazards without fear of reprisal, and refuse to cut corners to save time. Arc welding is a safe occupation when sufficient measures are taken to protect the welder from potential hazards. When these measures are overlooked or ignored, however, welders can encounter such dangers as electric shock, over- exposure to fumes and gases, skin burns, arc radiation, and fire and explosion; which may result in serious, or even fatal injuries. 1. Electric Shock - Since most of the welding processes are using electric current as their source of power to produce heat to perform welding or cutting, the risk of electric shock is very possible. Electric shock can cause injuries and even death unless proper precautions are taken. Most welding and cutting operations involve electrical equipment in addition to the arc welding power supplies. Grinders, electric motors on automatic cutting machines, and drills are examples. Most electrical equipment in a welding shop is powered by alternating-current (AC) sources having input voltages ranging from 115 to 460 volts. However, fatalities have occurred when working with equipment operating at less than 80 volts. Most electric shocks in the welding industry are a result of accidental contact with bare or poorly insulated conductors.www.millerweld.com. Major Hazards in Weldingwww.millerweld.comThe Maritime Welding Handbook06
02Primary Voltage shock Secondary Voltage shock NOTE: Using the ship hull as a return lead is a safety violation.NOTE: Using the ship hull as a return lead is a safety violation.NOTE: Using the ship hull as a return lead is a safety violation.07 The primary voltage shock - at 110 volts to as high as 460 volts - is very hazardous because it is a much greater voltage than the welder secondary (or welding) voltage. You can receive a shock from the primary (input) voltage if you touch a lead or other electrically "hot" component inside the welding machine while you have your body or hand on the welder case or other grounded metal with the power to the machine "on." Occurs when you touch a part of the welding or electrode circuit - perhaps a bare spot on the electrode cable when at the same time another part of your body is touching the metal upon which you're welding (work). To receive a shock, your body must touch both sides of the welding circuit, electrode and work (or welding ground) at the same time when the welding output is on. (Secondary shock video clip) Since the ship hull is made of metal which is a good electrical conductor, the common practice is to connect the return lead to any part of the ship hull, making the whole ship electrically “hot”. The recommended practice is to connect the return (work) lead as close as possible to the base metal being welded to avoid possible injuries and/or loss of properties. Since the workplace is made of concrete flooring which is not an electrical conductor, there is no other option but to connect the return lead as close as possible to the base metal; thereby minimizing the possibility of electric shock and possible mechanical problems because of jumping of current specially on moving parts of the engine. What are the types of electric shock related to weldingAre you aware that welding process on-board ship and on-land are often times done differently? which greatly affect the possibility of exposing yourself into electric shock.The Maritime Welding HandbookThe Maritime Welding Handbook Difference of welding on board and on land SAFETYwww.millerweld.comThe Maritime Welding Handbook
Certainly NOT like thisThe Maritime Welding HandbookBut like thisThe Maritime Welding HandbookThe following are the recommended safety precautionary measures to be taken to avoid possible electric shock in welding lab and or on- board ship.08 Wear proper protective clothing…. for all parts of the body. Electrode and return leads should be fully insulated, free from internal and external defects. Ensure that work is grounded; return lead is not ground. Use gloves while welding and changing electrodes. Protect yourself against becoming a part of welding current. Wear dry gloves in good condition when welding. Do not touch the electrode or metal parts of the electrode holder with bare hand or wet gloves. Keep dry insulation between your body (including arms and legs) and the metal being welded or ground (i.e., metal floor, wet ground). Keep your welding cable and electrode holder in good condition. Repair or replace any damaged insulation. Work area should be as dry as possible and the return lead connected as close as possible to the metal being welded. If you have to weld in a position that makes your body come into contact with the ship’s structure, insulate yourself with a rubber mat or dry wood.The Maritime Welding Handbook 2. Radiation (arc ray) - is electromagnetic energy given off by the arc or flame that can injure eyes and burn skin. An operator sees visible light radiation. However, he does not see ultraviolet or infrared radiation. Radiation is often silent and undetected, yet injury occurs.Different types of arc rays related to arc welding a. Visible Light - Visible light is the light that we see. It is produced in varying quantities and colors during welding. Too much visible light may cause temporary night blindness (poor eyesight under low light levels).
The Maritime Welding Handbookc. Ultraviolet Light - Ultraviolet light waves are the most dangerous. They can cause first-degree and second-degree burns to a welder’s eyes or to any exposed skin. Because a welder cannot see or feel ultraviolet light while being exposed to it, the welder must stay protected when in the area of any of the arc welding processes. The closer a welder is to the arc and the higher the current, Certain types of UV radiation can produce an injury to the surface and mucous membrane (conjunctiva) of the eye called "arc eye," "welders' eye" or "arc flash". These names are common names for "conjunctivitis" - an inflammation of the mucous membrane of the front of the eye. The symptoms include: The amount of time required to cause these effects depends on several factors such as the intensity of the radiation, the distance from the welding arc, the angle at which the radiation enters the eye, and the type of eye protection that the welder or bystander is using. However, exposure to just a few seconds of intense UV light can cause arc eye. These symptoms may not be felt until several hours after exposure. Pain - ranging from a mild feeling of pressure in the eyes to intense pain in severe instances Tearing and reddening of the eye and membranes around the eye (bloodshot) Sensation of "sand in the eye" Abnormal sensitivity to light and/or inability to look at light sources (photophobia) - OSHA Use welding helmet (hood) with correct shade of filter plate. Use transparent welding curtains. These are not intended as welding filter plates, but rather are intended to protect passersby from incidental exposure.0209 Too little visible light may cause eyestrain; normally this dazzling does not produce a long-term effect but in welders it is thought to progressively reduce their ability to adapt to extreme light conditions. b. Infrared Light - Infrared light is the light wave that is felt as heat. Although infrared light can cause burns, a person will immediately feel this type of light. Therefore, burns can easily be avoided. When you are welding you feel infrared light, and you are probably being exposed to ultraviolet light at the same time; therefore, protective action should be taken to cover yourself. Precautions to be taken before welding to avoid possible arc rays SAFETYwww.millerweld.com
10Wear safety glasses with UV protective side shields in addition to a proper welding helmet with filter plate. Protect exposed skin with adequate gloves and appropriate clothing (PPE). Have all persons wear safety glasses with UV protective side shields anytime near welding or cutting areas. When grinding (pointing) thoriated tungsten electrodes, always use local exhaust and, if necessary, respiratory protection to prevent inhalation of dust. Control fumes by using local exhaust and, if necessary, an approved respirator. Wear a complete required personal protective equipment at all times. 3. Over-exposure to toxic fumes & gases - Welding fume is a mixture of airborne fine particles and gases. The composition of the fumes depends on: filler metal and method of welding, and base metal coating. The fume plume contains solid particles from the consumables, base metal, and base metal coating. For common mild steel arc welding, depending on the amount and length of exposure to these fumes, most immediate or short-term effects are temporary, and include symptoms of burning eyes and skin, dizziness, nausea, and fever. For example, zinc fumes can cause metal fume fever, a temporary illness that is similar to the flu. 1. Toxic substance composition 2. Length of time the welder is exposed 3. Toxicity concentration 4. Welder's health susceptibility The degree of risk to the welder's health from fume/gases will depend on following: SAFETYwww.millerweld.comThe Maritime Welding HandbookThe Maritime Welding HandbookThe Maritime Welding Handbook
0211Certain substances found in welding fumes are recognized as being particularly dangerous, even in very low concentrations. Welding operators should be aware of the dangers associated with metals such as beryllium, cadmium, zinc and lead. Table 1.1 gives an indication of the toxicity of some of the metals more commonly encountered by welding operators. Table 1.1 Common Base Metal Coatings Used in Welding and Level of Toxicity Metal Effect Typical Fume Source Ventilation Beryllium A highly toxic, quick acting poison a carcinogen Copper based bearing alloys, casting alloys Glove box, fresh air supply Cadmium A highly toxic carcinogen causes heart, lung, kidney damage Silver brazing alloys, surface coatings Glove box, fresh air supply Chromium A carcinogen Causes lung and skin disease, nasal irritation Chromium alloys, stainless steel electroplating Local exhaust Lead Causes fatigue, nerve and kidney damage, high blood pressure Copper base castings, lead based paints, free machining steels Local exhaust Copper An irritant to nose and throat; causes metal fume fever Copper alloys and castings Local exhaust Nickel Causes skin and respiratory irritation and kidney damage; a carcinogen Nickel alloy, stainless steel Local exhaust Zinc Causes metal fume fever Surface coatings, bronze and brass Local exhaust Aluminium Causes irritation to nose and throat and chronic bronchitis Plates, castings, extrusions Local exhaust
12Ways to Avoid Over-Exposure to Fumes and Gases SAFETYwww.millerweld.comPrecautions to be taken before welding to avoid exposure from fumes and gases SAFETYwww.millerweld.com Since fumes and gases are part of welding that cannot be eliminated and can cause serious health problems for students if inhaled, proper ventilation in welding workshop is an important engineering control to implement to lessen the exposure of students from hazard. According to the Occupational Safety and Health Administration, short- term exposure can result in nausea, dizziness, or eye, nose, and throat irritation. Prolonged exposure to welding fumes can lead to cancer of the lung, larynx and urinary tract, as well as the nervous system, and kidney damage. Natural ventilation – In the greater majority of workshops and open sites, the natural flow of air through open plan layouts and natural breeze is sufficient to disperse fume concentrations. General exhaust ventilation – This method is often used where the workshop does not have adequate natural ventilation. Fumes rise and are dispersed into the atmosphere, generally through ceiling exhaust fans. Local exhaust ventilation – This method collects fumes at its source and directs them away from the work area. The suction inlet should be as close as possible to the source. There are various types of local exhaust systems, each offering certain advantages and suited to certain applications. Do not weld or cut in locations near degreasing area, cleaning, or spraying operations. The heat from welding or cutting flame can react with vapors to form highly toxic and irritating gases. Keep your head out of the fumes. Do not breathe the fumes. Local dispersion ventilation – In some cases, suitable ventilation can be obtained locally by fans which deflect and disperse the fumes away from the operator. A. Utilization of Ventilation Types of Ventilation System that can be Used for Weldingwww.millerweld.com Good-to-know
Material Safety Data Sheet (MSDS) are: Required by law and Occupational Safety and Hazard Association (OSHA) Created by the manufacturer of a product per OSHA guidelines Designed to inform users https://www.youtube.com/watch?v=IZjJUDMPrrY Welding fume hazards in welding https://www.youtube.com/watch?v=Dk2rCnv9Vmc Importance of ventilation system in welding https://www.youtube.com/watch?v=6E946qsLZ0Y What is MSDS or SDS? MSDS outlines a product’s: Identity and composition Potential hazardsSafe use Handling information Manufacturer Contact information0213 Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Read and understand the MSDS for ventilation and respirator requirements. B. Checking and Reading Material Safety Data Sheet (MSDS) What is Material Safety Data Sheet (MSDS) - All manufacturers of potentially hazardous materials must provide to the users of their products detailed information regarding possible hazards resulting from the use of such products. These material safety data sheets are often called MSDS. They must be provided to anyone using the product or anyone working in the area where the products are in use. Often companies will post these sheets on a bulletin board or put them in a convenient place near the work area. Some states have right-to-know laws that require specific training of all employees who handle or work in areas with hazardous materials.www.millerweld.com Good-to-know
www.millerweld.com.Gases encountered in welding may be: Oxygen content (by volume) Effect and Symptoms (atmospheric Pressure) Approximately 21% Normal oxygen content of air 15 – 19% Decreased ability to work strenuously. May impair coordination and may induce early symptoms in persons with coronary, pulmonary, or circulatory problems. 12 – 14% Respiration increases in exertion, pulse up, impaired coordination, perception and judgment. 10 – 12% Respiration further increases in rate and depth, poor judgment, lips blue. 8 – 10% Mental failure, fainting, unconsciousness, ashen face, blueness of lips, nausea, and vomiting. 6 – 8% 8 mins- 100% fatal, 6 mins- 50% fatal, 4-5 mins- recovery with treatment. 4 – 6% Coma in 40 sec. convulsions, respiration ceases, death.14 Fuel gases which, on combustion, form carbon dioxide and sometimes carbon monoxide Shielding gases such as argon, helium and carbon dioxide, either alone or in mixtures with oxygen or hydrogen Carbon dioxide and monoxide produced by the action of heat on the welding flux or slag Nitric oxide, nitrogen dioxide and ozone produced by the action of heat or ultraviolet radiation on the atmosphere surrounding the welding arc Gases from the degradation of solvent vapors or surface contaminants on the metal The gases that result from an arc welding process also present potential hazard. Most of the shielding gases (argon, helium, and carbon dioxide) are non-toxic, but, as they are released, they displace oxygen in your breathing air, causing dizziness, unconsciousness, and death, the longer your brain is denied the oxygen it needs. Carbon monoxide can also be developed and may pose a hazard if excessive levels are present. C. Checking the presence of toxic vapor/gases before entering enclosed spaces)
Precautions to be taken before welding to avoid fire and explosionSAFETYwww.millerweld.com0215 4. Fire and Explosion - Fire is a constant danger to the welder. Welding is considered to be “hot work” aboard ship. In most cases performing welding repair on board may require a hot work permit to ensure proper coordination and avoid possible problem or injury. Performing without a permit can be a violation of ship working procedure. Highly combustible materials should be 35 ft (10.7 m) or more away from any welding. A fire watch is needed when it is necessary to weld within 35 ft (10.7 m) of combustible materials, when sparks can reach materials farther than 35 ft (10.7 m) away, or when anything more than a minor fire might start. Welding sparks can cause fires and explosions. Sparks and spatter from the welding arc can spray up to 35 feet from your work. Flammable materials should be removed from the welding area or shielded from sparks and spatter. Recognize and cover combustible materials from the welding arc, sparks and spatter. It is also important to be sure that work is not in contact with any combustible that may ignite when heated. These materials fall into three categories: liquid; solid, and gaseous. If it not possible, cover them with tarpaulins or sheet of metal before welding inflammable materials and liquids from the work site.Have a fire extinguisher ready at all times. Inspect area for fires 30 minutes after welding. A fire watch can be provided by any person who knows how to sound the alarm and use a fire extinguisher. Do not weld or cut on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 . Reminder: https://www.youtube.com/watch?v=9DP5l9yYt-gThe Maritime Welding HandbookThe Maritime Welding Handbook
www.millerweld.com.Classification of Burns16 5. Skin Burns - Burns are one of the most common and painful injuries that occur in welding. This hazard can be caused by ultraviolet light rays as well as by contact with hot welding material, hot spatter, hot slag, and from the heat of the flame. The chance of infection is high with burns because of the dead tissue. It is important that all burns receive proper medical treatment to reduce the chance of infection. Burns are divided into three classifications, depending upon the degree of severity. The three classifications include first-degree, second-degree, and third- degree burns. Whether burns are caused by hot material or by light, they can be avoided if proper clothing and other protective gears are worn. The first step in treating a first-degree burn is to immediately put the burned area under cold water (not iced) or apply cold water compresses (clean lint-free towel, washcloth, or handkerchief soaked in cold water) until the pain decreases. Then cover the area with sterile bandages or a clean cloth. Do not apply butter or grease. Do not apply any other home remedies or medications without a doctor’s recommendation. Again, the most important first step in treating a second degree burn is to put the area under cold water (not iced) or apply cold water compresses until the pain decreases. Gently pat the area dry with a clean lint-free towel, and cover the area with a sterile bandage or clean cloth to prevent infection. Seek medical attention. Do not apply ointments, sprays, antiseptics, or home remedies. First-Degree Burns - First-degree burns occur when the surface of the skin is reddish in color, tender, painful, and do not involve any broken skin. Second-Degree Burns - Second-degree burns occur when the surface of the skin is severely damaged, resulting in the formation of blisters and possible breaks in the skin. Third-Degree Burns - Third-degree burns occur when the surface of the skin and possibly the tissue below the skin appear white or charred. Initially, there may be little pain present because nerve endings have been destroyed.The Maritime Welding Handbook
Precautions to be taken before welding to avoid possible burn injuriesSAFETYwww.millerweld.comwww.millerweld.com. What are the Risks Involved When Welding in Confined Spaces Do not wear pants with cuffs or shirts with open pockets or any clothing that can catch and hold molten metal or sparks. Remove any combustibles, such as a butane lighter or matches, from your pocket before doing any welding or cutting. Allow cooling period before working on equipment. Have a specific area where the newly welded metal or HOT base metal will be secured while cooling it down to avoid accidentally touching the work.0217 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. If the victim is on fire, smother the flames with a blanket, rug, or jacket. Breathing difficulties are common with burns around the face, neck, and mouth; be sure that the victim is breathing. Place a cold cloth or cool (not iced) water on burns of the face, hands, or feet to cool the burned areas. Cover the burned area with thick, sterile, non-fluffy dressings. Hazards when Welding in Confined Spaces – Other than the major hazards in welding like electric shock, arc rays, fumes and gases, etc., working in confined spaces is more dangerous because of the presence of the following hazards: Wear proper protective clothing….. for all parts of the body. Use satisfactory means of handling hot work such as tongs. Mark hot work pieces to alert others of the burn and fire hazards. Lack of oxygen Presence of poisonous gas, fume, or vapor Fire and explosion Excessive noise Burns Metal dustsThe Maritime Welding HandbookThe Maritime Welding Handbook
18For these reasons, working in confined spaces require special attention to ensure safety of the welder. Avoid entry to confined spaces as much as possible, e.g. by doing the work outdoors. But if entry to a confined space is unavoidable, you need to ensure the following: According to the Code of Safe Working Practices for Merchant Seafarers (COSWP), welding onboard a ship is classified as hot work and requires strict precautions to prevent fire, explosion, electric shock, burns, and exposure to hazardous fumes. The following are the recommended safe practices to follow when working on hot work onboard ship before, during, and after based from COSWP. Thouroughly clean the area before welding. Test the air for poisonous gases, fumes, and vapors. Provide exhaust and proper ventilation, and wear approved PPEs. Secure a permit to work ; provide special tools and lighting. Never work alone. Read carefully the Material Safety Data Sheet (MSDS). Put in place adequate emergency arrangements before the work starts. Ready harnesses, rescue, resuscitation equipment, and first aid equipment. Have an emergency (quick) switch off in welding machine. 1. Obtain authorization and hot work permit Ensure a Hot Work Permit has been issued according to the ship's Safety Management System (SMS). Inform the responsible officer and obtain approval before starting work. 2. Conduct Risk Assessment in the Workplace Identify fire, explosion, electrical, and ventilation hazards. Confirm that the work area is safe for welding. 3. Inspect the work area Remove combustible materials such as: Paints, Oils and grease, Rags, Wood and dunnage, Flammable liquids and gases Check adjacent compartments, bulkheads, decks, and spaces where sparks may travel.www.millerweld.com. Different Safe Practices in the Workshop in Reference to Code of Safe Working Practice when Weldingwww.millerweld.com. Before Welding Starts (Preparation Stage)www.millerweld.com
02194. Ensure adequate ventilation Provide sufficient natural or mechanical ventilation. In enclosed spaces, follow enclosed-space entry procedures if required. 5. Check welding equipment Inspect: Welding machine, Cables and electrode holders, Earth connections, Gas hoses and regulators. Ensure equipment is in good condition and properly grounded. Ensure that there is readily available fire extinguisher in the work area. 1 . Follow approved welding procedures Only trained and competent personnel should perform welding. Do not deviate from the approved work permit conditions. 2 . Maintain fire watch Continuously monitor for: Sparks, smoldering materials, any signs of fire Pay special attention to the opposite side of bulkheads and decks. 3 . Keep the area ventilated Prevent accumulation of welding fumes and gases. Avoid oxygen-deficient atmospheres 1. Shut down equipment safely Switch off welding machines. Close gas cylinder valves. Release pressure from hoses if applicable. 4 . Stop work immediately if unsafe conditions arise like: Fire risk develops. Gas leaks are detected. Ventilation fails. Equipment becomes defective. Noticeable concern about the welder/fitter. 6. Prepare the necessary and approved PPE to wear for all parts of the body. Such as : Safety shoes, Heat resistant coverall, leather gauntlet , ear muff, respiratory protection, welding hood with correct dark glass, full face shield, and alike.www.millerweld.com. During Welding Operation (Operational Stage)www.millerweld.com. After Welding Operation (Completion Stage)
Part of MAAP’s health and safety management is through Risk Assessment. This process is done to control the risks in the workplace such as welding workshop. This approach is an important system that will protect the cadets, teachers, employees, and the entire institution.www.millerweld.com. What is Risk Assessment and Why is it an Important Process to Mitigate the Hazards in the Workplace?www.millerweld.com20 2. Conduct a fire check Thoroughly inspect: Work area, adjacent spaces, opposite sides of bulkheads and decks Look for hot spots, smoldering material, or hidden fires. 3. Maintain fire watch after completion Continue monitoring the area for a suitable period as required by the ship's permit- to-work system and SMS. 4. Clean and return (store) equipment and tools properly Coil cables neatly. Return tools and power tools to designated storage locations. Secure tools and remove trip hazards. Clean the work area, remove all unncessary materials. 5. Close the Hot Work Permit Report completion to the responsible officer. Sign off the permit according to ship procedures. Risk Assessment is the careful examination of potential hazards in our workplace which could cause harm to people, so that you can likewise weigh the precautions to prevent them. - HSE INDG 163. You can easily do this step if you know how to classify the different hazards in you workplace. So, let us start by identifying the different category of hazard. Five Steps to Risk Assessment
WWW.MILLERWELD.COM GOOD-TO-KNOW21 Biological – bacteria and viruses from insects, plants, birds, animals, and humans, etc., Chemical – depends on the physical, chemical and toxic properties of the chemical, gases, presence of toxic vapour Ergonomic – repetitive movement, improper set up of workstation, improper work posture etc., Physical – radiation, magnetic fields, temperature extremes, pressure extremes (high pressure or vacuum), noise, improperly lit workplace, unorganized work stations. etc., Psychosocial – stress, violence, hazing, bullying, working under pressure, etc., Safety – slipping/tripping hazards, inappropriate machine guarding, equipment malfunctions or breakdowns which make the machine unsafe to operatewww.millerweld.com. What is Hazard Identification? The overall goal of hazard identification is to find and record possible hazards that may be present in your workplace. It may help to work as a team and include the people familiar with the work area, as well as those who are not. This way you have both the experienced and fresh eye to conduct the inspection. - CCOHS n.d. Hazard identification is part of the process used to evaluate if any particular situation, item, thing, etc. may have the potential to cause harm. The term often used to describe the full process is ”risk assessment”. Visit and roam around the workshop (welding lab) while carefully examining the area. Bring a ball pen and checklist to record whatever potential sources of danger you will see and recognize. Read the procedure manual, operation manual, and material safety data sheet (MSDS), whichever is available. Conduct actual interview with the cadets, shop keeper, and other employees who are using the workshop. Read records of previous accidents that happened in the workshop.www.millerweld.com. Classification of Hazardswww.millerweld.com Good-to-know
The overall goal of hazard identification is to find and record possible hazards that may be present in your workplace. It may help to work as a team and include the people familiar with the work area, as well as those who are not. This way you have both the experienced and fresh eye to conduct the inspection. - CCOHS n.d. Take note that severe risk will need to be addressed more urgently than the minor or low risk. To guide you on the risk evaluation, we will be using the risk assessment matrix (interpretation guide) developed by Peter Ribbe in his book How to Achieve a Safe Workplace: A Guide for Supervisors and Managers. The matrix shown below will help you as a risk assessor on how to classify the hazard based on the likelihood of occurrence and the possible severity of injury that it will bring to the welder or cadet once he encounters the unsafe condition in the workshop. Risk is the combination of likelihood and consequence- in short, a potential chance or probability of a hazard to cause harm correlating to the severity of injury, illness, and damage to property as a result of an accident. Once the hazard has been identified, the likelihood and corresponding severity of injury need to be assessed before determining how best to eliminate or minimize the risk. Let me use an illustration to explain more what risk evaluation really is. What is Risk Evaluation?0222
Step1 - Consider the consequences/degre e of severity Step 2 - Consider the likelihood/probability to cause harm Step 3 - Calculate the risk level What could be the consequence should this event (accident) occur? Consider what could reasonably happen when preventive controls are not in place. Look at the descriptions and choose the most suitable consequence. What is the likelihood of the consequence(s) identified in step 1 happening? Look at the descriptions and choose the most suitable level of likelihood. 1. Assess the consequence(s) rating from one to five (1-5) and mark under the correct column. 2. Assess the likelihood rating from one to five (1-5) and mark in the correct row. 3. Select the risk rating, where the two (2) ratings cross on the matrix below. VH = Severe Risk - Act immediately H = Major Risk - Act today M = Moderate Risk - Act this week L = Minor Risk - Act this month I - Insignificant Risk - No action is needed 1.Insignificant: Injuries not requiring first aid. 2.Minor: First aid required 3. Moderate: Medical treatment required 4.Major: Hospital admission required. 5. Severe: Death or permanent disability to or more persons 1 - Rare: May occur only in exceptional circumstances 2 - Unlikely: Is not likely to occur in normal circumstances 3 - Possible: Could occur some time 4. Likely: Will probably occur in most circumstancest 5. Almost certain: Expected to occur in most circumstances CONSEQUENCE/ DEGREE OF SEVERITY LIKELI- HOOD OF AN OCCU- RENCE 1 2 3 4 5 5 M H H VH VH 4 M M H H VH 3 L M H H H 2 L L M M H 1 I L L M M HAZARD INTERPRETATIONS (Calculated Risk Level) ( How to Achieve a Safe Workplace: A Guide for Supervisors and Managers, Peter Ribbe 2012.) Controlling risks is easier said than done. Management of any given risk may involve a number of measures drawn from various options, one of the most effective of which is by doing it in the workplace by using the hierarchy of controls.www.millerweld.com. What is Hierarchy of Controls?www.millerweld.com23 GUIDE FOR RISK ASSESSMENT INTERPRETATIONS 3. How to Control the Risk?RareInsignificantMinorModerateMajorSevereUnlikelyPossibleLikelyAlmostCertainwww.millerweld.com Good-to-know
https://www.hsestudyguide.com/hierarchy-of-controls-in-risk-assessment/0224The hierarchy of control is a step-by-step approach to eliminating or reducing risks. It ranks risk controls from the highest level of protection and reliability down to the lowest and least reliable protection. The idea behind this hierarchy is that the control methods at the top of graphic are potentially more effective and protective than those at the bottom. Following this hierarchy normally leads to the implementation of inherently safer systems, where the risk of illness or injury has been substantially reduced. The question is, can we remove heat from the welding process? Definitely not. So, even though elimination is the most effective approach in addressing the hazards, it is not always possible to implement. In this case, we can proceed to the next effective method- substitution. The first approach is elimination. The main goal of elimination stage is to physically remove the hazard from the workplace. This is the most effective method of controlling the hazards and risks in the workplace. The only problem is that, not all potential hazards can be easily removed. Say for example in welding process. Heat is the source of several hazards with high severity of risk. Substitution approach is only used when elimination is not possible. The main goal of this method is the replace or change the hazardous process, consumables, substance, and gases with less toxic materials. In welding process, if a certain type of electrode coating produces high concentration of toxic fumes or vapour, this should be replaced immediately with a lesser toxic coating, or if possible (ideally) a non-toxic one.Gemini (AI) Generated IllustrationGemini (AI) Generated Illustration
Gemini (AI) Generated IllustrationThe next approach is engineering controls. The main goal of this method is to isolate workers or cadets from the source of danger. This control is merely a modification of the existing machine or equipment setup in order put a barrier between the hazard and the operator of the machine tools. This method is much less costly as compared to the first two approaches simply because it does not require to remove or replace the whole process. The only concern with this method is that, there should be a precedent accident before we can apply such technique.25 Elimination and Substitution While most effective at reducing hazards, also tend to be the most difficult and costly to implement in an already existing process. If the process is still at the design or development stage, these methods may be inexpensive and simple to implement. For an existing process however, major changes in equipment and procedures may be required. For this reason, it is not always, the most practical way in controlling hazards in the workplace. The fourth approach is administrative control. The main objective of this method is to educate the workers, employees and/or cadets in order to change the way they work. This includes training, seminars and/or formal education like what we are having in the classroom. This control is also the foundation of a specific system that can be implemented in the workplace, such as 5S, standard operating procedure in doing something, posting safety signages, painting certain area to indicate possible danger etc. This technique will keep the employees and cadets well aware of the hazards in the workplace.Gemini (AI) Generated Illustration
“Administrative controls and PPE are frequently used with existing processes where hazards are not particularly well controlled. Administrative controls and PPE programs may be relatively inexpensive to establish but, over the long term, can be very costly to sustain. These methods for protecting workers have also been proven to be less effective than other measures, requiring significant effort by the affected workers.” - Center for Disease Control and Prevention (CDCP) After careful analysis of different control measures indicated in the hierarchy of control, the next thing to do is to record the findings and the recommended mitigations for the identified hazard(s) and risk(s). These include the following: Type of hazard identified Assessment of risks associated with the identified hazard Measures to implement (mitigation) to manage exposure to the risks How often and when the control measures are implemented Who is/are the responsible person(s)/department(s) to carry the needed replacement, repair, or modifications.0226 The last approach is proper utilization of Personal Protective Equipment (PPE). Do note that wearing of PPE is only required if the first four approaches are not enough to control the hazards and risk in the workplace. You might ask, ‘Really’? Yes. For example, we do not wear PPE while having academic instruction. 4. How to Document the Process?Gemini (AI) Generated Illustration Why? Simply because there is very little (insignificant) risk (possibly none at all) inside the classroom. Checking the risk assessment interpretation table shown above, it says that no action needs to be performed if the risk involved is insignificant.
1. Area(s) of Concern: Welding lab Conditions Identify the Potential Hazardous Conditions (HPC) in the area. Risk Poosible injury might iccurr due to hazard exposure Ha- zard Inter- pre- ta- tion Suggested mitigation & responsible person to carry out the solution Level of Risk (Severity of injury) Likelihood of Occurrence of Consequence(s) 5 4 3 2 1 5 4 3 2 1 Poorly lit welding booth Possible tripping, skin burn H Replace busted bar light today - PMGS/Sir Bobby Poorly ventilated workshop Exposure to arc rays, toxic fumes/ gases VH Install additional ventilation immediately -PMGS/ Sir Bobby Presence of excessive noise Possible miscommu- nication, impaired hearing VH Open the windows before the lab ins. starts- Cadet/ Instructor27 5. How to Monitor and Review? Example of Risk Assessment Form Continue to monitor if the identified hazard(s) and risk(s) is/are properly mitigated. Check if the recommendation(s) is/are properly addressed by the appropriate personnel and/or department. Review the most recent accident and/or near miss accident records for verification if the risk assessment process is done, and if it indeed helps improve the safety habits of the employees and cadets. Feedback from the end-users of the workshop will also help monitor and review the effectiveness of the risk assessment. Direction: Evaluate each item as observed in the laboratory. Tick the possible level of risk (5 – severe risk, 4 – major risk, 3 – medium/moderate risk, 2 – minor or low risk, and 1 – insignificant risk) and the likelihood of occurrence of its consequence(s) (5 - almost certain, 4 - likely, 3 - possible, 2 - unlikely, and 1 - rare to happen). Hazard interpretations and recommendations will be discussed in class.
Reviewwww.millerweld.com Accident - ___________________________________________________________________________________ _____________________________________________________________________________________________. Incident - _____________________________________________________________________________________ ______________________________________________________________________________________________. Near miss - ___________________________________________________________________________________ ______________________________________________________________________________________________. 1.______________ 5.______________ 6.______________ 7.______________ 8.______________ 2.______________ 3.______________ 4.______________ 1. Define in your own words the following terms relating to hazards and safety in welding: safety, hazards, accident, incident, near miss, and risk assessment. Safety - ______________________________________________________________________________________ _____________________________________________________________________________________________. Hazards - _____________________________________________________________________________________ ______________________________________________________________________________________________. Risk - __________________________________________________________________________________________ ______________________________________________________________________________________________.0228
29Reviewwww.millerweld.com 1. Choose two to three (2-3) major welding hazards and cite examples of their uniqueness in the welding process as compared with the others, as well as their similarities to each other. a. ____________________________________________________________________________________________ _____________________________________________________________________________________________. b. ____________________________________________________________________________________________ ______________________________________________________________________________________________. c. _____________________________________________________________________________________________ ______________________________________________________________________________________________. 2.. How can the risk assessment process help the organization to control the hazards and risks in their workplace? Cite example to support your answer. ________________________________________________________________________________________________ ________________________________________________________________________________________________ _______________________________________________________________________________________________. 3. Explain how the proper organization of tools and materials inside the workshop improves the safety of the worker/welder. Support your answer with specific examples ________________________________________________________________________________________________ ________________________________________________________________________________________________ _______________________________________________________________________________________________. 4. Watch this video clip (https://www.youtube.com/watch?v=Qhfz1PQKig4) and explain how the proper care of equipment helps and ensures safety of life on board ship. ________________________________________________________________________________________________ ________________________________________________________________________________________________ _______________________________________________________________________________________________.
0230Direction: Read the following questions related to welding hazards and safety in the welding workshop. Choose the best answer from the following questions. Write letters only on the answer sheet provide. Safety - ___________________________________________________________________________________ ____________________________________________________________________________________________ ___________________________________________________________________. Hazard - __________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________. Risks - ____________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________. Accident - ________________________________________________________________________________ ____________________________________________________________________________________________ ___________________________________________________________________________. Incident - _________________________________________________________________________________ ____________________________________________________________________________________________ ___________________________________________________________________________. Near miss - _______________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________. Risk assessment - ________________________________________________________________________ ____________________________________________________________________________________________ ___________________________________________________________________________. Safety culture - __________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________. Quiz no. 1.1 Common Terminologies used Pertaining to Hazards and Safety in the Welding Workshop
31Direction: Read the following questions related to welding hazards and safety in the welding workshop. Choose the best answer from the following questions. Write letters only on the answer sheet provide.1. A fitter onboard ship is instructed to repair a simple steel bracket in a workshop. Several cans of paint and solvents are stored nearby. Which actions should be taken before welding? A. Remove or relocate the paint and solvents B. Proceed immediately since the job is urgent and simple only C. Prepare fire-fighting equipment nearby, then start the work D. Stop and obtain a hot-work permit2.An engine cadet onboard ship notices smoke and fumes accumulating while welding inside a compartment. What should be done? A. Improve ventilation by turning on the other exhaust fan before continuing B. Leave the compartment and report the situation C. Continue welding to finish the task quickly D. Use appropriate respiratory protection3. Before starting work, a welder discovers exposed wires on one of the welding cables. What is the safest course of action? A. Stop and report the defect B. Replace or repair the cable before use C. Wrap the damaged area with cloth and continue working D. Inspect the rest of the equipment record the issues and continue working 4.During welding, the fire watch noticed sparks are passing through an open hatch into another compartment. What should be done? A. Check the adjacent compartment B. Continue welding because no fire has started yet C. Install spark shields or fire blankets D. Stop welding temporarily and wait for the safe remedy 5.A welding spark lands on an oily rag but does not start a fire. Which actions support a positive safety culture? A. Report the near miss B. Investigate why the rag was present C. Remove combustible materials from the area D. Keep the event secret because no damage occurred Quiz no. 1.3 Major Hazards in Welding
02326. A midshipwoman complains that she can’t see the weld at 100 ampere setting through a #13 dark lens (shade) fixed on the welding helmet. So she puts #8 dark lens on her welding helmet and starts to weld. Is it the safe thing to do? Why? ___________ , ________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________________________________________________. 7. A fitter demonstrate to cadet engineer that the easiest way of fixing the return lead while welding onboard ship, is by connecting it in the nearest ship hull. Is really the safest way of doing it? Why? __________ , __________________________________________ _____________________________________________________________________________________________ ___________________________________________________________________________________________. 8. A marine engineering cadet holds his newly-welded base metal and brought it to his instructor for evaluation using a pair of leather gloves. Is that a safe way of holding a newly welded metal? Why? __________ , _____________________________________ _____________________________________________________________________________________________ ___________________________________________________________________________________________. 9. A midshipman is attempting to replace a tension spring in an electrode clamp while the welding machine is still on. Is that a safe way of doing itl? Why? _________ , _____________________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________________________________________________. 10. 3rd class De la Cruz is performing arc welding without the transparent curtain inside the welding booth that has several other midshipmen working. Is that a safe way of welding in the workshop? Why? __________ , ___________________________________ _____________________________________________________________________________________________ ___________________________________________________________________________________________. 10. A marine engineering cadet from the main campus left the electrode holder with electrode stub on top of a working table while having a slop chest break. Is that practice of leaving the electrode holder on the worktable safe? Why? __________ , _____________________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________________________________________________.
ELECTRIC SHOCK BURNS 1. 2. 3. 4. 5. ARC RAYS FIRE & EXPLOSION 1. 2. 3. 4. 5.33 Direction: Identify different safety precautionary actions to employ when the following hazards occur. You need to get at least fifteen (15) correct answers to pass this assessment. Quiz no. 1.4 Identify Different Safety Precautionary Actions to Employ on given Welding Hazards
2. Click and watch this YouTube link, https://www.youtube.com/watch? v=Qhfz1PQKig4. Then explain how the proper care of equipment helps and ensures safety of life on board ship. _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ ______________________________________________________________________________________.One (1) PointPoor Three (3) PointsFair Five (5) pointsExcellent Quality of answer and example(s) given Explanation is incorrect Example(s) is/ are not relevant to the topic Explanation is acceptable Example(s) is/are correct but not as relevant to the topic Explanation is correct and on- point Example(s) is/are correct and relevant to the topic Cohesiveness of thought Main thought is not clearly statedIdeas are confusing and not connected to each other There is acceptable statement of main thoughtIdeas are generally connected to each other There is clear and direct statement of main thoughtOne idea clearly leads to another Grammatical correctness With more than 3 grammatical errors With 1-3 grammatical errors With no grammatical errors0234 Direction: Hold control button and click the given YouTube links, then answer the questions below. You need get at least seven (7) points to pass this assessment. 1. Click and watch this YouTube link, https://www.youtube.com/watch? v=OrKS8A3nINo. Then state how a well-organized work shop can be most effective in ensuring a safe working environment when using electric arc and gas welding equipment. ________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ ______________________________________________________________________________________. Quiz no. 1.5 SAFETY AND HAZARDS IN WELDING Essay: Rubric
35Direction: Discuss safe practices in the workshop in reference to Code of Safe Working Practice Before, During, and After welding . Cite example of each stage to support your answer. Quiz no. 1.6 Safe Practices in the Workshop in Reference to COSWP Before Welding Starts: During Welding Operation: After Welding Operation: 1. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 2. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 3. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 4. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 5. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 6. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 7. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 8. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 9. ______________________________________________________________________________________. Example: ______________________________________________________________________________. 10. ______________________________________________________________________________________. Example: ______________________________________________________________________________.
36Direction: List down the five steps in risk assessment process and explain them briefly. Cite examples related to welding to support your answers. You need to get at least seven (7) points to pass this assessment. Step 1: ___________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ___________________________________________________________________________. Step 2: ___________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ___________________________________________________________________________. Step 3: ____________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ___________________________________________________________________________. Step 4 :____________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ___________________________________________________________________________. Step 5: ____________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ___________________________________________________________________________. Quiz no. 1.7 Enumerate the Steps and Explain the Process of Risk Assessment
0237Workbook Activity #1: Common Terminologies used Pertaining to Hazards and Safety in the Welding Workshop ACCROSS DOWN 2. Shared values, beliefs, attitudes, and behaviors regarding safety within a workplace or team. 4. Systematic process of identifying hazards, evaluating the risks , and implementing specific control measures to eliminate or minimize the dangers before work ever begins. 5. Unplanned event that had the potential to cause injury or damage but didn't, purely by luck or split-second timing. 6. Unplanned, undesired event that results in actual injury, illness, death, or property damage. 1. Unexpected event that disrupts standard operations that might cause damage to equipment or a brief halt in production without necessarily hurting a human being. 3. Is the light wave that is felt as heat during welding. 9. Is a brief, informal safety meeting conducted right before a shift or specific task begins. 10. Is the ongoing state of being protected from harm, injury, or damage to property.. 11. Is electromagnetic energy given off by the arc or flame that can injure eyes and burn skin. 7. Anything that can be a possible source of danger. 8.Is the likelihood or probability that a specific hazard will actually cause harm, combined with how severe that harm would be.
38Direction: Identify 10 hazards present in the workshop. The explain why it is considered unsafe condition in the workplace. Workbook Activity #2 : HAZARD HUNT 2. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 1. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 3. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 4. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 5. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 6. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 7. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 8. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 9. _________________________________________________________________________________________. Reason: _________________________________________________________________________________. 10. ________________________________________________________________________________________. Reason: _________________________________________________________________________________.Gemini (AI) Generated Illustration
RISK ASSESSMENT FORM NUMBER _________ (1. Area(s) of Concern: Welding lab Conditions Identify the Potential Hazardous Conditions (HPC) in the area. Risk Poosible injury might iccurr due to hazard exposure Ha- zard Inter- pre- ta- tion Suggested mitigation & responsible person to carry out the solution Level of Risk (Severity of injury) Likelihood of Occurrence of Consequence(s) 5 4 3 2 1 5 4 3 2 139 Direction: Proceed to welding lab, then identify 10 possible sources of danger inside the workshop. Assess the level of risk and likelihood of occu- rence of the identified hazard. Give example of probable injury/ies and suggest possible mitigation to eliminate the danger. Workbook Activity #3 : RISK ASSESSMENT Direction: Evaluate each item as observed in the laboratory. Tick the possible level of risk (5 – severe risk, 4 – major risk, 3 – medium/moderate risk, 2 – minor or low risk, and 1 – insignificant risk) and the likelihood of occurrence of its consequence(s) (5 - almost certain, 4 - likely, 3 - possible, 2 - unlikely, and 1 - rare to happen). Hazard interpretations and recommendations will be discussed in class.
www.millerweld.comReferences/Reading Materials0240Basic Gas Welding and Cutting, Learning Resource Metals and Engineering, 2008. Fundamentals of Gas Cutting and Welding, A. Bhatia Maritime Welding Handbook, Welding and Related Processes for Repair and Maintenance On board, by Wilhelmsen Ships Service Naval Education and Training Professional Development and Technology Center, Chapter 4, Gas Cutting Welding Essentials: Questions & Answers 2nd Edition, William L. Galvery, Jr., Frank M. Marlow, PE Welding Handbook, 9th Edition Vol. 2, American Welding Society. Annette O’Brien, 2004. Welding Principles and Applications, 8th Edition by Larry Jeffus, 2017. https://www.youtube.com/watch?v=DTvazwpwxL8 Major hazards in welding https://www.youtube.com/watch?v=MVrI2kuRKdA Major hazards in welding https://www.youtube.com/watch?v=L-V824nQNpQ Electric shock/Welding confined https://www.youtube.com/watch?v=jy79I_AuXgc 10 Biggest welding failures https://www.youtube.com/watch?v=duqJFBPnFjs Secondary electric shock https://www.youtube.com/watch?v=4g7OqvkzC-I Factors that affect electric shock https://www.youtube.com/watch?v=fY6KGN72d7Q Risk Assessment Made Easy https://www.youtube.com/watch?v=XOkPcLD5Soo Hierarchy of Controlling HazardsPut plants that absorb carbon dioxide (CO2) inside the workshop and/or utilize solar energy to power your fans, lightings, and commonly used power tools in the welding lab. Reducing energy consumption from the power grid will lessen the CO2 emission in the atmosphere while having lab workshops.www.millerweld.com Enrichment Additional Links Think Green
41www.millerweld.comFeedback 1. What is/are the most important part/s of the topic that you think will help you most as a Maritime Engineering cadet? Why?____________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________. 2. Is there any part of the module that you want to change or improve? How? ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ___________________________________________________________________________________________________. 3. As a Maritime engineering cadet, do you think this module will help you learn better? ________________How?___________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________. B. WHAT I HAVE LEARNED (REFLECTION) How will I apply my newly acquired knowledge into my chosen profession? ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ ___________________________________________________________________________________________________. A. FEEDBACK
0242A. SPECIAL REMINDER This e-module is intended for MAAP use ONLY. This is developed in support of the academy’s goal for flexible learning instructions. This self-guided learning material is developed to help address disrupted synchronous classes due to intermittent internet connections, resulting to unnecessary stress and anxiety to both cadets and instructors. The developer DOES NOT give permission to anyone else to use or reproduce the said material in any manner, for personal use and/or for other reasons outside its original purpose. By default, the soft copy of this learning material is protected by password(s) which prohibit(s) other people from copying and/or saving the file on different file formats, including printing the workbook. In case there is an official need to do any of such tasks, kindly inform the developer and he will be the one to do it. This reminder is done to protect the work that has been a product of the developer’s valuable time and effort. Thank you, Ronaldo B. Rearte, Ed. D Module Developer For questions and suggestions: email me @ ronaldo.rearte@maap.edu.ph