Reprinted from the ACJ - July, 2002
�Welcome aboard son, let me show you around the shop before you start. Hang your coat over there on that rack.� � You mean this portable welding rig?� �Yeah... we use it for that sometimes...anyway, let me show you the lunch room.�
Depending on your shop and how diverse your automotive work is you may have a welding rig pushed over into the corner. Often used more for cutting than welding, the �Hot Wrench� is nice to have available. But, like the combination to the bike lock you haven�t used sice you were sixteen, the methodology and safety practices associated with an fuel-oxygen welding system may be stored so far back in your memory your wife has already boxed it up and sent it to goodwill with some old clothes.
In 1919 the American Welding Society was established to organize a growing industry. After arranging a monthly meeting, complete with refreshments, they set about establishing; standards for welding equipment and safety practices for it�s use. These safety guidelines can be broken down into three categories; equipment, personal, and area safety. As with most safety practices, the nexus of this safety information is �think before you act�. That is a lot easier than dodging a fire breathing hose whipping around like the Medusa.
Inspection of the equipment is the first order of business. Especially if the unit is wheeled out only for sporadic use. Confirm that everything is in working order. Each time, check the gas supply. Is the rig upright? Acetylene bottles must be stord upright for a minimum of eight hours before being put into use. Are both the fuel and oxygen chained to a wall or portable cart designed for welding use, to prevent them from falling over? Is the oxygen bottle present, or did the delivery guy take it scuba diving? Industry tip; store your full bottles with the safety bonnet in place and the empty bottles with it removed. It�s an easy way to know if you are out of juice. Check the valving. The tank valve should open and close easily and completely. The regulator valves should turn easily and the needles on the gauges should rise smoothly and steadily. To facilitate this, remove the stress on the regulator by closing the tank and relieving the pressure on the regulator and hoses when you are done for the day. If you seldom use your rig this is especially important. Check the torch. Are the hoses in good shape? No nicks, cuts or melted spots. Hoses should be replaced regularly, even if not in constant use. Weather cracking and solvent attack can destroy a hos fairly fast. As can using it to tie up the lid to the boilout tank so it doesn�t slam shut. Remember the threads on fuel fittings is left hand thread. Think finesse, not force, or think new regulator. When lighting up, start with the torch valves closed. Then if a customer walks in you didn�t leave the gas running. Oxygen bottles should be opened all the way. For Acetylene bottles open only 3/4 of a turn, maximum. Acetylene should never run above 15 psi at the tank regulator.
The welder is ready. What about the wielder? Welding leathers may not be as pretty as motorcycle leathers, but the gloves, gauntlets, apron and skull cap are heavy duty and still make you feel tough. An AWS approved welding helmet and/or goggles is a must. The bright light at the torch tip gives off ultraviolet light which can �sunburn� your eye balls faster than a bald head at the ball game. With all that gear on it gets warm, hydration is very important. Drink lots of water while suited up and afterward.
Securing thearea before cutting into your work is the next step. Move all flammables, combustibles and customers at least 35 feet away from the work area. If that�s not feasible, such as when cutting off exhaust parts near the gas tank, cover or isolate the flammable area with a welding blanket or shield designed for such a purpose. As you cut, Vesuvious-like eruptions of hot metal, called slag, fly everywhere. Be sure that coworkers or anything that may melt is cleared out of the way. Slag is drawn to open shirt collars and breast pockets. Close the top button and tape the breast pocket closed. By the way, if there is a butane lighter in that breast pocket, you are a disaster waiting to happen. Consider �everything flammable� when securing the area. If you can, enclose or divide, the welding/cutting work area from the general work space with welding curtains. These sometimes translucent, colored, sheets can be portable and will deflect some of the flying slag. They also filter the ultraviolet light so the rest of the flks in the shop don�t toast their retinas by staring at the arc. And stare they will. You can�t help it. Like the Bikini top, standing next to the bald guy, at the ball game. You shouldn�t look but you are drawn to the flame.
The equipment is in good shape. Protective gear is on. Work area is safe and secure. OK, fire the cutting torch up. Cut that exhaust clamp. OK shut it down. Ten minutes of prep work and one minute of work. That is all right. When it comes to your safety, that is an important ten minutes. Usually job safety breaks down for one of two reasons. First, it is a job that you do everyday. You know what you are doing, but you get complacent and ignore the cumbersome safety equipment and guidelines. Conversely, you do the job only occasionally and may not remember all the rules. Having a set checklist or set of rules attached to the welding rig may help remind both the old hand and the novice of it�s safe use. Always chose to protect yourself, your coworkers and your shop first. Then pul the new guys coat off of the rig and let the sparks fly.
The above article was written by David M. Brown, Chief Engineer of Johnson Manufacturing Company, Inc. and is published by JOHNSON with the expressed approval of the National Automotive Radiator Service Association and the Automotive Cooling Journal. Other reproduction or distribution of this information is forbidden without the written consent of JOHNSON and NARSA/ACJ. All rights reserved.
JOHNSON MANUFACTURING COMPANY
114 Lost Grove Road / PO Box 96 / Princeton, Iowa 52768-0096
Phone 563-289-5123 or Fax 563-289-3825