TESTINGANDINSPECTIONOF

WELDING
AWE & WE COURSE, INDONESIA UNIVERSITY,
FEBRUARY 2011
Short Resume

Wing Hendroprasetyo Akbar Putra

Perumahan ITS Jl. T. Sipil Blok V-10, Keputih, Sukolilo
NDE Center
Laboratorium Konstruksi & Kekuatan, Jurusan Teknik Perkapalan
Fakultas Teknologi Keluatan Institut Teknologi Sepuluh Nopember (ITS) Surabaya
HP 0816 542-8017
HP: 542 8017
Fax.: (031) 591 4533
Email: [email protected]

Sarjana Teknik Perkapalan ITS 1994

Master of Engineering, Memorial University of Newfoundland Canada 1999

ASNT Level III, MT, PT, UT, RT, 2009

Level II, NACE International Coating Inspector Training, Orlando - Florida, USA, 1999
Welding Inspector Course, Politeknik Perkapalan, angkatan V, 1995
What is inspection?

Inspection is the process of examining equipment to:

1. Make sure its performing as designed.

2. Evaluate all components for potential problems.
3. Identify any component that may cause a
breakdown and estimate the time until failure
MENGAPASAMBUNGAN
LASHARUSDIPERIKSA?
LAS HARUS DIPERIKSA?
IN WELD JOINTS:

To confirm the quality of weld joints

To confirm if a structure satisfies quality standards as prescribed in

specifications and drawings

Inspection methods shall be chooses to economize time and cost

Sambunganlasharusdiperiksakarena:
g p
1.Selalumengandungcacat
g g
Cacatmetalurgi
Cacatgeometri

2.Memilikifaktor konsentrasiteganganyang tinggi

3.MemilikiHAZ
butiranbesar,mudahdimasukiatomhidrogen,kekuatanrendah

4.Memilikikekuatanfatikyangrendah
ketangguhan yang rendah
ketangguhanyangrendah

5. Memiliki tegangan sisa

kekuatan fatik yang rendah
menimbulkan deformasi
Sambunganlasharusdiperiksakarena:
g p
6.Materialnyacenderunggetas,keras
retakmudahmerambat
k d h b
mudahmengalamikepecahan

7.MemerlukanpemeriksaanDT&NDT
Toconfirmthequalityofweldjoints
Toconfirmifastructuresatisfiesqualitystandardsasprescribedinspecifications
anddrawings
8.Hasilnyatergantungpadawelder,mesinlas,
material dan proses
material,danproses
memerlukankualifikasisepertiWPQT,WPS,PQR

9
9.Inspectionmethodsshallbechoosestoeconomize
I ti th d h ll b h t i
timeandcost
timeandcost
 PEMERIKSAANSAMBUNGANLAS

UNDERSIZED SMALL C.S.A.

WELDMENTS
OVERSIZED TOO HIGH
RIGID STRESS

WASTING (PEMBOROSAN)

WELDER

GEOMETRY
MEASUREMENT SUPERVISOR

INSPECTOR
PemeriksaanSEBELUMpengelasan:
p g
1. Mereviewsemuagambarproduksidanstandard
2. MemeriksaPOuntukmenjaminbahwabasedanfiller
metalyangdipakaisesuaispec.
3 Memeriksadanmengidentifikasimaterialyangditerima
3. Memeriksa dan mengidentifikasi material yang diterima
apakahsudahsesuaidenganPO.
4. Memeriksakondisidanpenyimpananfillermetal
Memeriksa kondisi dan penyimpanan filler metal
5. Memeriksakondisiperalatanyangdipakai.
6. Memeriksapersiapansisi
7. Memeriksakesesuaiansambungandengangambar
8. Memeriksakebersihansambungan
9 MemeriksaWPSdankualifikasiwelder
9. Memeriksa WPS dan kualifikasi welder
10. Memeriksasuhupreheat.
PemeriksaanSAATpengelasan:
p g
1. Memeriksaparameterpengelasandanteknikyang
digunakanapakahsudahsesuaidenganWPS.
2. Memeriksakualitasweldpass
3 Memeriksainterpasscleaning
3. Memeriksa interpass cleaning
4. Memeriksasuhuinterpass
5. MemastikanapakahNDTtelahdilakukan.
Memastikan apakah NDT telah dilakukan.
PemeriksaanSETELAHpengelasan:
p g
1. Memeriksatampilanvisualsambunganlas
2. Memeriksaukurandanpanjanglas
3. Memeriksakeakuratanukurandarikomponen.
4
4. Memastikan apakah NDT telah dilakukan
MemastikanapakahNDTtelahdilakukan
5. MemastikanapakahPWHTtelahdilakukan
6. Membuat
Membuatlaporanpemeriksaan.
laporan pemeriksaan.
 TYPESOFTESTING
TYPES OF TESTING
NONDESTRUCTIVE
No/minor change to the material being examined
Early warning, no need to shutdown the operation,
operation,
qualitative
lit ti & quantitative
tit ti information
i f ti may be
b obtained
bt i d
Low cost

DESTRUCTIVE
Potentially causes significant change to the material being
examined
Used as statistical sampling basis only
only, not suited to huge
and expensive structures
Visual, with or without aid
Liquid Penetrant Testing (PT)
Magnetic Particle Testing (MT)
Propagation of Elastic Waves/Vibration
Ultrasonic Testing (UT)
Acoustic Emission (AE)
Radiation
Radiography Techniques (X-Ray,
(X Ray Gamma-Ray)
Gamma Ray)
Electromagnetic Field
Eddyy Current Testing
g (ET)
( )
Alternating Current Potential Drop (ACPD)
Alternating Current Field Measurement (ACFM)
TYPES
TYPESOFDESTRUCTIVETESTING
OF DESTRUCTIVE TESTING

Mechanical Test
MechanicalTest
Tensiletest:weldmetal,weldjoint,nickbreak
Bend test: face bend, root bend, side bend
Bendtest:facebend,rootbend,sidebend
Charpy impacttest:Vnotch,Unotch,keyhole
Hardnesstest:Brinell,Vickers,Rockwell
Fracturetest:filletweld
FatigueTest
ChemicalCompositionTest
MetallurgicalTest
Fractography
Macrography
Micrography
g p y
Strength is defined as the ability of a material to
withstand an applied load.
Ductilityy is a term which is related to the ability
y of a
material to deform, or stretch, under load without
failing.
Toughness is the ability of a material to absorb energy.
Material with low toughness will fail at low value with
little evidence of deformation.
A tough
to gh material will
ill fail at high value
al e with
ith a
significant amount of permanent deformation.
TENSILE
S TEST
S
MECHANICALPROPERTIES

1. UltimateTensileStrength(UTS)
Ultimate Tensile Strength (UTS)

[MPa]

Original
g C.S.A
Rectangular =wxt
Round = D2
Turbular = ( OD2 - ID2 )

REMEMBER! 1N/mm2 =1MPa

MECHANICALPROPERTIES

2. Yield Strength

[MPa]

3. Elongation

[%]

[%]
MECHANICAL PROPERTIES
MECHANICALPROPERTIES

4. Reduction of Area

[%]

[%]
FractureAppearance
pp & MaterialProperties
p

Ductile Material

9 Deformation at fracture plane

9 Angle
g of fracture 45o to the p
primary
y load
9 Fibrous/shear fracture
9 Cup & cone
FractureAppearance
pp & MaterialProperties
p

Brittle Material

9 Little or no deformation at fracture plane

9 Angle
g of fracture 90o to the pprimaryy load
9 Granule/cleavage fracture
9 Flat cleavage
BEND TEST
S
CHARPY IMPACT
C C TEST
S
 DeterminationofMaterialDuctilityy

4oC 38oC 100oC

TemperatureEffect
Hot Glycerin
Temperature DUCTILE Furnace/oven

T
TemperatureBRITTLE
t BRITTLE Dry ice + alcohol
Liquid Nitrogen, CO2
Fatigue Test
Chemical Composition Test

Niton
ARL Spectrometer X-Ray Fluorescence (XRF)
Welding Procedure Specification (WPS)

A WPS iis a written

itt qualified
lifi d welding
ldi procedure
d prepared
d to
t provide
id
direction for making production welds to Code requirements.

WPS shall contain all variables (essential

essential, nonessential
nonessential, and
supplementary essential
essential) that will be used in welding process and shall
refer to the Procedure Qualification Record (PQR).

31
Welding Procedure Specification (WPS)

Change may be made to the nonessential variable to fit with production

requirements without doing requalification to the original WPS
WPSWPS
WPS
awal. Change in the nonessential variable shall be recorded and
awal
ammended to the original
g WPS,, or by
y making g new WPS.

Change in essential va
variabel
riabel essential and supplementary essential
requires requalification to the original WPS, followed by making PQR to
support the change in the essential variables.
variables

32
Definisi NDT/NDE

Secara umum, NDT didefinisikan sebagai:

An examination, test, or evaluation performed on any type
of test object without changing or altering the object in any
way, in order to determine the absence or presence of
conditions or discontinuities that may have an effect on the
usefulness or serviceability of that object.
 Beberapa Kegunaan NDT
BeberapaKegunaanNDT

Fl D t ti
FlawDetectionandEvaluation
d E l ti
LeakDetection
Location Determination
LocationDetermination
Fluorescent penetrant indication
DimensionalMeasurements
Structure and Microstructure Characterization
StructureandMicrostructureCharacterization
EstimationofMechanicalandPhysicalProperties
Stress(Strain)andDynamicResponseMeasurements
MaterialSortingandChemicalCompositionDetermination
 Kapan NDT Digunakan?
KapanNDTDigunakan?
Th
There are NDE application
li ti att almost
l t any stage
t
in the production or life cycle of a component.

Toassistinproductdevelopment
Toscreenorsortincomingmaterials
Tomonitor,improveorcontrolmanufacturing
processes
Toverifyproperprocessingsuchasheattreating
Toverifyproperassembly
Toinspectforinservicedamage
According to WES 2005, the main point of NDE are:

1. Type of internal weld defects detected by qualification test:

RT or UT may
be used

2 Judgement of test results.

2. results
Metoda--metoda NDT
Metoda

1. Visual Testing
2. Liquid Penetrant Testing
3. Magnetic Particle Testing
4
4. R di
Radiographic
hi Testing
T ti
5. Ultrasonic Testing
6
6. N t
Neutron R
Radiography
di h
7. Computed Tomography
8
8. Eddy Current Testing
9. Thermal Infrared Testing
10 Acoustic Emission Testing
10.
11. Sherography Testing
12. Optical Holography
Pemilihan Metoda NDT

Pertimbangan Utama Pemilihan Metoda NDT:

1. Alasan melakukan NDT.

2. Tipe diskontinuitas yang hendak dicari.

3. Ukuran dan orientasi diskontinuitas yang dicari.

4 Lokasi
4. L k i diskontinuitas
di k ti it dalam
d l benda.
b d

5. Ukuran dan bentuk benda yang diperiksa.

6. Karakteristik material yang akan dievaluasi.

Jenis Diskontinuitas

Ada dua macam bentuk diskontinuitas:

1. Volumetric
Berbentuk tiga dimensi (memiliki volume).

2. Planar
Tipis, tapi lebar dan panjang.
Jenis Diskontinuitas
Diskontinuitas volumetric:
Diskontinuitas planar:
Lokasi Diskontinuitas

Ada dua macam lokasi diskontinuitas:

1. Di permukaan benda (surface).

2. Di dalam benda (interior).

43
Lokasi Diskontinuitas
Lokasi diskontinuitas dan metoda NDT:
Terminology in NDT/NDE

Terminology commonly found in NDT/NDE

Interpretation & Evaluation

Visual Inspection
VisualInspection
Most basic and common
inspection method.

Can be done quickly,

quickly at any
place, at any time without any
particular tools.
Purpose
p of the Visual Inspection
p includes:

1. Dimensional defects and their measurement

Purpose
p of the Visual Inspection
p includes:

2. Seeking weld defects

Crack
Overlaps
Pits
Undercut
Spatter
Crater
C t
DIRECT VISUAL INSPECTION
INDIRECT VISUAL INSPECTION
However, reliability of visual inspection is highly
affected by human factor since even an
experienced
i d personnell can be
b fooled
f l d byb the
th
presence of scratches or machining marks into
seeing defects which are not present
present.

Due to the reasons

reasons, there are some aids to visual
inspection which help to reveal defects more readily
and consistently.
Radiographic Testing

Radiology adalah istilah untuk metoda pemeriksaan material yang

didasarkan pada penembusan radiasi yang berbeda.
Radiasi bisa berasal dari gelombang elektromagnetic dengan
panjang gelombang sangat kecil, atau dari radiasi partikel.
Radiography adalah teknik radiology khusus yang menghasilkan
citra permanen pada sebuah film atau kertas.
Radiographic Testing

Source of Radiation:

Isotope: Ir-192, Co-60, Cs-137, Tm-170

1. g-ray

2 X-ray
2. X X ray machine
X-ray
Radiographic Testing
Radiation source : g-ray
Radiographic Testing
Radiation Source: X-ray
Radiographic Testing

Principle
Radiographic Testing

Principle
Radiographic Testing

Inverse Square Law:

Radiographic Testing

Formula-formula
Radiographic Testing

Techniques:

Single Wall
Single View

Double Wall
Single View
Radiographic Testing

Techniques:

Double Wall
Double View
Radiographic Testing

Radiographic Image Quality

Radiographic Testing

Radiographic Image Quality Indicator

H l t
Hole-type IQI

Wire type IQI

Wire-type
Radiographic Testing

Radiographic Images

Slag inclusion

Tungten inclusion

An Introduction to NDT
68
Radiographic Testing
Radiographic Safety Devices

Pocket Dosimeter

Survey Meter

g
Film Badge

Area Alarm
Ultrasonic Testing

Penggunaan gelombang suara ultrasonik untuk mengevaluasi

kondisi suatu material frekuensi gelombang suara > 20.000 Hz.
Range pendengaran manusia: 20 20.000 Hz.
Anomali di dalam material akan menyerap atau mengubah arah
gelombang suara, yang kemudian akan dideteksi sebagai perubahan
g
gelombang.
g
lubang, laminasi, pori-pori
retak, debonding
resin-rich, poor areas
Ultrasonic Testing

Pulse Echo System

Through-transmission
System
Ultrasonic Testing

1. Transducer/probe
2. Couplant
3. Material
4. Void/flaw
5. Layar CRT
6. Indikasi permukaan depan
7. Indikasi void
8. Indikasi back wall.
Ultrasonic Testing
Ultrasonic Testing
Ultrasonic Testing

Trade-off antara frekuensi (resolusi) dan kedalaman penetrasi.

makin tinggi frekuensi, makin baik resolusinya, namun makin kecil
kedalaman penetrasinya.
Ultrasonic Testing

A-scan Display

Pulsa digambarkan sebagai jarak atau waktu sepanjang sumbu X dan energi
suara (amplitudo) sepanjang sumbu Y.
Tampilan A-scan lebih kompleks karena semua pantulan ditampilkan dan
memerlukan interpretasi yang teliti.
Ultrasonic Testing

B-scan Display

Tampilan dua dimensi dalam arah penampang melintang.

Ultrasonic Testing

C-scan Display

Tampilan dua dimensi dimana pantulan diskontinuitas ditampilkan dalam

arah pandangan atas pada permukaan benda.
Dapat menggunakan sistem pulse-echo atau through-transmission.
Biasanya kedalaman diskontinuitas tidak ditampilkan.
Ultrasonic Testing

D-scan Display

Tampilan dua dimensi dimana jarak atau kedalaman diskontinuitas dari

permukaan benda uji langsung dapat diketahui.
Merupakan modifikasi dari C-scan.
Ultrasonic Testing
Transducer/Probe

P b normall single
Probe i l transducer
t d

Menghasilkan
g gelombang
g g
longitudinal (compression wave)

Menghasilkan
gelombang transversal
(shear wave)

Probe sudut
Ultrasonic Testing

Dead Zone
Ultrasonic Testing

TR Probe

Probe normal dual transducer

Ultrasonic Testing

Calibration Blocks

V1 Calibration Block V2 Calibration Block

Ultrasonic Testing
Ultrasonic Testing
UT Phased-Array:
Ultrasonic Testing
UT Phased-Array:

Transducer konvensional
Hanya satu kristal

Transducer phased array

M iliki 16
Memiliki 16, 32
32, 64
64, 128 elemen
l
yang masing-masing dapat
dieksitasi terpisah.
Ultrasonic Testing
UT Phased-Array: Omniscan
Ultrasonic Testing
Omniscan Display:

Omniscan analysis view of one-line scan using 45-70 degree

sector scan
scan. Red areas on C scan display non fusion in the weld
weld.
Ultrasonic Testing

UT Time of Flight Diffraction (TOFD):

Menggunakan difraksi ujung (tip diffraction) untuk mengidentifikasi bagian
atas, bawah, dan panjang diskontinuitas dalam satu kali jalan.
Memakai gelombang longitudinal yang membentuk sudut (tidak memakai
gelombang transversal) karena:
signal difraksi ujung akibat gelombang longitudinal lebih kuat
ketimbang signal difraksi dari gelombang transversal.
menghasilkan gelombang lateral yang dapat dipakai untuk mengukur
jarak horizontal antara pemencar dan penerima gelombang
gelombang.
Ultrasonic Testing
UT Time of Flight Diffraction (TOFD):
Ultrasonic Testing
TOFD Signal:

Emission Reception
Lateral Wave

Reflected Wave

LW BW

Upper Tip Lower Tip

Ultrasonic Testing

Visualisasi

White
+

A-scan
Ampllitude

Time

- Bl k
Black

Time
One A-Scan is replaced by one grey line
Ultrasonic Testing
Visualisasi
A-scan

Indication

B-scan

Lateral Wave Reflected Wave

Magnetic Particle Testing

Material dialiri medan magnet

Partikel besi disemprotkan/ditaburkan di atas permukaan
material.
Partikel besi akan tertarik ke daerah y
yang
g ada kebocoran medan
magnet akibat diskontinuitas.
Indikasi yang timbul dapat dilhat secara visual.
Magnetic Particle Testing
Magnetic Particle Testing

Magnetisasi Circular
Magnetic Particle Testing

Magnetisasi Longitudinal
Magnetic Particle Testing
Magnetic Particle Testing

Orientasi
diskontinuitas
terhadap medan
magnet
Magnetic Particle Testing

Subsurface discontinuity sedalam 3 4 mm masih dapat terdeteksi.

terdeteksi
Magnetic Particle Testing

Peralatan yang dipakai di lapangan:

9 AC atau DC elektromagnetik yoke
9 Permanent magnet yoke
9 Contrasting background coat (white-contrast paint)
9 Magnetic particle
dry particle (serbuk magnetik kering) berwarna abu-abu atau
merah tua
wet particle (tersuspensi dalam kaleng semprot bertekanan)
berwarna hitam
Magnetic Particle Testing

magnetic yoke
Magnetic Particle Testing
Magnetic strength & yoke calibration

AC elektromagnetik yoke harus mampu mengangkat 10 kg

DC elektromagnetik yoke & permanen harus mampu mengangkat 40 kg
Magnetic Particle Testing
Magnetic strength verification
Magnetic Particle Testing

DC
elektromagnetik
yoke

AC elektromagnetik yoke

Permanent
magnett yoke
k

AC elektromagnetik coil
Magnetic Particle Testing

Aplikasi: yoke

Aplikasi: central conductor

Magnetic Particle Testing
Magnetic Particle Testing

Aplikasi: single-leg AC yoke

Lamination check
Magnetic Particle Testing

Indikasi partikel magnet:

Fluorescent
Visible - dry
Magnetic Particle Testing

Sensitivitas sistem:

Betz Ring Test

Liquid Penetrant Testing

Merupakan metoda pengujian yang banyak digunakan

untuk mencari adanya diskontinuitas permukaan pada
material yang permukaannya tidak berpori.
Liquid Penetrant Testing

Cairan
C i penetrant d
dengan karakteristik
k k i ik pembasahan
b h yang tinggi
i i
diaplikasikan ke permukaan benda dan dibiarkan beberapa lama untuk
meresap ke dalam cacat permukaan.

Serbuk developer diaplikasikan ke permukaan untuk menarik cairan

penetrant keluar dari dalam cacat dan menyebarkannya di permukaan
sehingga dapat dilihat.

Pemeriksaan visual merupakan tahapan akhir pada proses ini.

Cairan penetrant yang dipakai dapat berwarna merah atau diberi warna
fluorescent (hijau kekuningan) untuk meningkatkan sensitivitas, yang
h
hanya terlihat
lih di bawah
b h sinar
i ultraviolet
l i l (lampu
(l black
bl k light).
li h )
Liquid Penetrant Testing
Liquid Penetrant Testing

Visible penetrant

Fluorescent penetrant
Black Light
Liquid Penetrant Testing

Karakteristilk pembasahan cairan penetrant

Liquid Penetrant Testing

Ada tiga macam proses pada pengujian penetrant:

Water-washable
Post-emulsifiable
Solvent Removable
Liquid Penetrant Testing
Liquid Penetrant Testing
Liquid Penetrant Testing

Water-washable
Liquid Penetrant Testing

Post-emulsifiable
Liquid Penetrant Testing

Teknik Solvent Removable terdiri dari tiga kaleng bertekanan:

1. Cleaner/remover berwarna bening
2 Penetrant berwarna merah
2.
3. Developer berwarna putih
Liquid Penetrant Testing

Tahapan Pemeriksaan solvent removable:

1 Precleaning memakai solvent
1. solvent,
tunggu 3 menit sampai kering
2. Aplikasi penetrant, tunggu 5 menit.
3. Bersihkan penetrant dari permukaan
Jangan menyemprot solvent langsung
ke permukaan material
4. Tunggu 3 menit.
5. Semprotkan developer ke permukaan.
6. Amati terbentuknya indikasi.
7. Setelah 20 menit dari penyemprotan,
lakukan pengukuran.
8. Pembersihan.
LIQUID PENETRANT INDICATIONS
 EDDY CURRENT TESTING

Applications

Surface crack detection

Non-ferrous metal sorting
Sub-surface crack/corrosion detection
Heat exchanger tube testing
In-line inspection of Steel tubing
Ferrous weld inspection
EDDY CURRENT APPLICATION
EDDY CURRENT APPLICATION
EDDY CURRENT APPLICATION
EDDY CURRENT APPLICATION
EDDY CURRENT EQUIPMENT
 ACCOUSTIC EMISSION METHOD
ACCOUSTICEMISSIONMETHOD

Band pass Measurement

Preamplifier Amplifier
filter circuits

Data buffers

Visual monitor

Microcomputer
p Audio monitor

X-Y recorder

Sensor

Test Component

Schematic diagram for an acoustic emission technique.

ACCOUSTIC EMISSION SIGNALS
ACCOUSTICEMISSIONSIGNALS
LEAK TESTING
 LEAK TESTING

Water pressure test for water ballast pipes of 5 kg/cm2

 LEAK TESTING

Water pressure test for water ballast pipes of 5 kg/cm2

 LEAK TESTING

Hose test for hull butt joint of 300 bars

 LEAK TESTING

Hose test for hull butt joint of 300 bars

 LEAK TESTING

Air pressure test for double bottom tank of 0.25 kg/cm2

 LEAK TESTING

Air pressure test for double bottom tank of 0.25 kg/cm2

 LEAK TESTING

Air pressure test for double bottom tank of 0.25 kg/cm2

 STRAIN MEASUREMENT

Strain Gauges
X-Ray Difraction
THERMOGRAPHY
 MAINTENANCE INSPECTION
Berdasarkan fungsinya:

1. BASE LINE INSPECTION / SURVEY

Pengukuran/inspeksi/survey pada komponen pada saat
dalam kondisi masih baru atau saat commissioning
new plant.
Record dipakai sebagai dasar pembandingan hasil
pengukuran berikutnya saat komponen beroperasi.

Record dapat dipakai untuk pemeriksaan/cross check

konstruksi (dibandingkan dengan drawing/design).
2 KEY POINT INSPECTION / SURVEY
2.
Pengukuran/inspeksi/survey rutin yang berulang pada
lokasi tertentu saat komponen telah beroperasi.
Lokasi inspeksi
p ditentukan berdasarkan p
performance
characteristic atau dari performance history
komponen tersebut.
Jarak waktu antar survey umumnya ditentukan sama.

M
Memungkinkan it
ki k pemonitoran f
performance
komponen (pengurangan ketebalan, penambahan
getaran,
getaran dll) secara teratur sehingga program
maintenance dan reparasi dapat dilakukan secara
teratur.
SAFETY
AND
HEALTH
EYE AND EAR
PROTECTION
SPECIAL PROTECTIVE
CLOTHING
SPECIAL PROTECTIVE
CLOTHING
 VENTILATION
The actual welding area should be well ventilated.

Excessive fumes, ozone, or smoke may collect in the welding area; ventilation
should be provided for their removal. Natural ventilation is best, but forced
ventilation may be required.

Areas that have 283 cubic meters or more per welder, or that have ceilings 4.9
meters high or higher may not require forced ventilation unless fumes or smoke
begin
g to collect.

General room ventilation must be at a rate of 2,000 cu ft (56 m3) or more per person
welding.
ldi L
Localized
li d exhaust
h t pickups
i k mustt have
h a suction
ti strong
t enoughh to
t provide
id
100 linear feet (30.5 m) per minute velocity of welding fumes away from the welder.

Small shops or shops with large numbers of welders require forced ventilation.
Forced ventilation can be general or localized using fixed or flexible exhaust pickups.
VENTILATION
ELECTRICAL SAFETY
 ELECTRICAL SAFETY
Most electric shocks in the welding industry does not occur from contact with
welding electrode holders, but as a result of accidental contact with bare or poorly
i
insulated
l t d conductors.
d t

Injuries and even death can be caused by electric shock unless proper precautions
are taken.
t k

Most electrical equipment in a welding shop is powered by alternating-current (ac)

sources having
h i input
i t voltages
lt ranging
i from
f 115 volts
lt tto 460 volts.
lt However,
H
fatalities have occurred when working with equipment operating at less than 80
volts.

The workpiece being welded, and the frame or chassis of all electrically powered
machines, must be connected to a good electrical ground.

Cable connectors for lengthening leads must be insulated. Cables must be

checked periodically to be sure that they have not become frayed, and, if they
have,, they
y must be replaced
p immediately.
y
BURNS
Burns are one of the most common and painful injuries that occur in the
welding shop.

Burns can be caused by ultraviolet light rays as well as by contact with hot
welding material. The chance of infection is high with burns because of the dead
tissue.
ti

Burns are divided into three classifications, depending upon the degree of
severity. The three classifications include first-degree, second-degree, and third-
degree burns.
First--degree Burns
First
First-degree burns have occurred when the surface of the skin is reddish in color,
tender, and painful and do not involve any broken skin.

The first step in treating a first-

degree burn is to immediately put
the burned area under cold water or
apply cold water compresses (clean
towel, washcloth, or handkerchief
soaked in hot water) until the pain
decreases.

Then cover the area with nonfluffy

sterile or clean bandages.

Do not apply butter or grease.

Second--degree Burns
Second

Second-degree burns have occurred when the surface of the skin is severely
damaged, resulting in the formation of blisters and possible breaks in the skin.

Again, the most important first step in treating a second-degree burn is to put the
area under cold water or apply cold water compresses until the pain decreases.
decreases

Gently put the area dry with a clean

towel, and cover the area with a
sterile bandage or clean cloth to
prevent infection. Seek medical
attention.
attention

Note: any cold liquid you drink- for

example water,
example, water cold tea,tea soft
drinks, or milk shake- can be
poured on a burn. The purpose is to
reduce the skin temperature as
quickly as possible to reduce tissue
damage.
Third-degree Burns
Third-degree burns have occurred when the surface of the skin and possibly the
tissue below the skin appear white or charred.

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.
antiseptics, burns

Place a cold cloth or cool ((not iced))

water on burns of the face, hands,
or feet to cool the burned areas.

Call for an ambulance

immediately; people with even
small third
third-degree
degree burns need to
consult a doctor.
 FIRE PROTECTION
Fire is a constant danger at welding shop. The possibilities of fires cannot always
be removed, but they should be minimized.

Highly combustible materials should be 10.7 m or more away from any welding.

When it is necessary to weld within 10.7

10 7 m of combustible materials
materials, when sparks
can reach materials farther than 10.7 m away, or when anything more than a minor
fire might start, a fire watch is needed.

A fire watch can be provided by any person who knows how to sound the alarm
and use a fire extinguisher.

The fire extinguisher must be the type required to put out a fire of the type of
combustible materials near the welding.

The four types of fire extinguishers are type A,

A type B,
B type C,
C and type D.
D

Using the wrong type of fire extinguisher can cause the fire to spread, cause
electrical shock,
shock or cause an explosion.
explosion
 Type A Extinguishers

Type A extinguishers are used for combustible solids (articles that

burn),
) such as paper, wood, and cloth. The symbol y for a type
y A
extinguisher is a green triangle with the letter A in the center.
 Type B Extinguishers

Type B extinguishers are used for combustible liquids, such as

oil gas
oil, gas, and paint thinner.
thinner The symbol for a type B extinguisher
is a red square with the letter B in the center.
 Type C Extinguishers

Type C extinguishers are used for electrical fires. For example,

they are used on fires involving motors,
motors fuse boxes
boxes, and welding
machines. The symbol for a type C extinguisher is a blue circle
with the letter C in the center.
 Type D Extinguishers

Type D extinguishers are used on fires involving combustible metals,

such as zinc,
zinc magnesium
magnesium, and titanium.
titanium The symbol for a type D
extinguisher is a yellow star with the letter D in the center.
 Location of Fire Extinguishers

Fire extinguishers should be of a type that can be used on the types of

combustible materials located nearby.
nearby
 Location of Fire Extinguishers

They should also be placed at a level low enough to be easily lifted off the
mounting
g
 Location of Fire Extinguishers

The location of fire extinguishers should

be marked with red paint and signs, high
enough so that their location can be
seen from a distance over people and
equipment.
i The
Th extinguishers
i i h should
h ld
also be marked near the floor so that
they can be found even if a room is full
of smoke
 HANDLING AND STORING CYLINDERS
Cylinders equipped with a valve protection cap must have the cap in place unless
the cylinder is in use. The protection cap prevents the valve from being broken off
if the cylinder is knocked over.

If the valve of a full high-pressure cylinder (argon, oxygen, CO2, and mixed
gases) is broken off, the cylinder valve can fly around the shop like a missile if it
has not been secured properly.

Never lift a cylinder by the safety cap or the valve. The valve can easily break off or
be damaged.

The cylinders must never be dropped or handled roughly.

Acetylene cylinders that have been lying on their sides
must stand upright for 15 minutes or more before they
are used.
HANDLING AND STORING CYLINDERS
HANDLING AND STORING CYLINDERS
WORK AT HIGH LOCATIONS
 SUMMARY
G
Generalhazards
lh d Welding hazards
fireandexplosion - electrical shock
hotmetal - arcs
mechanical - fumes and gases
- enclosed
l d spaces

Cutting and burning

- safety
f t requirements
i t
- storage
SEKIAN & TERIMA KASIH