Mr. R.D.

Pennathur

Mr. R.D.Pennathur
Mr. R.D.Pennathur
ASPECTS IN WELDING

Welding primarily uses a heat s0urce

Fusion welding implies that the
material is taken above the melting
point

Weld metal is a miniature cast metal
Mr. R.D.Pennathur
EYE PROTECTION IN WELDING
Radiation emitted by
heated solids/ gases

Ultra violet rays

Intense visible rays

Infrared rays
Mr. R.D.Pennathur
SOURCES OF FUMES...
Action of heat on the parent metal

Action of heat on the surface treatment of the parent
metal

Action of heat on the coating/ consumables

Action of heat on surrounding air/ shielding gas
Mr. R.D.Pennathur
ASSESSMENT & CONTROL
MAKE AN ASSESSMENT OF HEALTH RISKS
CREATED BY HAZARDOUS SUBSTANCES
PREVENT GENERATION OF FUMES
CONTROL EXPOSURE TO FUMES
PROVIDE ADEQUATE INFORMATION TO THE
WELDER
CARRY OUT PERIODIC AUDITS ON THE RISKS
INVOLVED
Mr. R.D.Pennathur
FUME PROTECTION
General ventilation of
the site, with
unrestricted disposal
of fumes

Local extraction

Personal protection
Mr. R.D.Pennathur
SPHERES OF CONTROL &
INFLUENCE...
Smoking is injurious to
health

Welding fume is injurious
to health

Automobile exhaust is
injurious to health
Mr. R.D.Pennathur
OSHA.
Occupational safety and health act

To assure safe and healthy working conditions

Authorizing enforcement of standards thereof

Providing information, education and
training
Mr. R.D.Pennathur
PERCEPTIONS.
Perceived problems of

Equipment mfgs

Consumable mfgs

Industrial users

Welders
Mr. R.D.Pennathur
ENLIGHTMENT
Enlightened non-
governmental
organisations

Enlightened employers

Enlightened employees
Mr. R.D.Pennathur
SAFE PRACTICES
22 - 12
Safety most important consideration to both worker
and employer

Welding no more dangerous than other industrial
operations

Safety precautions and protective equipment
required for MIG/MAG process essentially same as
for any other electric welding process
Mr. R.D.Pennathur
EYE, FACE, AND BODY PROTECTION
22 - 13
Welding helmets and protective clothing necessary
Radiant energy produced by gas-shielded process 5
to 30 times more intense than produced by shielded
metal arc welding
Lowest intensities produced by gas tungsten arc
Highest by gas metal arc
Argon produces greater intensities than helium
Mr. R.D.Pennathur
CLOTHING REGULATIONS
22 - 14
Standard arc welding helmets with lenses ranging
in shade from no. 6 for work using up to 30
amperes to no. 14 for work using more than 400
amperes should be worn
Arc should never be viewed with the naked eye when
standing closer than 20 feet
Skin should be covered completely to prevent burns
and other damage from ultraviolet light
Back of the head and neck should be protected from
reflected radiation
Gloves should always be worn
Mr. R.D.Pennathur
HANDLING OF GAS CYLINDERS
22 - 15
Stored cylinders should be in protected area away
from fire, cold, and grease and away from general
shop activity

Cylinders must be secured to equipment to prevent
their being knocked over

Proper regulators and flow-meters must be used with
each special type of cylinder
Mr. R.D.Pennathur
HANDLING OF GAS CYLINDERS
22 - 16
Cylinders should not be dropped, used as rollers,
lifted with magnets, connected into electric circuit,
or handled in any other way that might damage
cylinder or regulator

When cylinders empty, should be stored in upright
position with valve closed
Mr. R.D.Pennathur
ELECTRICAL SAFETY
22 - 17
Hazard less than that with shielded meal arc
process
Open circuit voltage considerably less

Electrical maintenance should be done only by
qualified person
NEVER work on in electrical Equipment in HOT
condition

Mr. R.D.Pennathur
WIRE-FEEDER SAFETY
22 - 18
Turn power off when aligning and adjusting drive
rolls

Remember force being applied to wire is sufficient to
push it through your hand or other body parts

Never let exposed wire come in contact with or be
pointed at your body
Mr. R.D.Pennathur
FIRE SAFETY
22 - 19
Welding should not be done near areas where flammable
materials or explosive fumes present

Paint spray or dipping operations should not be located
close to any welding operation

Combustible material should not be used for floors, walls,
welding tables, or in immediate vicinity of welding
operation

When welding on containers that have previously contained
combustible materials, special precautions should be taken

Use hot work permit as required
Mr. R.D.Pennathur
CARE OF NOZZLES
22 - 20
Keep the gun nozzle, contact tube, and wire-feeding
system clean to eliminate wire-feeding stoppages
Nozzle is natural spatter collector

If spatter builds up thick enough, it can actually
bridge gap and electrically connect
insulated nozzle to contact tube

To remove spatter, use soft, blunt
tool for prying
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or
display.
Mr. R.D.Pennathur
22 - 21
Spatter almost falls out by itself if nozzle kept clean,
shiny and smooth
Antispatter compound may be applied to gun nozzle
and contact tube end
Do not clean by tapping or pounding on solid object
Bends gun nozzles, damages threads and high temperature
insulation in nozzle can break
CARE OF NOZZLES
Mr. R.D.Pennathur
ASSUMED SAFETY PRECAUTIONS
22 - 22
Welding equipment installed properly

Welding machine in dry location, and no water on floor
of welding booth

Welding booth lighted and ventilated properly

All connections tight, and all hoses and leads arranged so
they cannot be burned or damaged

Gas cylinders securely fastened so they cannot fall over
and not part of electrical circuit
Mr. R.D.Pennathur
ELECTRIC SHOCK
FUMES, DUST AND OZONE
ULTRAVIOLET / INFRA-RED RADIATION
HOT WORK-PIECE AND WELDING
EQUIPMENT
FIRE AND EXPLOSION HAZARDS
NOISE
HANDLING COMPRESSED GAS CYLINDERS
TRIPPING & FALLING



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SAFETY ASPECTS
Mr. R.D.Pennathur
CHOICE OF FILTER GLASS
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Current Range Filter Number
15-40 A 7-9
40-60 A 8-10
60-150 A 10-11
150-250 A 11-12
250-500 A 12-14
Mr. R.D.Pennathur
OPERATION
SH
AD
E
NU
MB
ER
Shielded metal-arc welding, up to 5/32 in. (44 mm)
electrodes
10
Shielded metal-arc welding, 3/16 to 1/4 in. (4.8 to 6.4
mm)electrodes
12
Shielded metal-arc welding, over 1/4 in. (6.4 mm)
electrodes
14
Gas-shielded arc welding (nonferrous), up to 5/32 in.
(44 mm) electrodes
11
Gas-shielded arc welding, (ferrous), up to 5/32 in. (44
mm)electrodes
12
Gas tungsten-arc welding 12
Atomic hydrogen welding 10
to
14
Carbon arc welding 14
Torch soldering 2
Torch brazing 3 or
4
Light cutting, up to 1 in. (25 mm) 3 or
4
Medium cutting, 1 to 6 in. (25 to 150 mm) 4 or
5
Heavy cutting, 6 in. (150 mm) and over 5 or
6
Gas welding (light) up to 1/8 in. (3.2 mm) 4 or
5
Gas welding (medium) 1/8 to 1/2 in. (3.2 to 12.7 mm) 5 or
6
Gas welding (heavy) 1/2 in. (12.7 mm) and over 6 or
8
OPERATION
SHADE
NUMBER
Shielded metal-arc welding, upto 4.0 mm electrodes 10
Shielded metal-arc welding, 4.8 to 6.4 mm electrodes 12
Shielded metal-arc welding, > 6.4 mm electrodes 14
Gas-shielded arc welding (nonferrous), up to 4.0mm
electrodes
11
Gas-shielded arc welding, (ferrous), up to 4.0mm
electrodes
12
Gas tungsten-arc welding 12
GMAW 14
Torch soldering 2
Torch brazing 3 or 4
Light cutting, up to 25 mm 3 or 4
Medium cutting, 25 to 150 mm 4 or 5
Heavy cutting, 150 mm and over 5 or 6
Gas welding (light) up to 3.2 mm 4 or 5
Gas welding (medium) 3.2 to 12.7 mm 5 or 6
Gas welding (heavy) 12.7 mm and over 6 or 8
Mr. R.D.Pennathur
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Mr. R.D.Pennathur
Wrong
positioning
during
welding
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Mr. R.D.Pennathur
Correct
positioning
during
welding
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Mr. R.D.Pennathur
Mr. R.D.Pennathur
Mr. R.D.Pennathur
Mr. R.D.Pennathur
Mr. R.D.Pennathur
Mr. R.D.Pennathur
Mr. R.D.Pennathur
For light duty work (200 Amps or
lower)

Working overall w/long sleves (flame
retardent material). Preferably
without too many pockets that easily
catch sparks.
For same reason avoid zips.
Avoid synthetic materials, including
nylon, rayon and polyester.

Safety boots with steel toes.

Face shield w/handle or face shield
w/head band

Welders gloves


Mr. R.D.Pennathur
For heavy duty work
(above 200 Amps)

Working overall

Safety boots with steel toes

Face shield w/head band

Welders gloves

Leather jacket

Leather trousers
Mr. R.D.Pennathur
For work in vertical and
overhead position

Working overall

Safety boots with steel toes.

Face shield w/head band

Welders gloves

Arm protector

Leather spats
Mr. R.D.Pennathur
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Eye Exposed to
Arc Radiation
Mr. R.D.Pennathur
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Burn Injuries
Mr. R.D.Pennathur
Safe
Working
Conditions

Good
House
keeping
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Mr. R.D.Pennathur
Unsafe
Working

Fire Hazards

Arc Radiation
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Mr. R.D.Pennathur
GOOD
WORK
TABLE
Mr. R.D.Pennathur
We are one of the renowned manufacturers of various grades of welding
consumables which are second to none in terms of quality. We have the most
modern manufacturing facility equipped with latest sophisticated machinery
at Pondicherry, India
We are manufacturing a vast range of Shielded Metal Arc Welding
Electrodes and Flux Cored Arc Welding Electrodes. We also supply
tested GMAW and GTAW welding consumables for all the applications.
Our hardworking team would always be interested in any opportunity to cater
your requirement of welding consumables.
Currently we are supplying massive quantity of welding consumables to many
world class EPC companies in various range of welding consumables
including Carbon steel, Low Temperature Carbon Steel, Stainless Steel, Low
alloy steel etc.
If at all the need arises for a special consumable which is not in our arsenal,
our R&D team is fully equipped in developing special electrodes to meet
Service Requirements, Impact Test Requirements with strict chemistry
controls and as welded hardness test criteria.
We built quality and consistency in our consumables. Our manufacturing
facility always had the market pulse to meet its demands and fast track
delivery requirements without compromising quality and consistency.
Willing to be a part of your esteemed organization, we took this privilege to
approach and request your kind consideration for providing opportunity to
MAILAM INDIA LTD for the following consumables.