Area and/or Course Introduction to Welding
Lesson Title Shop Safety and Personal Protective Equipment
No. Periods 1 (73-minute period)
Teacher Goal(s):
1. Students will recognize potential hazards of the welding shop
2. Students will pass shop safety tests with 100% accuracy
Rigor/RelevanceFramework
Knowledge / 6
5
4
3
2
1 / C
Assimilation
______/ D
Adaptation
___X____
A
Acquisition
______/ B
Application
______
1 2 3 4 5
Application
Objectives:
The student will be able to (TSWBT). (Oregon Skill Set numbers in parentheses at the end of the objective statement.)
1. Understand difference between various welding shop machinery (CS.HS.02)
2. Describe welding shop safety hazards associated with electricity, gases, and tools (PST 02.02.02.b)
3. Compare and contrast safe behaviors and situations with unsafe conditions (AG 06.02.01.05)
4. Identify the need for personal protective equipment (AGS 06.01.01.01)
5. Complete welding shop safety exam (CS.HS.02)
State Standards met by Objectives:
Subject Strand Eligible Content
1. Agriculture PST 02.01.01.b. Ensure the presence and function of safety systems and hardware on tools and equipment.
2. Agriculture PST 02.02.02.b. Demonstrate safe practices and regulations in the operation of power units and equipment.
3. Agriculture AG06.02.01.05 Demonstrate specific actions to avoid hazardous work situations
4. CRLS CS.HS.02 Listen attentively and summarize key elements of verbal and non-verbal communication.
5. CRLS CS.EF.02 Select, apply, and maintain tools and technologies appropriate for the workplace.
Materials, Equipment, Audio-Visual Aids:1. Whiteboard
2. Welding Shop
3. Safety glasses
4. Welding helmet(s)
5. Gloves / References:
http://www.lincolnelectric.com/knowledge/articles/content/migvs fluxcored.asp
http://www.stanford.edu/group/prl/documents/html/OAweld.htm
http://www.osha.gov/OshDoc/data_General_Facts/ppe-factsheet.pdf
Anticipatory Set/Introduction/Motivation/Interest Approach:
Review Yesterday’s Lesson:
Yesterday we discussed the school rules and went over the syllabus. Many of you told me that you have never welded before, and many of you have never been into a welding shop before.
Set:
The teacher is going to put up a series of pictures on the board from the PowerPoint projector. The pictures show eye injuries from various individuals who actually worked in Oregon. A good way to enter into this set:
(Q) What is your most important sensory organ? Taste, Hearing, Touch, Feel, or Sight
(A) Sight
(Q) Life would be very different without the ability to see, wouldn’t it?
The pictures I’m about to show you are four eye injuries which occurred in Oregon Welding Shops in the last 5 years. You may step out if you need to. I cannot stress enough how important eye protection in the welding shop is. We can get sunburns on our eyes, or something could very easily fly into our eye like a hot piece of metal.
Transition (Use Objective):
1. Understand difference between various welding shop machinery
2. Describe welding shop safety hazards associated with electricity, gases, and tools
3. Compare and contrast safe behaviors and situations with unsafe conditions
4. Identify the need for personal protective equipment
5. Complete welding shop safety exam
Strategy – Includes Teacher Activity, Student Activity, Questions/Answers and Objectives / Subject Matter Outline/Problem and Solution (Application Points Lace in Throughout Lesson) (Modeling, Guided Practice, and Content)Objective #1
The teacher will begin the class by taking students around the shop to look at different equipment.
Students will be asked to take a piece of paper with them and write down the name of each machine and where each part is that the teacher mentions.
The teacher will open up the MIG welder, but ask students to come and find assistance before attempting to fix any problems
(Q) What is another name for the FCAW welding process?
(A) Arc Welding
(Q) In comparison, which welder looks like it is the most complex?
(A) the O/A is actually the most complex process in the shop because of all the variables we can have, which we will discuss later in the term
(Q) Can anyone see any obvious dangers or hazards associated with any of these processes?
(A) all have risks / Gas Metal-Arc Welding:
GMAW as identified by the American Welding Society, is also popularly known as MIG (Metal Inert Gas) and uses a continuous solid wire electrode for filler metal and an externally supplied gas(typically from a high-pressure cylinder) for shielding. The wire is usually mild steel, typically copper colored because it is electroplated with a thin layer of copper to protect it from rusting, improve electrical conductivity, increase contact tip life and generally improve arc performance.
Self-shielded Flux-Cored Arc-Welding process
FCAW per the American Welding Society, or flux-cored for short, is different in that it uses a wire which contains materials in its core that, when burned by the heat of the arc, produce shielding gases and fluxing agents to help produce a sound weld, without need for the external shielding gas. We achieve a sound weld, but in a very different way. We have internal shielding instead of external shielding. The shielding is very positive and can endure a strong breeze. The arc is forceful, but has spatter. When finished, the weld is covered with a slag that usually needs to be removed. A "drag" angle for the gun is specified which improves operator visibility. The settings on the wire feeder welder are slightly more critical for this process. Improper technique will have results that are magnified. This type of welding is primarily performed on mild steel applications outdoors.
Oxy-Acetylene Welding
Oxy-Acetylene (OA) welding is one of the many types of welding supported by the PRL. It is extremely versatile, and with enough skill and practice you can use this type of welding for virtually any metal. In fact, the oxy-acetylene flame burns at 6000 °F, and is the only gas flame that is hot enough to melt all commercial metals. Oxy-acetylene welding is simple in concept - two pieces of metal are brought together, and the touching edges are melted by the flame with or without the addition of filler rod.
Objective #2
The teacher will take students back around to each welding process after the students have been introduced to that machine.
The teacher will ask questions to the students are guiding the safety instruction for each piece of equipment, but this is only the introduction to safety of each machine.
In the following days each machine will have a lesson dedicated to each.
(Q) What are some safety hazards associated with MIG welding.
(A) Electricity, compressed gas, etc
(Q) Why is it important to discuss safety of the Arc Welder?
(A) Many accidents happen around the arc welder because it is loud and can be intimidating to students.
(Q) Why is it especially important to clean up spills around the Arc Welder?
(A) Liquid can increase the chance of someone being electrocuted / Hazards in the Welding Shop
Follow these guidelines for general shop safety:
1. Know the hazards associated with your work. Be sure you are fully educated on the proper use and operation of any tool before beginning a job.
2. Always wear appropriate safety gear and protective clothing.
3. Wear nitrile gloves when cleaning with degreasers or ferric chloride (latex gloves do not provide adequate protection.)
4. Ensure that there is adequate ventilation to prevent exposure from vapors of glues, lacquers, paints, and from dust and fumes.
5. Maintain good housekeeping standards.
Keep the work area free from slipping/tripping hazards (oil, cords, debris, etc.)
Clean all spills immediately
Remove sawdust, wood chips, and metal chips regularly
It is recommended that electrical cords pull down from an overhead pulley rather than lying on the floor
1. Leave tool and equipment guards in place.
2. Know where fire extinguishers are located and how to us them.
3. Make sure all tools and equipment are properly grounded and that cords are in good condition.
Double-insulated tools or those with three-wire cords are essential for safety
Use extension cords that are large enough for the load and distance
1. Secure all compressed gas cylinders. Never use compressed gas to clean clothing or skin.
2. Always use flashback arresters on cutting/welding torches.
3. Take precautions against heat stroke and heat exhaustion.
4. Wear infrared safety goggles when appropriate.
Objective #3
(Q) What happens if someone is observed in the shop being unsafe?
(A) Kicked out of class
The teacher will begin this objective in the classroom with the students and make sure to emphasize the importance of safety in the shop.
There are NO second warnings in safety. This is where the teacher can tell a horror story involving an unsafe situation. i.e. student losing finger, catching on fire, etc.
(Q) Why are the shop teachers so strict with safety?
(A) They don’t want anyone to get hurt.
(Q) If there is an emergency in the shop, what is the most important thing I want you to remember?
(A) remain calm / Safe or Unsafe
Welding and cutting are two forms of hot metal work that require special safety considerations. Unless they are done in a designated shop area, welding and cutting are strictly prohibited without proper authorization.
Before conducting welding or cutting operations, inspect your equipment for the following:
1. Welding leads must be completely insulated and in good condition.
2. Cutting tools must be leak-free and equipped with proper fittings, gauges, regulators, and flashback devices.
3. Oxygen and acetylene tanks must be secured in a safe place.
In addition, follow these guidelines for most welding and cutting procedures:
1. Conduct welding and cutting operations in a designated area free from flammable materials. When welding or cutting is necessary in an undesignated or hazardous area, have someone nearby act as a fire attendant.
2. Periodically check welding and cutting areas for combustible atmospheres.
3. Take care to prevent sparks from starting a fire.
4. Remove unused gas cylinders from the welding and cutting area.
5. Keep hoses out of doorways and away from other people. A flattened hose can cause a flashback.
6. Mark hot metal with a sign or other warning when welding or cutting operations are complete.
Objective #4
(Q) Who is OSHA?
(A) Occupational Safety and Health Administration
(Q) What are some examples of PPE?
(A) goggles, gloves, helmet, glasses, pants, long sleeves, boots, respirator, etc.
(Q) Why do I ask you to wear PPE?
(A) Because it’s the law, and to keep you safe
(Q) Wearing PPE is only part of the deal, what is the rest?
(A) making sure PPE fits, adjusting PPE, maintaining PPE, and use PPE properly
Objective #5
Students will take a general shop safety test to conclude the shop safety and PPE lesson. / Personal Protective Equipment
OSHA requires the use of personal protective equipment (PPE) to reduce employee exposure to hazards when engineering and administrative controls are not feasible or effective in reducing these exposures to acceptable levels. Employers are required to determine if PPE should be used to protect their workers.
If PPE is to be used, a PPE program should be implemented. This program should address the hazards present; the selection, maintenance, and use of PPE; the training of employees; and monitoring of the program to ensure its ongoing effectiveness.
You must also train employees who are
required to wear PPE on how do the following:
_ Use PPE properly
_ Be aware of when PPE is necessary
_ Know what kind of PPE is necessary
_ Understand the limitations of PPE in
protecting employees from injury
_ Don, adjust, wear, and doff PPE
_ Maintain PPE properly.
Closure/Summary/Conclusion (Tie in Objectives)
The teacher will discuss the basics of the welding equipment with students to ensure they understand where equipment is located in the shop, and a verbal question and answer session will check for students understanding of the objectives.
1. Understand difference between various welding shop machinery
2. Describe welding shop safety hazards associated with electricity, gases, and tools
3. Compare and contrast safe behaviors and situations with unsafe conditions
4. Identify the need for personal protective equipment
5. Complete welding shop safety exam
Evaluation: (Authentic forms of Evaluation, Quizzes, or Written Exam)
Safety Quiz
Verbal check for understanding of shop safety and Personal Protective Equipment
Assignments: (Student Activities Involved in Lesson/Designed to Meet Objectives)
Daily calendar
Shop safety notes
Safety quiz
Lesson Reflection
This lesson was more fun to deliver to the beginning welding class than the advanced because most of the beginning students were still nervous about being in the shop and were very attentive to what I was saying. The lesson went longer than expected (into 2 periods), but it was mostly because I wasn’t planning for students to have so many questions about all of the equipment. They were coming up with questions that I had not thought of. Overall the introduction to safety went very well.