How to Weld Fuel Tanks
Welding gas or diesel tanks is extremely hazardous. In addition to the risk of setting fuel vapors on fire, MIG or TIG welding inside fuel storage tanks can result in argon gas suffocation for the welder and anyone attempting a rescue.
"Disconnect the battery and remove or turn off ignition sources before draining the tank,". This reduces the chance that a spark might set off fuel residue.
Drain fuel tank completely into an approved container for use with flammable liquids. "Do not drain gasoline tanks over or near inspection pits."
Remove fuel tank (if for a vehicle). Open access point if welding a storage tank. Take appropriate safety measures, including donning breathing apparatus and any necessary monitoring equipment. Arrange an observation, evaluation, rescue and evacuation plan that will not endanger rescue crew members according to OSHA regulations for hot work/welding.
Rinse tanks thoroughly several times with warm, soapy water. Drain into approved containers for flammable liquids.
Evacuate fuel fumes from the tank with an air hose for a minimum of one hour or until fuel smell from filter is not detectable. Conduct chemical tests to determine whether all fuel fumes have been removed and whether the tank is now safe to weld.
Please following all applicable laws, regulations, safety standards and best welding practices. Allow tank to cool to within 5 to 10 degrees of 70 degrees Fahrenheit.
Once tank has cooled, put a small amount of fuel in the tank and test for leaks. If tank does not leak, reinstall it according to manufacturer's specifications.
From United States, Fpo
495Welding gas or diesel tanks is extremely hazardous. In addition to the risk of setting fuel vapors on fire, MIG or TIG welding inside fuel storage tanks can result in argon gas suffocation for the welder and anyone attempting a rescue.
"Disconnect the battery and remove or turn off ignition sources before draining the tank,". This reduces the chance that a spark might set off fuel residue.
Drain fuel tank completely into an approved container for use with flammable liquids. "Do not drain gasoline tanks over or near inspection pits."
Remove fuel tank (if for a vehicle). Open access point if welding a storage tank. Take appropriate safety measures, including donning breathing apparatus and any necessary monitoring equipment. Arrange an observation, evaluation, rescue and evacuation plan that will not endanger rescue crew members according to OSHA regulations for hot work/welding.
Rinse tanks thoroughly several times with warm, soapy water. Drain into approved containers for flammable liquids.
Evacuate fuel fumes from the tank with an air hose for a minimum of one hour or until fuel smell from filter is not detectable. Conduct chemical tests to determine whether all fuel fumes have been removed and whether the tank is now safe to weld.
Please following all applicable laws, regulations, safety standards and best welding practices. Allow tank to cool to within 5 to 10 degrees of 70 degrees Fahrenheit.
Once tank has cooled, put a small amount of fuel in the tank and test for leaks. If tank does not leak, reinstall it according to manufacturer's specifications.
From United States, Fpo
Raghu,
You have indeed covered in quite detail regarding welding & gas cutting. Good. Keep it up.
The information given by you shoulde be shared with supervisors & those doing welding as part of their induction before they start any such work. If these information is not shared to the people involved, it becomes wasted. These toolbox talks should be jointly carried out by the HSE professional and the welding supervisor almost everyday as a reminder until the knowledge & practice becomes a habit.
Rgds
Gopi
From Malaysia, Kuala Lumpur
You have indeed covered in quite detail regarding welding & gas cutting. Good. Keep it up.
The information given by you shoulde be shared with supervisors & those doing welding as part of their induction before they start any such work. If these information is not shared to the people involved, it becomes wasted. These toolbox talks should be jointly carried out by the HSE professional and the welding supervisor almost everyday as a reminder until the knowledge & practice becomes a habit.
Rgds
Gopi
From Malaysia, Kuala Lumpur
Dear Sir,
I would like to thank you personally for your wonderful inputs on Safety measures esp in Welding. Eventhough I am not in that particular profession, I am working as a coordinator in Skill Development initiatives particularly with various welding training institutes in Tamil Nadu.
It'd help me a lot to relook our activities under safety point of view.
Thank you very much
Raja Ganesh. M
From India, Madras
I would like to thank you personally for your wonderful inputs on Safety measures esp in Welding. Eventhough I am not in that particular profession, I am working as a coordinator in Skill Development initiatives particularly with various welding training institutes in Tamil Nadu.
It'd help me a lot to relook our activities under safety point of view.
Thank you very much
Raja Ganesh. M
From India, Madras
Dear Gopi,
Yes!! I agree with you. Same thing I am doing on my site daily especially I conduct one meeting to our Fabricators (at least 15 minutes). . .
Dear Raja,
Nice to hear this I am very happy mate. Mr. Rajesh as per your message you’re working as a coordinator (welding training institutes) please share the message to our students/guys it’s easily reach to them. . .
If u need anything regarding welding safety please come forward we will help you. . .
Keep on sharing & gaining. . .
From United States, Fpo
Yes!! I agree with you. Same thing I am doing on my site daily especially I conduct one meeting to our Fabricators (at least 15 minutes). . .
Dear Raja,
Nice to hear this I am very happy mate. Mr. Rajesh as per your message you’re working as a coordinator (welding training institutes) please share the message to our students/guys it’s easily reach to them. . .
If u need anything regarding welding safety please come forward we will help you. . .
Keep on sharing & gaining. . .
From United States, Fpo
How to Weld a Gas Tank
Welding gas tanks is particularly hazardous. The danger of gas-tank welding does not come necessarily with the liquid fuel, but more specifically with gas fumes. Fuel vapors can be extremely flammable and even a small spark can cause a massive explosion. Furthermore, argon gas build up inside the fuel tank can cause suffocation for anyone welding. It is important to use extreme caution when working with gas tanks and flames.
Remove the battery from the vehicle if the tank is still strapped on the vehicle. This will help prevent the possibility of a spark igniting the fuel or vapors. Detach the straps holding the fuel tank in place. Use a screwdriver to remove the screws in the strap. Avoid cutting the straps unless it is impossible to remove them otherwise. Move the tank away from the vehicle so the container may be drained.
Turn the tank over so the fuel drain hose or outlet drain is facing toward the ground. Place a breathing mask on for your safety so fumes from the fuel will not be inhaled. Empty the fuel from the tank into an approved fuel container. Ensure the tank is as empty as possible. Place sand over any fuel that might have spilled onto the ground.
Rinse the tank with warm water by pouring it into the gas tank as you would a gas pump. Apply a small amount of soap to the water. Empty the mixture into a small bucket after swishing the soap and water together. Repeat this process two or three times to clean the tank as best as possible.
Use an air hose to pull the remaining fuel fumes from the tank. This process should take anywhere from one to four hours depending on the size of the tank and the amount of fumes in the tank before it was emptied. Smell the inside of the tank by removing the breathing mask and waving your hand over the outlet hose. Do not directly sniff inside the tank drain as this might cause harmful fumes to enter your body.
Weld the tank using a welding torch and a welding mask. Conduct the welding in the desired manner and be sure to follow all safety protocol and fuel tank regulations, if applicable. Let the tank cool to about 75 degrees Fahrenheit. Use a small, hand held air thermometer to take the temperate reading. Fill the tank with a small amount of fuel to test for any leaking. Reattach the tank to the vehicle just as it was by tightening down the straps and inserting the screws.
From United States, Fpo
Welding gas tanks is particularly hazardous. The danger of gas-tank welding does not come necessarily with the liquid fuel, but more specifically with gas fumes. Fuel vapors can be extremely flammable and even a small spark can cause a massive explosion. Furthermore, argon gas build up inside the fuel tank can cause suffocation for anyone welding. It is important to use extreme caution when working with gas tanks and flames.
Remove the battery from the vehicle if the tank is still strapped on the vehicle. This will help prevent the possibility of a spark igniting the fuel or vapors. Detach the straps holding the fuel tank in place. Use a screwdriver to remove the screws in the strap. Avoid cutting the straps unless it is impossible to remove them otherwise. Move the tank away from the vehicle so the container may be drained.
Turn the tank over so the fuel drain hose or outlet drain is facing toward the ground. Place a breathing mask on for your safety so fumes from the fuel will not be inhaled. Empty the fuel from the tank into an approved fuel container. Ensure the tank is as empty as possible. Place sand over any fuel that might have spilled onto the ground.
Rinse the tank with warm water by pouring it into the gas tank as you would a gas pump. Apply a small amount of soap to the water. Empty the mixture into a small bucket after swishing the soap and water together. Repeat this process two or three times to clean the tank as best as possible.
Use an air hose to pull the remaining fuel fumes from the tank. This process should take anywhere from one to four hours depending on the size of the tank and the amount of fumes in the tank before it was emptied. Smell the inside of the tank by removing the breathing mask and waving your hand over the outlet hose. Do not directly sniff inside the tank drain as this might cause harmful fumes to enter your body.
Weld the tank using a welding torch and a welding mask. Conduct the welding in the desired manner and be sure to follow all safety protocol and fuel tank regulations, if applicable. Let the tank cool to about 75 degrees Fahrenheit. Use a small, hand held air thermometer to take the temperate reading. Fill the tank with a small amount of fuel to test for any leaking. Reattach the tank to the vehicle just as it was by tightening down the straps and inserting the screws.
From United States, Fpo
What are the OSHA Requirements for Oxygen-Fuel Storage?
Oxygen fuel is used in welding, cutting and brazing. Oxygen fuel is prone to fire and explosions. The fire that is used to weld or cut is very hot and dangerous. If an oxygen cylinder is leaking and the leak comes into contact with an ignition source, the cylinder can explode. Proper storage of oxygen fuel can help minimize the risk of fire and explosion. The Occupational Safety and Health Administration (OSHA) of the U.S. Department of Labor sets requirements for oxygen-fuel storage.
Mixing Gases
Mixing oxygen fuel with other flammable gases before use can cause the cylinder to explode. Mixture of oxygen fuel with other gases should happen only at the burner or in a standard torch.
Cylinders
Each cylinder must be marked with the name of the gas, either in chemical or trade name form. Any cylinder that has a capacity of 30 lbs. or more must have a cap to provide protection for the valve or recess the valve so that it is not exposed should the cylinder tip over.
Storage of Cylinders
An oxygen cylinder must not be stored near highly combustible materials such as oil, grease or acetylene. Oxygen cylinders must be separated from combustibles by 20 feet or by a barrier that is five feet high and noncombustible. If an oxygen cylinder is to be stored outside of a generator house, it must be separated from the generator by a gas tight, noncombustible partition that will resist fire for at least one hour.
Cylinder Maintenance
An oxygen cylinder must be kept free of oil or grease and must not be handled with gloves that have oil or grease on them. Oxygen fuel must not touch oily or greasy objects. Cylinders must not strike one another or other objects violently and all valves should be closed when not in use. Store cylinders away from the area where welding or cutting takes place so that sparks or slag cannot contact the cylinder. Oxygen cylinders must be kept away from open electrical currents.
Hope its helps. . .
Keep on sharing and gaining. . .
From United States, Fpo
Oxygen fuel is used in welding, cutting and brazing. Oxygen fuel is prone to fire and explosions. The fire that is used to weld or cut is very hot and dangerous. If an oxygen cylinder is leaking and the leak comes into contact with an ignition source, the cylinder can explode. Proper storage of oxygen fuel can help minimize the risk of fire and explosion. The Occupational Safety and Health Administration (OSHA) of the U.S. Department of Labor sets requirements for oxygen-fuel storage.
Mixing Gases
Mixing oxygen fuel with other flammable gases before use can cause the cylinder to explode. Mixture of oxygen fuel with other gases should happen only at the burner or in a standard torch.
Cylinders
Each cylinder must be marked with the name of the gas, either in chemical or trade name form. Any cylinder that has a capacity of 30 lbs. or more must have a cap to provide protection for the valve or recess the valve so that it is not exposed should the cylinder tip over.
Storage of Cylinders
An oxygen cylinder must not be stored near highly combustible materials such as oil, grease or acetylene. Oxygen cylinders must be separated from combustibles by 20 feet or by a barrier that is five feet high and noncombustible. If an oxygen cylinder is to be stored outside of a generator house, it must be separated from the generator by a gas tight, noncombustible partition that will resist fire for at least one hour.
Cylinder Maintenance
An oxygen cylinder must be kept free of oil or grease and must not be handled with gloves that have oil or grease on them. Oxygen fuel must not touch oily or greasy objects. Cylinders must not strike one another or other objects violently and all valves should be closed when not in use. Store cylinders away from the area where welding or cutting takes place so that sparks or slag cannot contact the cylinder. Oxygen cylinders must be kept away from open electrical currents.
Hope its helps. . .
Keep on sharing and gaining. . .
From United States, Fpo
Welding, Cutting, Brazing & Grinding
Welding and other hot work presents significant opportunity for fire and injury. Hot work is any temporary operation involving open flames or which produces heat/sparks. Typical operations include brazing, open flame soldering, grinding, arc welding/cutting, oxy-fuel gas welding, hot taps, and torch applied roofing. Because of the high temperatures involved and the potential for fire and serious injury, care must be taken to ensure that work is performed safely.
Hazard Avoidance
The hazards associated with hot work are:
Fires/Explosions (hot surfaces can be ignition sources)
Burns (both from welding equipment itself and hot surfaces)
Toxic fumes, particulates and smoke
Eye injuries (burn and particulates)
Electric shock
Noise
Fire/Explosion Precautions
Do not cut, weld, braze, or grind in the presence of combustible or flammable liquids or atmospheres (gases, vapors, dust).
Do not cut, weld, braze, or grind on drums, barrels, tanks, or other containers.
Inspect cracks and holes in floors, walls, and ceilings of the work area to ensure that no combustible materials, or personnel, will be exposed to sparks should they pass through a crack, hole, or penetration.
If the object to be worked cannot readily be moved to a routine welding area, move all combustible materials at least 35' from where the hot work will take place.
If any remaining combustibles cannot be moved, ,protect the combustibles with appropriate guards and covers.
Do not cut,, weld, braze, or grind inside a building if you have reason to suspect the sprinkler system (if present) is not working properly.
Do not mix aluminum grinding dust and iron or steel grinding dust. Such a mixture can, under special conditions, explode. Finely divided aluminum mixed with finely divided ferrous oxide forms thermite, a compound that burns greater than 3,000° C
Hot Work Safety
Burns and Personal Injury Precautions
Using welding curtains and shields.
Ensure adequate ventilation during the hot work process.
Materials such as lead, cadmium, and beryllium generate toxic gases when heated to their vaporization point.
Sanding, grinding, or similar activities can release dangerous respirable particles.
Protect workers from electrical shocks by maintaining electrical welding equipment in good condition. Repair damaged leads promptly.
Goggles and face shields that give maximum eye protection for each welding, flame cutting and soldering process shall be worn by personnel performing these operations and helpers assisting in the hot work.
It is not necessary to have a direct view of a welding arc to injure your eyes. Sufficient light can reflect from nearby surfaces to cause a "welders flash" - especially with prolonged exposure.
Flame resistant gloves and aprons shall be worn during welding, flame cutting and soldering processes.
Should protective hard hats be worn, they shall be made of a flame resistant material.
Safety shoes with protected tops should be worn to protect the operator from spark hazard.
Ensure worker protection from high noise levels produced by grinding or cutting activities.
Personal Awareness
Do not bring combustibles or flammables into an area where welding, cutting, brazing, or grinding occurs.
Ensure all compressed gas cylinders and fuels are stored and transported properly, and that any regulators, valves, hoses, and fittings are in good condition.
Thoroughly clean a grinding machine of all aluminum dust before grinding iron or steel.
Hope its helps. . .
From United States, Fpo
Welding and other hot work presents significant opportunity for fire and injury. Hot work is any temporary operation involving open flames or which produces heat/sparks. Typical operations include brazing, open flame soldering, grinding, arc welding/cutting, oxy-fuel gas welding, hot taps, and torch applied roofing. Because of the high temperatures involved and the potential for fire and serious injury, care must be taken to ensure that work is performed safely.
Hazard Avoidance
The hazards associated with hot work are:
Fires/Explosions (hot surfaces can be ignition sources)
Burns (both from welding equipment itself and hot surfaces)
Toxic fumes, particulates and smoke
Eye injuries (burn and particulates)
Electric shock
Noise
Fire/Explosion Precautions
Do not cut, weld, braze, or grind in the presence of combustible or flammable liquids or atmospheres (gases, vapors, dust).
Do not cut, weld, braze, or grind on drums, barrels, tanks, or other containers.
Inspect cracks and holes in floors, walls, and ceilings of the work area to ensure that no combustible materials, or personnel, will be exposed to sparks should they pass through a crack, hole, or penetration.
If the object to be worked cannot readily be moved to a routine welding area, move all combustible materials at least 35' from where the hot work will take place.
If any remaining combustibles cannot be moved, ,protect the combustibles with appropriate guards and covers.
Do not cut,, weld, braze, or grind inside a building if you have reason to suspect the sprinkler system (if present) is not working properly.
Do not mix aluminum grinding dust and iron or steel grinding dust. Such a mixture can, under special conditions, explode. Finely divided aluminum mixed with finely divided ferrous oxide forms thermite, a compound that burns greater than 3,000° C
Hot Work Safety
Burns and Personal Injury Precautions
Using welding curtains and shields.
Ensure adequate ventilation during the hot work process.
Materials such as lead, cadmium, and beryllium generate toxic gases when heated to their vaporization point.
Sanding, grinding, or similar activities can release dangerous respirable particles.
Protect workers from electrical shocks by maintaining electrical welding equipment in good condition. Repair damaged leads promptly.
Goggles and face shields that give maximum eye protection for each welding, flame cutting and soldering process shall be worn by personnel performing these operations and helpers assisting in the hot work.
It is not necessary to have a direct view of a welding arc to injure your eyes. Sufficient light can reflect from nearby surfaces to cause a "welders flash" - especially with prolonged exposure.
Flame resistant gloves and aprons shall be worn during welding, flame cutting and soldering processes.
Should protective hard hats be worn, they shall be made of a flame resistant material.
Safety shoes with protected tops should be worn to protect the operator from spark hazard.
Ensure worker protection from high noise levels produced by grinding or cutting activities.
Personal Awareness
Do not bring combustibles or flammables into an area where welding, cutting, brazing, or grinding occurs.
Ensure all compressed gas cylinders and fuels are stored and transported properly, and that any regulators, valves, hoses, and fittings are in good condition.
Thoroughly clean a grinding machine of all aluminum dust before grinding iron or steel.
Hope its helps. . .
From United States, Fpo
"Hot work" can cause catastrophic workplace accidents
There are many causes of industrial/construction workplace accidents, but perhaps one of the most deadly, yet easily preventable, occurrences is an explosion caused by "hot work".
The Health and Safety Executive describes "hot work" as "any process that generates a source of ignition (eg naked flames, heat, sparks) arising from working methods such as welding, flame cutting, grinding and using disc cutters".
Where hot work is carried out on drums, containers or any receptacle which contains, or previously contained, flammable or combustible liquids, then a serious risk of explosion can occur. Drums or containers used to store waste thinners, new or used engine oil, anti-freeze, solvents, petrol or diesel fuel should be handled with extreme care, and an alternative to hot work should be found if they need to be repaired or altered in any way.
The use of flammable materials is a significant factor in many industries across the UK and the types of containers used to transport and store them are numerous. If a container is reused after being emptied, especially if labelling is removed or becomes unreadable, there may be a danger that a worker could unwittingly begin hot work on it, or carry out hot work near to an old flammable liquid container, which may, in turn, cause an explosion.
Even when a container appears to be empty, seams, creases and folds in its surface material may still hold sufficient liquid residue to provide an explosive vapour which could provide perfect fuel for an explosion should hot work be carried out on the vessel.
The HSE reports that it has investigated a number of serious accidents involving hot work and, following two deaths in North East Scotland, occurring in separate incidences but within a short period of time, a Safety Alert was issued to warn employers and duty holders of the inherent risks involved in performing hot work on containers and drums..
Key advice to prevent personal injury from a workplace accident involving "hot work"
The hazards associated with performing hot work on tanks and drums are great, so alternatives should always be considered. These could include:
using cold cutting or cold repair techniques; or
container replacement rather than repair.
If the work is considered to be unavoidable and absolutely necessary, a specialist company should be employed or the risks reduced by using methods such as gas-freeing, cleaning or "inerting" before hot work commences.
The HSE advises that no-one should repair or cut up tanks or drums unless they have received full training and are aware of all the risks involved.
Hope its helps. . .
From United States, Fpo
There are many causes of industrial/construction workplace accidents, but perhaps one of the most deadly, yet easily preventable, occurrences is an explosion caused by "hot work".
The Health and Safety Executive describes "hot work" as "any process that generates a source of ignition (eg naked flames, heat, sparks) arising from working methods such as welding, flame cutting, grinding and using disc cutters".
Where hot work is carried out on drums, containers or any receptacle which contains, or previously contained, flammable or combustible liquids, then a serious risk of explosion can occur. Drums or containers used to store waste thinners, new or used engine oil, anti-freeze, solvents, petrol or diesel fuel should be handled with extreme care, and an alternative to hot work should be found if they need to be repaired or altered in any way.
The use of flammable materials is a significant factor in many industries across the UK and the types of containers used to transport and store them are numerous. If a container is reused after being emptied, especially if labelling is removed or becomes unreadable, there may be a danger that a worker could unwittingly begin hot work on it, or carry out hot work near to an old flammable liquid container, which may, in turn, cause an explosion.
Even when a container appears to be empty, seams, creases and folds in its surface material may still hold sufficient liquid residue to provide an explosive vapour which could provide perfect fuel for an explosion should hot work be carried out on the vessel.
The HSE reports that it has investigated a number of serious accidents involving hot work and, following two deaths in North East Scotland, occurring in separate incidences but within a short period of time, a Safety Alert was issued to warn employers and duty holders of the inherent risks involved in performing hot work on containers and drums..
Key advice to prevent personal injury from a workplace accident involving "hot work"
The hazards associated with performing hot work on tanks and drums are great, so alternatives should always be considered. These could include:
using cold cutting or cold repair techniques; or
container replacement rather than repair.
If the work is considered to be unavoidable and absolutely necessary, a specialist company should be employed or the risks reduced by using methods such as gas-freeing, cleaning or "inerting" before hot work commences.
The HSE advises that no-one should repair or cut up tanks or drums unless they have received full training and are aware of all the risks involved.
Hope its helps. . .
From United States, Fpo
Dear all, Please find the attached "16 Steps to Fire Safety on Timber Frame Construction Sites" file. . . Hope its helps. . .
From United States, Fpo
From United States, Fpo
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