Welding Explosion—The Case of the Cracked Fuel Tank

Case Study
Let’s Talk About Welding Hazards
 Welder’s flash
 Exposure to fumes and gases
 Explosions or fires
 Electric shock
 Asphyxiation
Take a Look at the Facts
 Experienced welder
 Assigned to weld crack in empty fuel tank
 Diesel fuel tank had been removed that morning
 Welder did not personally inspect tank before commencing his work
 At 7:30 a.m., welder struck an arc on the tank
 Tank exploded away from welder Fractures to jaw, wrist, and hand
 Hospitalized for 4 days
What Do You Think Went Wrong?
 Why do you think the tank exploded?
 Is it important to inspect fuel tanks before welding?
 Is it important to always clean a tank of fuel and fumes before welding it? Why?
 Who should ensure the tank has been cleaned?
 Do you think “assumptions” or “miscommunication” contributed?
 Does the company need a written procedure?
Let’s Review the Causes
 Fuel tank not cleaned
 Fuel tank removed that morning
 Tank still contained diesel vapors
 Shop foreman did not communicate that tank needed cleaning
 Welder did not personally inspect tank
 Welder not trained to clean tanks first
Safe Welding Practices
 Read and follow your company’s safety policy for welding
 Always wear proper personal protective equipment
 Clear the area of combustible objects
 Inspect your equipment
 Inspect your work before starting
 Clean and flush tanks or drums
Protective Clothing
 Fire-retardant clothing with no cuffs or pockets
 Flameproof skull cap
 Eye and face protection with filter lens
 Fire-resistant gauntlet gloves
 Protective boots
Don’t Let It Happen to You
 Clean fuel tanks or drums
 Allow fuel tank to “breathe”
 Inspect work before starting a job
 Make sure you are trained on the job requirements
 Never assume and always communicate

from OSHA Accident Case Studies.