Arc Eye Injury (Flash Burn)

On 4th February 2013, an Orbital Welding Instructor sustained an arc eye injury as a result of exposure from looking directly into the welding flame. This occurred while welding a 16-inch pipe

with an orbital welding machine at Unit 72A pipe rack.

While adjusting the settings on the orbital welding machine, the welding instructor repeatedly removed his welding shield due to the tight ergonomic working condition thereby looking directly into the welding flame without his face shield.

What Went Wrong

•  In the process of adjusting/setting the orbital welding machine, IP repeatedly removed his face shield resulting in exposure to the ultraviolet rays of the welding flame
• Ergonomic factors associated with orbital welding operation in a place with limited space for maneuvering was not identified in the JSA/TSTI for the job.
•  Existing welding procedure does not include Orbital Welding.

Lessons Learned and Required Actions

• Always utilize appropriate PPE (welding shield, welding hood, and safety glasses) and welding screens at all time during welding activities to prevent direct exposure to welding flame.
• Revise welding procedure to include orbital welding operation and inspections.
• Ensure welders are trained on the safety requirements for welding activities. Training should include set-up of work area and consideration of ergonomic design to prevent injuries.