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Welding and Cutting Safety Program

Purpose

This procedure establishes minimum safety procedures for the selection, inspection and use of welding torches, cutting torches and associated equipment as well as required safe procedures and training for personnel involved in welding and cutting operations.

Scope

This procedure applies to all of our company employees, all contractors and vendors performing work on company property, and all other individuals who are visiting or have business with our company.

Responsibilities

-Management is responsible for development and review of this program.
-Management is also responsible for appropriate employee training.
-Management and supervisors are responsible for enforcement of this program.
-Employees shall comply with all procedures outlined in this policy.
-Contractors and vendors shall comply with all procedures outlined in this policy.

Definitions

Arc Welding/Cutting: Use of an electric arc to melt metal

Base Metal : Starting parts in a welding or brazing operation; not the filler metal

Brazing : A technique use to join base metals with a filler metal. The base metals are not melted in brazing

Contractor : A non-company employee being paid to perform work in our facility.

Cutting : Use of a torch to melt metal and cut a unit part into multiple parts

Filler Metal : The material that is melted to join the base metals in a welding or brazing operation

Filter Lens : A deeply tinted lens used to protect the eyes from the intensely bright light of welding and cutting. The shade (relative darkness) of the lens will vary depending upon the type and intensity of the energy released by the various techniques

Fire Watch : A worker who is designated to stay in the area of hot work and look for fires. A fire watch must be capable of traveling above, below and to the sides of the hot work or additional personnel must be assigned to watch these exposures. Fire watch personnel must be trained and equipped with fire extinguishment equipment and must be trained how to activate the fire alarm. A fire watch is not a fire brigade.

Hot Work : Welding, Cutting and Brazing

Hot Work Permit : A permit issued after an area has been inspected and found not to contain any unusual fire hazards. After issuance of the permit, hot work can be undertaken for the duration of the permit but never longer than one shift.

Inert Gas : A gas that is non-reactive, non-flammable and does not contain oxygen

Inert Gas Welding : Welding techniques where the electrical welding activity is conducted under an inert gas blanket such as carbon dioxide or argon. The inert gas prevents the oxygen in air from interfering with the weld. Also called Shielded Gas welding.

MIG Welding : Metal Inert Gas welding: a wire is fed under an inert gas blanket and transfers the heat for welding as it is consumed to form the weld bead

Oxygen-Fuel Gas Welding/Cutting : Mixing of oxygen and a fuel gas to the correct proportions and burning the resultant mixture with a torch.

Resistance Welding : Technique of using the resistance of pieces of metal to create heat and fuse the pieces together

TIG Welding : Tungsten Inert Gas welding, the tungsten electrode is not consumed

Vendor : A non-company employee being paid to perform a service in our facility.

Welding : Technique of joining metal by melting the base metals with or without the use of filler metal

Procedure

Fire Protection

• Only personnel trained and authorized to weld, cut or braze will perform such operations. Contractors will be required to furnish only trained and authorized personnel for jobs in this facility.
• Welding, cutting and brazing will be performed in designated areas designed and maintained for the hot work processes or a hot work permit will be issued for an area to certify that there are no unusual fire hazards for the duration of the hot work
• At least one 10 lb. Multipurpose dry chemical fire extinguisher (or an equivalent extinguisher(s) provided) will be permanently mounted in each area where hot work occurs or will be located temporarily in areas where a hot work permit has been issued
• Hot work will be suspended whenever our facility fixed fire protection systems are impaired unless alternate precautions are taken
• Combustible materials will be located at least 35 feet from hot work areas or fire proof barriers will be erected. Floor and wall openings will be sealed and precautions will be taken to prevent transmission of heat along pipes, conduit, ducts, etc.
• Hot work will not be allowed in any area where there is any detectable flammable vapor or gas-a reading of 0% Lower Explosive Limit (LEL) on the meter is required
• Hot work is not permitted on drums, tanks or other closed and semi-closed containers until the container is emptied, cleaned and purged of all possible flammable residue, vapor or gas. Closed containers (pipes, tanks, etc.) must be vented prior to welding or cutting.
• Areas where hot work has taken place will have a fire watch in attendance during the hot work and for at least 30 minutes after the conclusion of the work. Exception: for areas designated and maintained as production welding areas.

Welding & Cutting Safety

Welding and cutting tasks are dangerous, even for the most experienced worker. To avoid injuries on the job, consider these safety recommendations:

• Always check for fire hazards before you start welding. Wood, paper, and other flammable materials should be removed from the area. Flammable liquids should be removed as well.
• Clean wood floors before welding over them. Then cover them with metal or some other material that will not burn. It may also be advisable to wet the floor, though this can cause an added shock hazard. Guard against these hazards, as necessary.
• Seal cracks so that sparks or slag cannot fall through them, and never allow these hot materials to fall into machine pits.
• Shield open doorways, broken windows and similar openings with an asbestos curtain. Hot slag may roll along a floor, so be sure the curtain is in contact with the floor.
• If you must weld near combustible materials, a fire extinguisher, pail of water, fire hose or a pail of sand should be at hand. It may be necessary to have a worker stand by with a fire extinguisher to put out sparks as well.
• If you are welding or cutting a tank or drum containing flammable liquids or gas, do not start your operation until an approved test shows that there is no dangerous vapor present. Do not rely on another employee's word that the tank or drum was tested previously; insist on a new test before you start your work.
• Wear face and eye protection such as goggles and a helmet to protect against hazards. Welders working with metal, chipping and cleaning should always have their helmets lowered to prevent throw particles of metal from coming into the eyes. Eye protection, such as goggles, are worn to protect against sparks, slag and molten metal, and flash burns caused by radiation from the welding equipment.
• Make sure your work area is properly ventilated. Many of these operations produce fumes that are harmful in heavy concentrations, and good ventilation is one of the best methods of protecting yourself against this hazard. Utilize special ventilating equipment, if necessary.

Make safety a top priority as you weld and cut. Taking these precautions will lower your risk of occupational injuries, which will make your job a lot more safe and enjoyable.

Hot Work Hazard Prevention for Oil Field Workers

"Hot work" is defined as any tasks that involve burning, welding, using fire- or spark-producing tools, or actions that produce sources of ignition. There are potential hazard areas on an oil jobsite, including well heads, fuel tanks, mud tanks, tank batteries, gas separators and oil treaters.

Workers performing hot work are exposed to the risk of fire from the ignition of flammable or combustible materials, from leaks of flammable gas and from hot work equipment. To reduce your risk of injury, abide by these safety recommendations:

• § Perform hot work in a safe location, or in places where fire hazards have been removed or covered.
• § Use guards to confine the heat, sparks and slag, and to protect the immovable fire hazards.
• § Do not perform hot work where flammable vapors or combustible materials exist. Work and equipment should be relocated outside of the hazardous area, if possible.
• § Make sure that suitable fire-extinguishing equipment is immediately available. This equipment may be pails of water, buckets of sand, a hose or portable fire extinguishers.
• § Have additional workers standing on hand to guard against fire while hot work is being performed. This includes locations where anything greater than a minor fire may develop, or if any of the following conditions exist:
  • Appreciable combustible material is closer than 35 feet to the point of the operation.
  • Appreciable combustibles are more than 35 feet away but are easily ignited by the sparks.
  • Wall or floor openings within a 35-foot radius expose combustible material in adjacent areas, including concealed spaces in walls or floors.
  • Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings or roofs, and are likely to be ignited by conduction or radiation.
• Monitor the atmosphere with a gas detector. If a flammable or combustible gas exceeds 10 percent of the lower explosive level, the work must be stopped.

Essential Fire Prevention Tips

Welding, Cutting and Brazing Hazards for the Oil and Gas Industry

Fire hazards are a danger for workers in most industries, but especially for those working in oil and gas because it is flammable by nature. To reduce your risk of fire or burn injuries while on the job, take these safety recommendations into consideration:

• Inspect the work area to ensure that all fuel and ignition sources are isolated by shielding, clearing the area, lockout/tagout or soaking flammable materials in water.
• Wear personal protective equipment (PPE), such as a face shield, leather welder's vest and gauntlet gloves. Also wear cotton or denim clothing only.
• Wear UV shielding equipment for arc welding, when appropriate.
• Inspect welding and cutting equipment before use.
• Leak test gas torches, gauges and hoses.
• Ensure that there is adequate fire protection equipment in place in case of an emergency.
• Ensure that there is adequate ventilation to remove toxic welding and cutting fumes.

Special Hazards

There are several special respiratory hazards present when doing welding and cutting work. They are:

To combat these hazards:

• An accumulation of toxic gases within a confined space.
• A hazardous atmosphere exists in oxygen-deficient areas (when the atmospheric concentration is less than 19.5 percent) and oxygen-enriched areas (when the atmospheric concentration is more than 23.5 percent).
• Ventilate toxic fumes mechanically when entering a confined space, such as inside of a mud tank, water tank, oil tank, hopper, sump, pit or cellar.
• Use a written permit system to document the authorization to enter, the work to be performed and the results of the gas monitoring (where there is a potential for a toxic, flammable or oxygen-deficient atmosphere).

Cover Up for Safety!

 

Always wear the appropriate personal protective equipment (PPE) to remain safe on construction sites. Use the following as a guide:

• Eyes and Face: Safety goggles or face shields should be worn during welding, cutting, grinding or nailing.
• Feet: Wear shoes or boots with slip and puncture-resistant soles.
• Hands: Wear the right gloves for the job, such as rubber gloves for concrete or insulated gloves for electrical hazards.
• Ears: Use earplugs/earmuffs in high noise work areas where heavy equipment is used.