ehs procedure: s-07-01-s page 1 of 37

EHS Procedure: S-07-01-S

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Sinclair Wyoming Refining Company

Environmental, Health & Safety

EHS PROCEDURE S-07.01-S (1):

Welding and Cutting Procedure

Purpose of Revision Date Reviewed By Approved By

Original 8/1/2008 John Pfeffer, EHS

Manager

Ed Juno, Refinery Manager

Revision 01

Scheduled review

Change responsibilities

from Rotating

Equipment Supervisor

to Metal Trades

Supervisor

11/11/11

Title: H&S Manager

Name: Kurt Haden

Church

Signature:

Title: Refinery Manager

Name: Jim Maguire

Signature:

Revision 02

Revision 03

Revision 04

Revision 05

Revision 06

Revision 07

Revision 08


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Sinclair Wyoming Refining Company

Environmental, Health & Safety

EHS PROCEDURE S-07.01-S (1):

Welding and Cutting Procedure

Table of Contents

1. PURPOSE..............................................................................................................................3

2. SCOPE ...................................................................................................................................3

3. REFERENCES .....................................................................................................................3

4. APPLICATION ....................................................................................................................4

5. RESPONSIBILITIES ...........................................................................................................4

6. PROGRAM ...........................................................................................................................4

7. EMERGENCY PROCEDURES .........................................................................................8

8. CONTRACTORS .................................................................................................................8

9. TRAINING ............................................................................................................................8

10. INSPECTIONS, AUDITS AND PROCEDURE UPDATES ............................................8

11. APPENDICES .......................................................................................................................9

11.1. Definitions ............................................................................................................................. 10

11.2. Employee Duties for Welding, Cutting and Brazing Positions ............................................. 13

11.3. General Welding Information ................................................................................................ 14

11.4. Rate of Ventilation for Freely Moveable Hoods ................................................................... 16

11.5. Oxy-Fuel Welding - Safe Cylinder and Equipment Handing and Use Procedures ............... 17

11.6. Oxy-Fuel Equipment and Storage Requirements .................................................................. 19

11.7. Oxy-Fuel Gas Equipment Requirements Checklists (Low-Pressure Manifolds) .................. 20

11.8. Oxy-Fuel Gas Equipment Requirements Checklists (Portable Outlet Headers).................... 21

11.9. Oxy-Fuel Gas Equipment Requirements Checklists (Service Piping Systems,

Painting and Signs) ................................................................................................................ 22

11.10. Oxy-Fuel Gas Equipment Requirements Checklists (Protective Equipment, Hose

and Regulators)...................................................................................................................... 24

11.11. Oxy-Fuel Gas Equipment Requirements Checklists (Hose and Hose Connections,

Pressure-Reducing Regulators) ............................................................................................. 26

11.12. Resistance Welding Equipment Checklist ............................................................................. 27

11.13. Arc Welding Equipment Operations and Maintenance ......................................................... 29

11.14. Arc Welding Equipment Checklist ........................................................................................ 30

11.15. Health Hazards and Fume Protection Requirements ............................................................. 33

11.16. Personal Protective Equipment Requirements ....................................................................... 35


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1. PURPOSE:

To establish welding and cutting procedures to protect personnel who do, or are affected by, work

involving welding, cutting or brazing.

2. SCOPE:

This procedure applies to all employees and contractors doing or supervising welding, cutting or brazing

at Sinclair Wyoming Refining Company.

It is not the intent of this procedure to provide complete details of all hazards associated with the varying

types of welding, soldering, arc-air cutting, oxy-fuel cutting etc. operations due to the varying conditions

of each job and task.

3. REFERENCES:

3.1. OSHA 1910.251 – Welding, Cutting & Brazing – Definitions.

3.2. OSHA 1910.252 – Welding, Cutting & Brazing – General Requirements.

3.3. OSHA 1910.253 – Oxygen-Fuel Gas Welding & Cutting.

3.4. OSHA 1910.254 – Arc Welding & Cutting.

3.5. OSHA 1910.255 – Resistance Welding.

3.6. OSHA 1910.1026 – Chromium.

3.7. OSHA 1910 Subpart S – Electrical Standards.

3.8. NFPA Standard 51B, 1962 – Standard for Fire Prevention in Use of Welding & Cutting

Processes

3.9. SOC EHS Standard: Welding, Cutting and Brazing. Sinclair Wyoming Refining Company EHS

Procedures

3.9.1. Hot Work Permit Procedure. S-01.04

3.9.2. Lockout / Tagout Procedure. S-01.02

3.9.3. Permit-Required Confined Space Procedure. S-01.03

NOTE: This standard does NOT address the specific hazards or requirements associated

with welding, cutting, grinding or brazing on metals containing Hexavalent

Chromium (Chrome VI). See the Hexavalent Chromium Procedure for detailed

information and hazards associated with Chrome VI.

NOTE: This standard does NOT address burning, cutting, welding, etc. of metals with

paints or coatings containing lead. For guidelines on welding, cutting and/or

brazing metals with lead paints and/or coatings, see the Lead Management

Program (currently under development) for details and consult the Sinclair

competent person.

Furthermore, welding, cutting and brazing are NOT allowed on coated metals.

The coatings must be previously removed using approved methods to minimize

potential exposures to hazards such as Lead and Chrome VI.

http://poedmsll.po.conoco.com/rmna/livelink.exe/IHS_9_-_Lead_Management_Program.doc?func=doc.Fetch&nodeId=18275973&docTitle=IHS+9+%2D+Lead+Management+Program

http://poedmsll.po.conoco.com/rmna/livelink.exe/IHS_9_-_Lead_Management_Program.doc?func=doc.Fetch&nodeId=18275973&docTitle=IHS+9+%2D+Lead+Management+Program


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3.9.4. Respiratory Protection Procedure. H-02.01

3.9.5. Hot Tapping Procedure

3.9.6. Definitions used in this procedure are contained in Appendix 11.1.

4. APPLICATION:

This procedure establishes requirements for all work involving welding, cutting or brazing. Such work

must also be performed in conformance with Sinclair Wyoming Refining Company Hot Work Permit

procedures.

5. RESPONSIBILITIES:

5.1. The welder, welder helper, electrician and their supervisors and anyone involved in the set up

and use of welding and cutting equipment will follow this procedure.

5.2. Inspection will certify all personnel who may perform welding, cutting or brazing.

5.3. Maintenance Supervisors will certify all personnel who inspect or repair welding, cutting or

brazing equipment.

5.4. Duties for those involved in welding, cutting and brazing at the Sinclair Wyoming Refinery are

included in Appendix 11.2.

6. PROGRAM:

6.1. Hot Work procedures

6.1.1. Welding, cutting and brazing operations must be conducted in conformance with

Sinclair Wyoming Refining Company Hot Work procedures.

6.1.2. Welding, cutting and brazing done outside of Hot Work Permit-Exempt Areas require a

Hot Work permit.

6.2. Welding and cutting containers

6.2.1. No welding, cutting or other hot work may be performed on used drums, barrels, tanks

or other containers until they have been cleaned of all substances that might produce

flammable or toxic vapors when heated. Exception: Hot Tapping is permitted. Follow

the Sinclair Wyoming Refining Company Hot Tap Procedure when appropriate.

6.2.2. Isolate, disconnect or blind any vessels, pipes, or connections prior to work in

accordance with the Sinclair Wyoming Refining Company Lockout/Tagout Procedure.

6.2.3. Ensure that all spaces to be exposed to the extreme heat and spark associated with

welding, cutting and brazing is free of explosive vapors (LEL). Follow Hot Work

Procedure and gas check all spaces where LEL may develop (such as piping, vessels and

tubular handrails). When necessary, purge/vent hollow spaces to permit the escape of

air or gasses before preheating, welding or cutting.

6.3. Welding in confined spaces

6.3.1. Leave gas cylinders and welding machines outside the confined space and secure any

heavy, wheel-mounted equipment to prevent accidental movement.

6.3.2. A method is provided to quickly remove a welder if entry is through a manhole or other

small opening, such that the welder’s body cannot become jammed in the opening.

6.3.3. After completing welding operations, mark hot metal with a warning sign or provide

some other means of warning other workers.

6.3.4. When welding is to be suspended for any substantial length of time such as for lunch:


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A. Arc welding: Remove all electrodes from their holders and locate the holders so

that accidental contact cannot occur. Disconnect the machine from the power

source.

B. Torch welding: Close all torch valves and shut off the gas supply to the torch at

some point outside of the confined space. Where practicable, remove the torch

and hose from the confined space and/or disconnect hoses or gauges from bottles.

6.4. Ventilation

6.4.1. Provide and arrange local exhaust ventilation (LEV) and general ventilation systems to

keep potential atmospheric hazards below Occupational Exposure Limits (OEL).

6.4.2. Provide LEV and/or general dilution mechanical ventilation at the rate of at least 2,000

cubic feet per minute per welder where any of the following conditions exist:

NOTE: Air flow measurement as well as exposure assessment must be conducted for

temporary enclosures constructed for welding operations under the following conditions:

A. In spaces allowing less than 10,000 cubic feet per welder.

B. In rooms with ceiling height of less than 16 feet.

C. In confined spaces. See Section 6.4.5. For additional confined space ventilation

requirements.

D. Where the welding space contains partitions or barriers that significantly block

cross ventilation. (Welding hutches, field shops, etc.)

E. For operations involving oxygen cutting, or plasma arc cutting of alloy metals.

F. Exceptions: No mechanical dilution ventilation is required if using local exhaust

ventilation (LEV) booths and hoods as specified in 6.4.4. below.

6.4.3. Provide local exhaust ventilation (LEV), and/or airline respirators or air purifying

respirators with an adequate protection factor for indoor, outdoor, or confined space

welding or cutting operations involving metals containing chrome VI, lead, beryllium,

cadmium, manganese or mercury.

A. Exceptions: If Industrial Hygiene monitoring demonstrates that airborne

concentrations of these contaminants are within acceptable levels then LEV may

not be required.

6.4.4. LEV booths and hoods may be used instead of mechanical ventilation if they meet the

following requirements:

A. Welding booths are fixed enclosures with a top and at least two sides that surround

the welding and cutting operation and have a rate of airflow, which maintains a

velocity away from the welder’s breathing zone of at least 100 feet per minute.

B. Welding hoods are freely movable and intended to be placed by the welder as near

as possible to the work. They must maintain air velocity at the rate of 100 feet per

minute in the welding zone and be situated such that the fumes are taken away

from the worker’s breathing zone.

6.4.5. Ventilation in Confined Spaces

A. Provide LEV and/or general dilution mechanical ventilation at the rate of at least

2,000 cubic feet per minute (CFM) per welder. Where LEV or general dilution

ventilation of 2,000 CFM per welder is not possible, then general ventilation and

air-supplied respiratory protection in confined spaces is required where work

involves:

A.1. Welding on alloy metals (i.e. Stainless, Inconel, Monel, etc.).


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A.2. During the use of fluxes or other compounds which contain fluorine.

A.3. Welding or cutting involving zinc-bearing base or filler metals or metals

coated with zinc-bearing materials (galvanized).

A.4. Welding involving lead-based metals.

NOTE: Welding, cutting, soldering, grinding, and brazing are NOT allowed

on coated/painted materials. The coating must be removed prior to Hot

Work

A.5. Welding or brazing involving cadmium-bearing filler metals, unless using a

ventilation hood as described in section 6.4.4.

B. If ventilation cannot be provided, use airline respirators or hose masks according

to the Respiratory Protection Procedure.

NOTE: Reference Refinery procedures for working in IDLH environments and

necessary precautions that must be taken prior to entering an IDLH space.

C. Oxygen shall never be used for ventilation.

6.4.6. When using screens or tarps, arrange them to avoid any serious restriction of ventilation.

6.5. Protection of Personnel – See Personal Protective Equipment Procedure.

6.5.1. Ensure the use of Fall Protection and follow the scaffolding procedure to ensure safety

while working at heights according to the site procedures.

6.5.2. Welders shall place welding cable and other equipment so that it is clear of passageways,

ladders and stairways.

6.5.3. Maintenance Shop Supervisor will ensure that precautionary labels and warnings

provided by the manufacturer remain with filler metals, fluxes, coatings and coverings

and that workers are aware of their hazards.

6.6. Oxy-fuel welding and cutting:

6.6.1. The following types of oxy-fuel welding and cutting are done in Sinclair Wyoming

Refining Company:

A. Cutting

B. Brazing

C. Silver Soldering

6.6.2. Inspections and equipment condition:

A. Equipment Operators will perform periodic inspections of all oxy-fuel welding

and cutting equipment.

B. Equipment Operators will promptly report any equipment defects to their

supervisors. Discontinue use of such equipment until safety repairs have been

completed by qualified personnel.

6.6.3. Compressed gas cylinders must be constructed, marked and stored in accord with

Appendices 11.2 and 11.3 of this procedure.

6.6.4. Other oxy-fuel equipment shall be constructed, installed, tested, connected and used in

accord with Appendix 11.4 of this procedure, including:

A. Cylinders.

B. Low-pressure manifolds.

C. Portable outlet headers.

D. Protective equipment, hose and regulators.

E. Service piping systems, painting and signs.


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F. Hose and hose connections, pressure-reducing regulators.

6.6.5. Sources of ignition must be isolated from flammable gas lines or other equipment with

uncapped openings.

6.6.6. No welding or cutting may be performed on an acetylene or oxygen pipeline, including

the attachment of hangers or supports, until the line has been purged.

6.6.7. Only oil-free air, oil-free nitrogen, or oil-free CO2 may be used to purge oxygen lines.

6.6.8. Testing of piping systems:

A. Before being placed in service, piping systems shall be tested and proved gastight

at 1.5 times the maximum operating pressure.

B. Piping shall be thoroughly purged of air before being placed in service.

C. Material used for testing oxygen lines must be oil free and noncombustible.

D. Flames shall not be used to detect leaks.

6.7. Resistance welding:

6.7.1. Resistance welding is done at Sinclair Wyoming Refining Company on an as needed

basis:

6.7.2. Resistance welding equipment shall be constructed, installed, tested, connected and used

in accord with Appendix 11.6 of this procedure.

6.7.3. Resistance welding operations and maintenance must be done in accord with Appendix

11.6 of this procedure.


A. Equipment operators will perform periodic inspections of all resistance welding

equipment. Only Qualified Electricians may inspect live electrical equipment.

B. Equipment operators will promptly report any equipment defects to their



6.7.5. Personnel protection.

A. For the protection of operators of nearby equipment, set up fire-resistant curtains

or suitable shields around flash welding machines in such a manner that operator

movements are not hampered.

6.8. Arc welding:

6.8.1. The following types of oxy-fuel welding and cutting are done in Sinclair Wyoming

Refining Company:

A. Shielded Metal Arc Welding

B. Gas-Tungsten Arc Welding

C. Gas Metal Arc Welding

D. Flux Cored Arc Welding

6.8.2. Arc welding equipment will be chosen, designed, constructed, installed and connected

according to requirements of Appendix 11.7 of this procedure.

6.8.3. Arc welding operations and maintenance must be done in accord with Appendix 11.7 of

this procedure.


A. Equipment operators will perform inspections prior to each use of all arc welding

equipment. Only Qualified Electricians may inspect live electrical equipment.


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B. Equipment operators will promptly report any equipment defects to their



7. EMERGENCY PROCEDURES:

7.1 Sounding of the Refinery-wide emergency alarm (fire whistle) will cause immediate

suspension of all welding work. Work may continue only after the Incident Commander

sounds the “All Clear” and the Permit Issuer (if a permit was issued) or Supervisor has

advised welders to resume work.

8. CONTRACTORS:

8.1. Permit Issuer or Contract Coordinator will notify contractors of any welding or cutting

operations which might affect their work.

8.2. Permit Issuer or Contract Coordinator will notify contractors of any flammable materials or

hazardous conditions of which they may not be aware.

8.3. Contractors must notify Permit Issuer and Contract Coordinator if any work they do involves

welding, cutting or brazing or if their work will introduce flammable materials to the worksite.

9. TRAINING:

9.1. Authorized Persons for Welding, Cutting and Brazing must be trained and competent in their

duties prior to performing and welding, cutting or brazing work.

9.2. Maintenance personnel who will inspect or maintain welding equipment must be trained in and

competent for this work.

9.3. EHS Staff will certify that required training / demonstration of competency has been

accomplished. Certification shall contain each employee’s name, the signatures or initials of the

trainers, the dates of training and a summary of training content. The certification shall be

available for inspection by employees and their authorized representatives.

9.4. Training records will be maintained by EHS for three (3) years.

10. INSPECTIONS, AUDITS AND PROCEDURE UPDATES:

10.1. The Metal Trades Supervisor will ensure that periodic inspections are performed. These are not

to exceed six months and shall be made by qualified maintenance personnel, and a certification

record maintained. The following information will be included in this inspection (Appendices

11.3, 11.5, 11.6).

10.1.1. Date of inspection.

10.1.2. Signature of the person who performed the inspection.

10.1.3. Serial number, or other identifier, for the equipment inspected.

10.2. Welding equipment shall be inspected prior to use. The equipment operator shall be instructed

to report any equipment defects to his/her supervisor and the use of the equipment shall be

discontinued until safety repairs have been completed.

10.3. A Multi-disciplinary Procedure Review Team will review these procedures:

10.3.1. Whenever equipment inspection, job reports or incidents indicate that procedures are not

understood or being followed.

10.3.2. At least every three (3) years.

10.3.3. The Multi-disciplinary Procedure Review Team will update these procedures when

review indicates a need.


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11. APPENDICES:

11.1. Definitions.

11.2. Employee Duties for Welding, Cutting and Brazing Positions.

11.3. General Welding Information.

11.4. Rate of Ventilation for Freely Moveable Hoods.

11.5. Oxy-Fuel Welding - Safe Cylinder and Equipment Handing and Use Procedures.

11.6. Oxy-Fuel Equipment and Storage Requirements.

11.7. Oxy-Fuel Gas Equipment Requirements Checklists (Low-Pressure Manifolds).

11.8. Oxy-Fuel Gas Equipment Requirements Checklists (Portable Outlet Headers).

11.9. Oxy-Fuel Gas Equipment Requirements Checklists (Service Piping Systems, Painting and Signs).

11.10. Oxy-Fuel Gas Equipment Requirements Checklists (Protective Equipment, Hose and Regulators).

11.11. Oxy-Fuel Gas Equipment Requirements Checklists (Hose and Hose Connections, Pressure-

Reducing Regulators).

11.12. Resistance Welding Equipment Checklist.

11.13. Arc Welding Equipment Operations and Maintenance.

11.14. Arc Welding Equipment Checklist.

11.15. Health Hazards and Fume Protection Requirements.

11.16. Personal Protective Equipment Requirements.


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Appendix 11.1

DEFINITIONS

ANSI: American National Standards Institute

Arc Welding: A process which uses a welding power supply to create an electric arc between an

electrode and the base material to melt the metals at the welding point. Arc welding can use

either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.

The welding region is sometimes protected by some type of inert or semi-inert gas, known as a

shielding gas and/or an evaporating filler material.

Brazing: A joining process whereby a non-ferrous filler metal or alloy is heated to melting

temperature above 842°F (450°C) or, by the traditional definition that has been used in the

United States, above 800°F (425°C) and distributed between two or more close-fitting parts by

capillary action. At its liquid temperature, the molten filler metal and flux interacts with a thin

layer of the base metal, cooling to form an exceptionally strong, sealed joint due to grain

structure interaction. Common brazements are about 1/3 as strong as the materials they join.

Cutting: A process where an oxy-fuel torch is used to heat up ferrous metal to kindling

temperature (about 1796°F or 980°C). A stream of pure oxygen is trained on the hot metal

which chemically combines with the iron, which then flows out of the cut, or kerf, as an iron-

oxide slag.

Electric Arc: An electrical breakdown of a gas that produces an ongoing plasma discharge,

resulting from a current flowing through normally nonconductive media such as air.

Electrode: An electrical conductor used to make contact with a nonmetallic part of a circuit.

Faying Surface: The surface of a member that is in contact with another member to which it is

joined.

Ferrous: Containing iron.

Filler Metal: A metal added in the making of a joint through welding, brazing or soldering.

Four types of filler metals exist:

1. Covered electrodes.

2. Bare electrode wire or rod.

3. Tubular electrode wire.

4. Welding fluxes.

Sometimes non-consumable electrodes are included as well, but since these metals are not

consumed by the welding process, they are normally excluded.

Flux: A substance which facilitates welding, cutting and brazing by chemically cleaning the

metals to be joined or by preventing oxidation of the base and filler materials.

Hot Tapping: A procedure that involves welding on a piece of equipment (pipelines or vessels)

under pressure, in order to install connections or appurtenances. It is commonly used to replace

or add sections of pipeline without interruption of service for gas, water, steam and

petrochemical distribution systems.

http://en.wikipedia.org/wiki/Welding_power_supply

http://en.wikipedia.org/wiki/Electric_arc

http://en.wikipedia.org/wiki/Direct_current

http://en.wikipedia.org/wiki/Alternating_current

http://en.wikipedia.org/wiki/Electrode

http://en.wikipedia.org/wiki/Inert_gas

http://en.wikipedia.org/wiki/Shielding_gas

http://en.wikipedia.org/wiki/Ferrous

http://en.wikipedia.org/wiki/Filler_metal

http://en.wikipedia.org/wiki/Alloy

http://en.wikipedia.org/wiki/Celsius

http://en.wikipedia.org/wiki/Celsius

http://en.wikipedia.org/wiki/Capillary_action

http://en.wikipedia.org/wiki/Flux_%28metallurgy%29

http://en.wikipedia.org/wiki/Electrical_breakdown

http://en.wikipedia.org/wiki/Plasma_%28physics%29

http://en.wikipedia.org/wiki/Electrostatic_discharge

http://en.wikipedia.org/wiki/Electrical_conductance

http://en.wikipedia.org/wiki/Air

http://en.wikipedia.org/wiki/Electrical_conductor

http://en.wikipedia.org/wiki/Electronic_circuit

http://en.wikipedia.org/wiki/Welding

http://en.wikipedia.org/wiki/Brazing

http://en.wikipedia.org/wiki/Soldering


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Hot Work: Work involving electric or gas welding, cutting, brazing, use of spark-producing

power tools, chipping operations, similar flame or spark-producing operations or work producing

temperatures or surfaces hot enough to cause ignition.

Hot Work Permit-Exempt Area: An area (such as a maintenance or welding shop) designed

and maintained to isolate hot work from material that the work could ignite.

Hot Work Permit: The written authorization to perform operations which could provide a

source of ignition, including riveting, welding, torch cutting, burning, heating, hot tapping or

vehicle entry.

Immediately Dangerous to Life or Health (IDLH): Any condition that poses an immediate or

delayed threat to life or that would cause irreversible adverse health effects or that would

interfere with an individual's ability to escape unaided from a permit space.

NOTE: Some materials--hydrogen fluoride gas and cadmium vapor, for example--may

produce immediate transient effects that, even if severe, may pass without medical

attention, but are followed by sudden, possibly fatal collapse 12-72 hours after exposure.

The victim "feels normal" from recovery from transient effects until collapse. Such

materials in hazardous quantities are considered to be "immediately dangerous to life or

health."

Inert Gas: Any gas that is not reactive (flammable, explosive or electrically conductive) under

normal circumstances.

Local Exhaust Ventilation (LEV) - the mechanical removal of contaminants at the point of

generation. The capture velocity shall be greater than 100 ft/min.

m3: Cubic meter. It is the volume of a cube with edges one meter in length.

mg: Milligram. A unit of mass equal to one thousandth (0.001) of a gram.

Mechanical Ventilation - the positive movement of air caused by mechanical means. The flow

rate shall be greater than 2000 ft3/min. per welder. This may consist of blowers and/or exhaust

fans located on the building walls, roofs, or vessel man-way(s).

Natural Ventilation - movement of air caused by the change in ambient temperature, within an

enclosure, cross drafts due to open doors or windows in a building, natural air movement out of

doors, etc.

Occupational Exposure Limit: The maximum amount or concentration of a substance that

nearly all workers may be exposed to during the working period without excess risk of harm to

their health. These limits may be internal (Sinclair), regulatory (OSHA), or based on consensus

standards (ACGIH TLV).

Operating Unit: All areas designed and used for processing, handling, storing, transferring and

distributing of petroleum or petroleum derived material. This includes facilities such as

Boilerhouse / Powerhouse, Loading / Unloading Facilities.

Oxy-fuel welding: Oxygen-fuel gas welding (also called oxyacetylene welding, oxy welding or

gas welding) processes that use fuel gases and oxygen to join metals.

Parts per Million (ppm): parts of vapor, gas or other contaminant per million parts of air by

volume.


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Permissible Exposure Limit (PEL): The maximum amount or concentration of a chemical that

a worker may be exposed to under OSHA regulations.

Resistance Welding: A group of welding processes that produce coalescence of faying surfaces

where heat to form the weld is generated by the resistance of the welding current through the

workpieces.

Shielding Gas: An inert gas used to protect the welding area from atmospheric gases (such as

oxygen, nitrogen, carbon dioxide or water vapor) that can reduce the quality of the weld.

Soldering: A process in which two or more metal items are joined together by melting and

flowing a filler metal into the joint, the filler metal having a relatively low melting point.

Source of Ignition: Any flame, arc, spark or heat which is capable of igniting combustible

liquids, gases or vapors or any work which might constitute a fire hazard.

Welding - the heating of a metal above its melting point, causing it to fuse to another metal

surface. See Appendix 11.3 for more information.

Welding Power Supply: A device that provides an electrical current to perform welding.

Welding usually requires high current (over 80 amps). Spot welding can require more than

12,000 amps. However, low current can also be used. A good example would be welding two

razor blades together at 5 amps with gas tungsten arc welding. A welding power supply can be

as simple as a car battery .


http://en.wikipedia.org/wiki/Coalescence_%28meteorology%29

http://en.wikipedia.org/wiki/Faying

http://en.wikipedia.org/wiki/Electrical_current


http://en.wikipedia.org/wiki/Gas_tungsten_arc_welding

http://en.wikipedia.org/wiki/Car_battery


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Appendix 11.2

EMPLOYEE DUTIES FOR

WELDING & CUTTING OPERATIONS

Duties of Authorized Employees for Welding, Cutting & Brazing:

Properly use equipment required for welding, cutting and brazing operations they perform.

Read, interpret and follow requirements of Hot Work Permits.

Immediately stop work and alert the Permit Issuer if any permit condition is not being met or

something occurs which affects the safety of the job.

Duties of Monitoring Personnel:

Use the appropriate equipment per manufacturer recommendations.

Monitor and test per requirements of the Permit Procedures.

Duties of EHS Personnel:

Take air flow measurements and perform exposure assessments for temporary enclosures constructed

for welding operations.


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Appendix 11.3

GENERAL WELDING INFORMATION

Types of Welding:

There are many types of welding: electric arc welding, oxyacetylene welding, and plasma arc

welding, etc. The major differences between types of welding are the methods of increasing the

temperature of the metal and the methods used to protect the heated area from cooling before the

metals unite.

The operation referred to as "silver soldering" is not true soldering but is usually brazing and the

materials used do not necessarily contain silver. The more common "silver brazing" alloys

contain varying amounts of phosphorus, silver, zinc, copper, and cadmium. The material of

prime concern as a hazard is cadmium. Cadmium fumes are released when alloys are overheated.

Therefore, care must be taken to control the temperature of silver brazing alloys. The fluxes

used in "silver soldering" may also present the additional hazard from the generation of fluorides.

Soft solders are generally made up of lead and tin alloys. Overheating of these alloys may

result in the production of lead fumes. Therefore, when soldering and brazing, know the

material you are working with and take care in not overheating the materials.

Hazards and cautions:

The principle hazards encountered during welding, arc-air cutting, soldering and brazing

operations are: Exposure to toxic fumes and gases produced by the heated metals and/or solvents

on the metals being worked on. This hazard is potentially one of the most dangerous to workers

because of its unnoticeable and chronic nature. For this reason, this standard has placed

emphasis on the potential effects of toxic fumes and gases. The most common metals

encountered in welding, soldering, and brazing include the following: Aluminum (Al),

Cadmium (Cd), Copper (Cu), Beryllium (Be), Lead (Pb), Iron Oxide (FeO3), Manganese (Mn),

Magnesium (Mg), Mercury (Hg), Nickel (Ni), Phosphorus (P4), Silver (Ag), Tin (Sn), Titanium

(Ti), and Vanadium (V).

The Common gases/vapors (non-metallic hazard) encountered in welding are: Ozone (O3),

Carbon Monoxide (CO), Oxides of Nitrogen (NO, NO2, N2O, N2O3, and N2O5), Fluorides.

Toxic Materials:

Toxic materials can be produced when certain solvents are used to de-grease/clean parts for

welding.

Hazards and cautions

Solvents present on the parts being welded may be below acceptable limits as for as the

flammability concern, however harmful vapors can still be produced. Solvents such as

trichloroethylene decomposed by ultraviolet radiation produce Phosgene (COCl2). The presence

of solvents in large quantities may also pose a fire hazard. See attachment 1 of this standard for

health hazards associated with the materials produced by welding and the means to reduce or

eliminate exposure. See Attachment A of this procedure for fume protection requirements.

Fire and/or Explosion hazards and cautions


of 37

Gas, arc and/or resistance welding and cutting shall be performed in a safe area location, the

equipment and area shall be tested before work is begun. See SP-2 , for additional precautions

to be taken to minimize or eliminate fire and/or explosion hazards.

Burns

Burns form metal sparks, eve and skin damage from ultraviolet and infrared radiation (light),

electrical hazards and noise hazards. See SP-21 Appendix 11.9 of this procedure for proper PPE

selection.

http://livelink.conocophillips.net/livelink.exe?func=ll&objId=35770629&objAction=browse&sort=name&viewType=1


of 37

Appendix 11.4

RATE OF VENTILATION FOR FREELY MOVEABLE HOODS

Welding Zone Minimum air flow cubic

feet/minutes 1

Duct diameter inches 2

4 to 6 inches from arc to torch 150 3

6 to 8 inches from arc to torch 275 3.5

8 to 10 inches from arc to

torch

425 4.5

10-12 inches from arc to torch 600 5.5

Footnotes:

1. When brazing with cadmium or chromium bearing materials or when cutting on such

materials, increased rates of ventilation may be required.

2. Nearest half-inch duct diameter based on 4,000 feet per minute velocity in pipe.


of 37

Appendix 11.5

OXY-FUEL WELDING -- SAFE CYLINDER AND EQUIPMENT

HANDLING and USE PROCEDURES (Mandatory – from OSHA 1910.253)

1. Keep cylinders and all cylinder connections and parts free from oil and grease.

2. Do not handle with oily hands or gloves.

3. Never let a jet of oxygen strike an oily surface, greasy clothes, or enter a fuel oil or other

tank.

4. When transporting cylinders by crane or derrick, use a cradle, boat or suitable platform.

Do not use slings or electric magnets. Where cylinders are designed to accept a valve

protection cap, keep it in place at all times during transport.

5. Do not drop or strike cylinders, or allow them to strike each other violently.

6. Do not lift cylinders by their valve-protection caps.

7. Do not use bars under valves or caps to pry cylinders loose when stuck or fixed. Use warm

(not boiling) water to loosen cylinders frozen to the ground.

8. Unless cylinders are secured on a special truck, remove regulators and put valve-protection

caps in place before cylinders are moved.

9. Cylinders not having fixed hand wheels shall have keys, handles, or nonadjustable

wrenches on valve stems while in service. In multiple cylinder operations only one key or

handle is required for each manifold.

10. Close cylinder valves:

10.1. Before moving cylinders.

10.2. When work is finished.

10.3. On empty cylinders.

11. Keep cylinders far enough from welding or cutting that sparks, hot slag or flame will not

reach them, or provide fire-resistant shields.

12. Do not place cylinders where they might become part of an electric circuit. Keep away

from tools or equipment such as radiators, piping systems or layout tables that may be used

for grounding arc welding machines.

13. Any practice such as tapping an electrode against a cylinder to strike an arc is prohibited.

14. Never use cylinders for rollers or supports, even when empty.

15. Do not tamper with numbers or markings stamped into cylinders.

16. No person other than the gas supplier shall try to mix gases in a cylinder.

17. No one except the cylinder owner or delegate may refill a cylinder.

18. Do not tamper with safety devices in cylinders or valves.

19. Do not drop or otherwise roughly handle cylinders.

20. Unless connected to a manifold, do not use oxygen without attaching an oxygen regulator

to the cylinder valve.

21. Before connecting a regulator, open the valve slightly for an instant and then close.

22. Always stand to one side of the outlet when opening the cylinder valve.

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23. Do not use a hammer or wrench to open cylinder valves.

24. Report problems to the supplier promptly. Follow the supplier’s instructions as to the

cylinder’s disposition.

25. Avoid complete removal of the stem from a diaphragm-type cylinder valve.

26. Keep fuel-gas cylinders valve end up when in use.

27. Store and ship liquefied gases with valve end up.

28. Never crack a fuel-gas cylinder valve near active welding work or other ignition sources.

29. Before removing a regulator, close the cylinder valve and release gas from the regulator.

30. Place nothing on top of an acetylene cylinder which might damage the safety device or

interfere with quick closing of the valve.

31. If cylinders or fittings are found to be leaky, immediately take them outdoors away from

sources of ignition and empty them slowly.

32. Tag leaky cylinders and place a sign warning not to approach them with a source of

ignition. Notify the supplier promptly and follow the supplier’s instructions.

33. Never tamper with safety devices.

34. Never use fuel gas through torches without a regulator between cylinder and torch.

35. Always open cylinder valves slowly.

36. Do not open acetylene cylinders more than 1 ½ turns of the spindle (preferably no more

than ¾ of a turn).

37. If special valve wrenches are needed, leave them in position on the valve stem while the

cylinder is in use so that gas flow can be turned off quickly in case of emergency.

38. If oxygen and fuel lines are taped together for convenience and to prevent tangling, no

more than 4” in 12” may be covered with tape.

39. When they are attached to cylinder valves, inspect union nuts and regulator connections for

faulty seats before use in order to prevent gas leakage.

40. Inspect hose for leaks, burns worn places or other defects and be sure it is repaired or

replaced before using equipment.


of 37

Appendix 11.6

OXY-FUEL GAS EQUIPMENT AND STORAGE

REQUIREMENTS CHECKLIST

CYLINDERS (Mandatory – from OSHA 1910.253)

Worksite:________________________ Checked by:___________________ Date:___________

OK/

NA

ITEM Deficiency

if any

Date

Corrected

ALL CYLINDERS:

Constructed and maintained per DOT 49 CFR 171-179

Marked (preferably on shoulder) with gas chemical or trade name

Connections comply with ANSI B57.1-1965

Equipped with either means to connect a valve protection cap OR with collar or

recess to protect the valve.

CYLINDER STORAGE:

Away from radiators and other sources of heat.

(Inside buildings) location is well-protected, well-ventilated, dry and at least 20 feet

from highly combustible materials.

Stored away from elevators, stairs, and gangways.

Stored where cylinders will not be knocked over or damaged by passing or falling

objects.

Guarded from tampering by unauthorized persons.

No cylinders in unventilated enclosures.

All empty cylinders have their valves closed.

Cylinders designed to accept a cap have caps in place, hand-tight, except when in use

or connected for use.

Total gas capacity of stored cylinders (except those in use or attached ready for use)

limited to 2,000 cubic feet or 300 pounds, unless in a separate room or compartment

(see next item).

Storage (more than 2,000 cubic feet or 300 pounds) in one of the following:

o Separate room of non-combustible construction with fire-resistance rating of at

least 1 hour; continuous floor-to-ceiling walls; at least one exterior wall.

o Outside.

o In a special building.

Buildings, rooms or compartments must have no open flames and must be well-

ventilated.

Acetylene cylinders stored valve-end up. OXYGEN STORAGE:

At least 20 ft. or separated by a noncombustible barrier at least 5 ft. high with fire-

resistance rating of at least 30 minutes from:

o Highly combustible material, especially oil or grease.

o Reserve stocks of acetylene or other fuel-gas cylinders.

o Any other substance likely to cause or accelerate fire.

Oxygen cylinders separated from fuel-gas cylinders


of 37

Appendix 11.7

OXY-FUEL GAS EQUIPMENT REQUIREMENTS CHECKLIST

LOW-PRESSURE MANIFOLDS (Mandatory – from OSHA 1910.253)


OK/

NA

ITEM Deficiency

if any

Date

Corrected FUEL-GAS MANIFOLDS:

Fuel-gas cylinders connected to one manifold inside a building have total capacity no

more than 300 pounds of LPG or 3,000 cubic feet of other fuel-gas.

If capacity exceeds the above, fuel-gas cylinders are outside or in a separate room of

non-combustible construction with fire-resistance rating of at least 1 hour; continuous

floor-to-ceiling walls; at least one exterior wall OR are outdoors or in a separate

building.

Multiple manifolds in one building separated by either 50 ft. or a 5-ft noncombustible

barrier with a fire-resistance rating of at least 30 minutes.

Manifolds installed under supervision of someone familiar with the proper practices

for their construction and use.

Fuel-gas manifolds used only for the gas for which they were approved.

Indoors: Approved flash arrestors installed between coupled acetylene cylinders.

Outdoors: Approved flash arrestors installed between coupled acetylene cylinders,

OR (if no more than 3 cylinders are coupled) one flash arrestor may be installed

between the coupler block and the regulator.

Acetylene and liquefied fuel-gas cylinders are manifolded in a vertical position.

Pressure in gas cylinders connected to and discharged simultaneously through a

common manifold is approximately equal.

LOW-PRESSURE OXYGEN MANIFOLDS:

Used with cylinders with DOT service pressure no more than 200 psig.

Of substantial construction rated for use with oxygen at pressure of 250 psig.

Minimum bursting pressure of 1,000 psig.

Cylinders equipped with safety devices which relieve at max pressure of 250 psig, or

235 psig if vacuum insulation is used.

Hose and hose connections subject to cylinder pressure comply with hose

requirements below.

Hose has minimum bursting pressure of 1,000 psig.

Assembled manifold including leads has been tested and proven gas-tight at pressure

of 300 psig, using fluid which is oil-free and not combustible.

Manifold separated from fuel-gas cylinders or combustible materials (especially oil or

grease) by at least 20 feet or a noncombustible barrier at least 5 feet high with a fire-

resistance rating of at least 30 minutes.

Multiple manifolds in the same room are separated by at least 50 feet or a

noncombustible barrier at least 5 feet high with a fire-resistance rating of at least 30

minutes.

Manifolds installed under supervision of someone familiar with the proper practices

for their construction and use.

Oxygen manifolds used only for oxygen.

Sign posted at each manifold reading:

Low-Pressure Manifold

Do Not Connect High-Pressure Cylinders

Maximum Pressure – 250 psig(1.7 MPa)


of 37

Appendix 11.8


PORTABLE OUTLET HEADERS (Mandatory – from OSHA 1910.253)


OK/

NA

ITEM Deficiency

if any

Date

Corrected

PORTABLE OUTLET HEADERS:

Used indoors ONLY for temporary service where connections preclude a direct

supply from outlets located on the service piping system.

All service piping outlets supplying oxygen or fuel-gas are equipped with a readily

accessible shutoff valve.

Hose and hose connections used for connecting the portable outlet header to the

service piping shall comply with requirements for hoses and hose connections below.

Master shutoff valves for both oxygen and fuel-gas provided at the entry end of the

portable outlet header.

Portable outlet headers for fuel-gas service are provided with an approved hydraulic

back-pressure valve installed at the inlet and preceding the service outlets, unless an

approved pressure-reducing regulator, approved back-flow check valve, or an

approved hydraulic back-pressure valve is installed at each outlet.

Outlets on headers for oxygen service fitted with pressure-reducing regulators OR

fitted for direct hose connection

Each service outlet is provided with a valve assembly that includes a detachable seal

cap, chained or otherwise attached to the body of the valve.

Materials and fabrication procedures for portable outlet headers comply with

requirements for piping and fittings below.

Headers are provided with frames that support equipment securely in the correct

operating position and protect them from damage during handling and operation.


of 37

Appendix 11.9


SERVICE PIPING SYSTEMS, PAINTING AND SIGNS (Mandatory – from OSHA 1910.253)


OK/

NA

ITEM Deficiency

if any

Date

Corrected

SERVICE PIPING SYSTEMS:

Piping and fittings comply with section 2, Industrial Gas and Air Piping Systems, of

the ANSI Code for Pressure Piping ANSI B31.1-1967, unless it conflicts with any of

the requirements below.

Pipe is at least Schedule 40.

Fittings are at least standard weight in sizes up to and including 6-inch nominal.

Copper tubing is Types K or L in accordance with the Standard Specification for

Seamless Copper Water Tube, ASTM B88-6a.

Piping is steel, wrought iron, brass or copper pipe, or seamless copper, brass or

stainless steel tubing, except as provided below.

Oxygen piping and fittings at pressures more than 700 psi are stainless steel or copper

alloys.

Hose connections and hose complying with requirements in that section of this

checklist may be used to connect outlets of manifold pressure regulators to piping if

the working pressure of the piping is 250 psi or less and hose is 5 feet long or less,

and hose has a minimum bursting pressure of 1,000 psig.

Where oxygen is supplied to service piping systems from low-pressure oxygen

manifolds without intervening pressure regulating devices, piping system has a

minimum design pressure of 250 psig AND a pressure regulator is provided at each

station outlet.

Piping for acetylene or acetylenic compounds is steel or wrought iron.

No unalloyed copper is used for acetylene or acetylenic compounds except as listed

above.

Piping joints in steel or wrought iron piping are welded, threaded or flanged.

Fittings such as ells, tees, couplings and unions are rolled, forged or cast steel,

malleable iron or nodular iron.

No gray or white cast iron fittings.

Joints in brass or copper pipe are welded, brazed, threaded or flanged. If of the socket

type, they are brazed with silver-brazing alloy or similar high melting point (not less

than 8000F) filler metal.

Joints in seamless copper, brass, or stainless steel tubing are approved gas tubing

fittings or are brazed. If of the socket type, they are brazed with silver-brazing alloy

or similar high melting point (not less than 800F) filler metal.

Distribution lines installed and maintained in safe operating condition.

Piping is run as directly as practicable, protected against physical damage, proper

allowance made for expansion and contraction, jarring and vibration.

Pipe laid underground in earth is located below the frost line and protected against

corrosion.

After assembly, pipe is thoroughly blown out with air, nitrogen or CO2 to remove

foreign materials. For oxygen piping, only oil-free gases are used.

Only piping which has been welded or brazed is installed in tunnels, trenches or

ducts.


of 37

OK/

NA

ITEM Deficiency

if any

Date

Corrected

Shutoff valves are located outside of conduits (tunnels, trenches or ducts).

Good natural or forced ventilation is provided where oxygen piping and fuel-gas

piping are placed in the same tunnel, duct or trench

Low points in piping carrying moist gas:

o Are drained and pumped as needed, and equipped with drain valves.

o Drain valves have outlets normally closed with screw caps or plugs.

o No open end valves or petcocks are used except for drips located outdoors,

underground AND not readily accessible – if equipped with means to secure

them in a closed position.

o Pipes leading to ground surface are cased or jacketed as needed to prevent

loosening or breaking.

Gas cocks or valves are provided for all buildings at points where they will be readily

accessible for emergency gas supply shutoff.

Shutoff valve is provided in discharge lines from generators, gas holds, manifolds and

other sources of supply.

Shutoff valves will not interfere with operation of safety relief devices.

During installation of new piping:

o Fittings and pipe lengths are examined internally before assembly and freed from

scale or dirt if needed.

o Oxygen piping is washed out with a solution (such as hot water solutions of

caustic soda or trisodium phosphate) which will remove grease or dirt but not

react with oxygen.

o Piping is thoroughly blown out after assembly in order to remove foreign

materials. Only oil-free gases are used in oxygen lines. For other piping air or

inert gas may be used.

Sources of ignition are isolated from uncapped openings in gas lines or other

equipment which has contained flammable gases.

PAINTING AND SIGNS:

Underground pipe and tubing and outdoor ferrous pipe and tubing is covered or

painted with material which protects against corrosion.

Aboveground piping systems are marked in accordance with the ANSI Scheme for

the Identification of Piping Systems, ANSI A13.1-1956.

Station outlets are marked with the name of the gas they contain.


of 37

Appendix 11.10


PROTECTIVE EQUIPMENT, HOSE AND REGULATORS (Mandatory – from OSHA 1910.253)


OK/

NA

ITEM Deficiency

if any

Date

Corrected

PROTECTIVE EQUIPMENT, HOSE AND REGULATORS:

Used only in the service for which it was installed.

Installed and used only as recommended by the manufacturer.

Service piping is protected by pressure relief devices:

o Set to function at not more than the system design pressure.

o Discharging upwards to a safe location.

Fuel-gas and oxygen piping systems, including portable outlet headers, incorporate

protective equipment shown in the figures below. Only the portions of the fuel-gas

system that are to be used with oxygen need to comply.

Approved protective equipment (designated P(F) in the figures above) is installed in

fuel-gas piping to prevent:

o Backflow of oxygen into the fuel-gas supply system, or fuel into the oxygen

system.

o Passage of a flash back into the fuel-gas supply system.

o Excessive back pressure of oxygen into the fuel-gas supply system.

The three functions can be combined in one device or provided by separate devices.

Devices are located as shown in the figure above. Only approved devices are used.


of 37

OK/

NA

ITEM Deficiency

if any

Date

Corrected

Back-pressure protection as required above:

o Is set at no more than the pressure rating of the backflow or flashback protection

device, whichever is lower.

o Is located downstream of the backflow and flashback protection devices.

o Has a vent at least as large and the relief device inlet.

o Is installed without low points that might collect moisture, unless low points are

unavoidable, in which case drip pots with drains closed with screw plugs or caps

are installed at the low points.

Backpressure venting:

o Does not endanger personnel or property through gas discharge.

o Is located away from ignition sources.

o Ends in a hood or bend.

If pipeline protective equipment incorporates a liquid:

o Liquid levels are maintained.

o A suitable antifreeze is used if needed to prevent freezing.

Fuel gas for use with equipment not requiring oxygen is withdrawn upstream of

piping protective devices.

STATION OUTLET PROTECTIVE EQUIPMENT:

A check valve, pressure regulator, hydraulic seal, or combination is provided at each

station outlet, including portable headers, to prevent backflow, as shown in the figure

above, unless approved pipeline protective equipment is located at the station outlet.

A shutoff valve (V(F) and V(O)) is:

o Installed at each station outlet.

o Located on the upstream side of other station outlet equipment.

Station outlets equipped with a detachable regulator terminate in a union connection

that complies with Regulator Connection Standards, 1958, Compressed Gas

Association and Rubber Manufacturers Association.

Station outlets connected directly to a hose terminate in a union connection

complying with the Standard Hose Specifications, 1957, Compressed Gas Association

and Rubber Manufacturers Association.

Station outlets may terminate in pipe threads to which permanent connections are to

be made, such as to a machine.

All station outlets are equipped with a detachable outlet seal cap secured in place

which is used to seal the outlet except when a hose, regulator, or piping is attached.

No more than four torches supplied from any one station outlet, and then only if each

outlet is equipped with a shutoff valve and fuel-gas capacity from any one torch is no

more than 15 cubic feet per hour. (Does not apply to machines.)


of 37

Appendix 11.11


HOSE AND HOSE CONNECTIONS, PRESSURE-REDUCING

REGULATORS (Mandatory – from OSHA 1910.253)


OK/

NA

ITEM Deficiency

if any

Date

Corrected

HOSE AND HOSE CONNECTIONS:

Hose for oxy-fuel gas service complies with the Specification for Rubber Welding

Hose, 1958, Compressed Gas Association and Rubber Manufacturers Association.

When parallel lengths of oxygen and acetylene hose are taped together for

convenience and to prevent tangling, not more than 4” out of 12” is covered by tape.

Hose connections comply with the Standard Hose Connection Specifications, 1957,

Compressed Gas Association.

Hose connections are clamped or otherwise securely fastened so as to withstand,

without leakage, 2x service pressure, but no less than 300 psi.

Oil-free air or oil-free inert gas is used for all pressure testing of hose.

Hose showing leaks, burns, worn places, or other defects rendering it unfit for service

is repaired or replaced.

PRESSURE-REDUCING REGULATORS:

Used only for the gas and pressures for which they were intended.

Regulator inlet connections comply with the Regulator Connection Standards, 1958,

Compressed Gas Association.

Repair on regulators or regulator parts are done only by skilled mechanics who have

been properly instructed.

Gauges on oxygen regulators are marked “USE NO OIL.”

Seats on union nuts and regulator connections are intact and will not cause gas

leakage when regulators are attached to cylinder valves.


of 37

Appendix 11.12

RESISTANCE WELDING EQUIPMENT CHECKLIST (Mandatory – from OSHA 1910.255)


OK/

NA

ITEM Deficiency

if any

Date

Corrected

GENERAL REQUIREMENTS:

All equipment is installed by a Qualified Electrician in conformance with OSHA

1910 Subpart S.

Each power circuit is equipped with a safety-type disconnect or circuit

breaker/interrupter, conveniently located at or near the machine.

Ignition tubes are equipped with a thermal protection switch.

Controls of all automatic or air and hydraulic clamps are arranged or guarded to

prevent the operator from accidentally activating them.

SPOT AND SEAM WELDING MACHINES:

All external weld initiating control circuits operate on voltage not more than 120

volts.

High-voltage (over 550 V) stored-energy / capacitor discharge welding equipment:

o Insulated and completely enclosed.

o Doors are provided with interlocks and contacts wired into the control circuit.

o Equipped with a manual switch or other device for manual shutoff if automatic

interlocks fail.

All doors and access panels are kept locked and interlocked to prevent access by

unauthorized persons.

Press welding machines where there is a possibility of the operator’s fingers being

under the point of operation are guarded by electric eye, two hand controls or other

employee protection.

Shield guards of safety glass or suitable fire-resistant plastic are installed where

practicable to eliminate flying spark hazards for equipment users as well as passing

personnel.

Foot switches are guarded to prevent accidental operation of the machine.

Two or more emergency stop buttons are provided on all special multipost welding

machines, including 2-post and 4-post weld presses.

Large machines: Four safety pins and receptacles are provided to render the press

inoperative when pins are removed and inserted into the ram or platen.

Grounding:

o Where technically practical, the secondary welding transformer used in

multipost, projection and seam welding machines is grounded by permanently

grounding of the welding secondary current circuit.

o Where the above is not practical, a center tapped grounding reactor connected

across the secondary or a safety disconnect switch in conjunction with the

welding control is used. Safety disconnects are arranged to open both sides of

the line when the welding current is not present.

PORTABLE WELDING MACHINES:

Portable welding guns have counterbalanced devices to support guns and cables

unless the design of the gun or fixture makes counterbalancing impractical or

unnecessary.


of 37

OK/

NA

ITEM Deficiency

if any

Date

Corrected

All portable welding guns, transformers and related equipment which is suspended

from overhead is equipped with safety chains or cables capable of supporting the total

shock load in the event of failure of any part of the support system.

Each clevis is capable of supporting the total shock load of the suspended equipment

in case of trolley failure.

All initiating switches, including retraction and dual schedule switches, located on the

welding gun are equipped with guards to prevent accidental initiation through contact

with items such as fixtures or operator clothing.

Initiating switches do not exceed 24 volts.

Movable holders have enough clearance to prevent shearing of fingers.

Secondary and case of all portable welding transformers is grounded with a center

tapped secondary or a center tapped grounding reactor connected across the

secondary.

FLASH WELDING EQUIPMENT:

Equipped with a hood to control flying flash.

Ventilation provided in cases of high production where materials may contain a film

of oil and where toxic elements and metal fumes are given off.


of 37

Appendix 11.13

ARC WELDING EQUIPMENT OPERATION AND MAINTENANCE (Mandatory per OSHA 1910.254)

Workers assigned to operate and maintain arc welding equipment must be acquainted with

equipment requirements and with general Hot Work requirements.

1. Before starting operations, check all machine connections to be sure they are properly

made.

1.1. Work lead must be firmly attached to the work.

1.2. Magnetic work clamps must be freed of adherent metal particles of spatter on contact

surfaces.

1.3. Coiled welding cable must be spread out before use to avoid serious overheating and

damage to insulation.

2. Check welding machine frame grounding, especially for portable machines.

3. Check for leaks of cooling water, shielding gas or engine fuel. No welding permitted if

such are found.

4. Determine that proper switching equipment for shutting down the machine is provided.

5. Follow manufacturer’s printed rules and instructions for equipment operation.

6. When not in use, place electrode holders so that they cannot make electrical contact with

persons, conducting objects, fuel or compressed gas tanks.

7. Do not use cords with splices within 10 feet of the electrode holder.

8. Do not coil or loop welding electrode cable around parts of the body while welding.

9. Report any equipment defect or safety hazard to supervisor and discontinue use of

equipment until its safety has been assured.

10. Equipment repairs shall be made only by qualified personnel.

11. Machines which have become wet must be thoroughly dried and tested before being used.

12. Cables with damaged insulation or exposed bare conductors shall be replaced.

13. Join lengths of work and electrode cables by use of connecting means specifically intended

for the purpose, with insulation adequate for service conditions.


of 37

Appendix 11.14

ARC WELDING EQUIPMENT CHECKLIST (Mandatory – from OSHA 1910.254)


OK/

NA

ITEM Deficiency

if any

Date

Corrected

DESIGN:

Equipment meets design requirements of NEMA EW-1-1962 – Requirements

for Electric Arc-Welding Apparatus, National Electrical Manufacturers

Association, OR Safety Standard for Transformer-Type Arc-Welding

Machines, ANSI C33.2-1956, Underwriters’ Laboratories.

Arc welding machines are designed and constructed to carry their rated load

with rated temperature rises where cooling-air temperature does not exceed

104F and where altitude does not exceed 3,300 feet.

Arc welding equipment is suitable for operation in atmospheres containing

dust, gases, and light rays produced by the welding arc.

Arc welding equipment meets special requirements for unusual service

conditions in which it is operated, such as exposure to:

o Unusually corrosive fumes.

o Steam or excessive humidity.

o Excessive oil vapor.

o Flammable gases.

o Abnormal vibration or shock.

o Excessive dust.

o Weather.

o Unusual seacoast or shipboard conditions.

Voltage limits as below are not exceeded:*

o AC Manual arc welding and cutting – 80 V.

o AC Automatic (machine or mechanized) arc welding and cutting – 100 V.

o DC Manual arc welding and cutting – 100 V.

o DC Automatic arc welding and cutting – 100 V.

* When special processes require values higher than the above, operator is

protected from making accidental contact with the voltage by adequate

insulation or other means.

AC welders used under wet conditions or warm surroundings where

perspiration is a factor are equipped with reliable automatic controls for

reducing no-load voltage.

Controllers on electric motor-driven welders:

o Are integrally mounted.

o Have capacity for carrying rated motor current.

o Are capable or making and interrupting stalled rotor current of the motor.

o May serve as the running over current device if provided with the number

or over current units as specified by OSHA Subpart S.

All arc welding controls are enclosed except for operating wheels, levers, or

handles.

Input power terminals, tap change devices and live metal parts connected to

input circuits are completely enclosed and accessible only by means of tools.


of 37

OK/

NA

ITEM Deficiency

if any

Date

Corrected

Terminals for welding leads are protected from accidental electrical contact

by personnel or metal objects (such as vehicles or crane hooks) by use of one

or more of the following:

o Dead-front receptacles for plug connections.

o Recessed openings with nonremovable hinged covers.

o Heavy insulating sleeving or taping.

o Other equivalent electrical and mechanical protection.

Welding lead terminals intended to be used exclusively for connection to the

work and connected to the ground enclosure are connected by a conductor at

least two AWG sizes smaller than the grounding conductor AND terminal is

marked to show it is grounded.

No connections for portable control devices such as handheld pushbuttons are

connected to AC circuits higher than 120 V.

Exposed metal parts of portable control devices on circuits above 50 V are

grounded by a grounding conductor in the control cable.

Auto transformers or AC reactors are not used to draw welding current

directly from any AC power source exceeding 80 V.

INSTALLATION:

Installation including power supply is in accordance with OSHA 1910

Subpart S.

Grounding:

o Welding machine frame or case (except engine-driven machines) is

grounded according to OSHA 1910 Subpart S.

o No conduits containing electrical conductors are used for completing a

work-lead circuit.

o Pipelines are not used as permanent parts of work-lead circuits (Note:

these may be used temporarily during construction, extension or repair

providing current is not carried through threaded joints, flanged bolted

joins, or caulked joints and that precautions are used to avoid sparking at

the work-lead cable connection).

o No chains, wire ropes, cranes, hoists or elevators are used to carry

welding current.

o Structures, conveyors or fixtures regularly used as welding current return

circuits are bonded or provided with adequate current collecting devices.

o Ground connections are mechanically strong and electrically adequate for

the required current (verified by periodic checks).

o Welding machines not equipped with integrally mounted disconnects are

provided with a switch or controller meeting OSHA 1910 Subpart S, at or

near each welding machine.

o Each outlet intended for connection to a portable welding machine is

provided with a disconnect switch for overload protection or equivalent

protective means.

For individual welding machines, the rated current-carrying capacity of the

supply conductors is not less than the rated primary current of the machine.

For groups of welding machines, the rated current-carrying capacity of

conductors may be less than the sum of the rated primary currents of the

welding machines supplied IF welding machines will not all be in use at the

same time.


of 37

OK/

NA

ITEM Deficiency

if any

Date

Corrected

In operations involving several welders on one structure, DC welding process

equipment may require use of both polarities, or supply circuit limitations of

AC welding may require distribution of machines among the phases of the

supply circuit. In such cases no load voltages between electrode holders will

be:

o 2 x normal in DC machines.

o 1, 1.41, 1.73 or 2 x normal in AC machines.

Similar voltage differences will exist if both AC and DC welding are done on

the same structure.

All DC machines are connected with the same polarity.

All AC machines are connected to the same phase of the supply circuit and

with the same instantaneous polarity.


of 37

Appendix 11.15

HEALTH HAZARDS AND FUME PROTECTION REQUIREMENTS ASSOCIATED WITH WELDING, CUTTING, SOLDERING AND BRAZING*

*Reference Respiratory Protection Procedure and PPE Procedure and all applicable craft specific procedures for more details.

HAZARD OEL HEALTH HAZARD SYMPTOM ASSOCIATED WITH OVER EXPOSURE

OUTSIDE SHOP/ENCLOSED BUILDING CONFINED

SPACES

Aluminum (Al) 5 mg/m3 Absorbed in the lungs and may result in a

disease of the lungs call pneumoconiosis or "dusty lungs".

Irritation of skin, eyes, nose, and throat. Natural ventilation in large open area. Mechanical Ventilation Conditions may warrant respirators.

Mechanical Ventilation and/or Airline respirators

Beryllium (Be) 0.002 mg/m

3

May result in lung damage. Similar to asbestos, damage may not show up for several years after excessive exposure,

(Be) is suspected carcinogen.

Respiratory tract irritation, weakness, fatigue, and weight loss.

Exhaust hoods and Airline respirators. Air Purifying Respirators With Local Exhaust or

Airline Respirators with No Mechanical Ventilation

Mechanical Ventilation. Airline

Respirators shall be required.

Cadmium (Cd) 0.002 mg/m

3

May cause bronchitis, pneumonitis, and pulmonary edema. Liver, kidney, or bone marrow may also be injured. (Cd) is a

suspected carcinogen.

Respiratory tract irritation accompanied by sore throat, and a metallic taste in

the mouth. Coughing, chest pain, nausea, headache, diarrhea, and labored breathing may follow over

exposure.

Natural ventilation and respirators in large open areas.

Air Purifying Respirators With Local Exhaust or




Chromium VI (Cr)

0.005 mg/m

3

Is suspected to cause lung cancer and has been associated with blood, liver, and

kidney disorders.

May cause coughing, edema and bronchitis. Some oxides of chromium can produce small painless skin ulcers

and dermatitis.






Carbon Monoxide

(CO)

25 ppm Combines with the hemoglobin in the blood, interfering with the up-take of (O2)

causing a form of anoxia.

Headaches, possible dizziness, and a general discomfort.

Natural ventilation in large open area. Mechanical Ventilation or Airline Respirators


Copper (Cu) 0.1 mg/m3 Irritation of the upper respiratory tract.

May also cause metal fume fever. Metallic or sweet taste in the mouth,

nausea, and in some instances, it may cause discoloration of the hair and skin.





Fluorides 2.5 mg/m3 Inhalation of high concentration of fluoride

dust or fumes may produce respiratory tract irritation. Fluorides may also be

absorbed into the bones.

Chills, fever, shortness of breath (dyspnea), coughing, eye irritation,

nausea, thirst, and sweating.

Natural ventilation in large open areas. Respirator may be required.

Exhaust hoods or Airline Respirators Exhaust hoods and/or

Airline Respirators

Iron Oxide (Fe203)

5 mg/m3 May cause a benign pneumoconiosis

referred as siderosis. It is not disabling but could be mistakenly diagnosed as

tuberculosis or silicosis when X-rays are examined.

Some scientists believe a symptom of over exposure may be stomach

cramps.

Natural ventilation in large open areas. Mechanical Ventilation. Air Purifying Respirators may be required.

Mechanical Ventilation. Airline Respirators may be

required.

Lead (Pb) .05 mg/m3 An accumulation of lead may cause

serious damage to the liver, spleen, kidneys, heart, lungs, brain, muscles, skeletal and reproductive systems.

Lead poisoning includes abdominal pain, headaches, weakness, muscular

aches or cramps, loss of appetite, nausea and vomiting.


Exhaust hoods or Airline Respirators Exhaust hoods and Airline Respirators


of 37

HAZARD OEL HEALTH HAZARD SYMPTOM ASSOCIATED WITH OVER EXPOSURE

OUTSIDE SHOP/ENCLOSED BUILDING CONFINED

SPACES

Manganese (Mn)

0.2 mg/m3 Irritating to the upper respiratory tract and

eyes. May also cause chronic effects to the nervous system.

Freshly formed fumes may cause symptoms similar to those experienced with metal fume fever, chills and fever. Mental confusion, dry throat, coughing, tightness in the chest and shortness of

breath may also occur.

Natural ventilation in large open areas. Air Purifying Respirators With Local Exhaust or



required.

Magnesium (Mg)

10 mg/m3 May induce metal fume fever. Slows the

body natural healing process. Eye and nose irritation. Wounds,

scratches, or cuts contaminated with (Mg) healing process is slowed down.

Natural ventilation in large open areas. Air Purifying Respirators With Local Exhaust or



required.

Mercury (Hg) 0.025 mg/m

3

May cause bronchitis, pneumonitis, gastrointestinal disorders, and anorexia.

Cough, chest pain, shortness of breath, tremors, insomnia, and eye and skin

irritation.


Exhaust hoods or Airline Respirators Exhaust hoods and Airline Respirators

Nickel (Ni) .1 mg/m3 Studies have shown that (Ni) dust and

fumes introduced into the pleural cavity, muscle and subcutaneous tissue of laboratory animals have resulted in

cancer.

(Ni) eczema or "nickel itch" is common in welders using nickel compounds. Headaches, dizziness, nausea, and

weakness.






Ozone (03) 0.1 ppm Respiratory diseases may occur years after excessive exposure. Irritating to the

respiratory tract, eyes, mucous membranes and mainly irritating to the

lungs.

Less severe exposu4re may produce headaches, malaise, shortness of

breath, and drowsiness.

Natural ventilation in large open areas. Local Exhaust Ventilation or Airline Respirators


Phosgene (COCI2)

{Decomposition of

Trichloroethylene}

0.1 ppm May cause eye and upper respiratory tract irritation, fluid build - up in the lungs,

oxygen deficiency to the blood and dermatitis.

Dry burning throat, vomiting, coughing, foamy saliva, shortness of breathe, chest pain, bluish or purplish skin discoloration, and burn to the skin.


Exhaust hoods and Airline Respirators Exhaust hoods and Airline Respirators

Phosphorus (P4)

.02ppm May cause eye and respiratory tract irritation, jaundice, anemia, dental and jaw

pain.

Nausea, abdominal pain, excessive saliva, and burns to skin and eyes.


Exhaust hoods and Airline Respirators

Exhaust hoods and Airline Respirators

Tin (Sn) 2 mg/m3 Inorganic (Sn) may result in "stannosis", a

benign dust disease. Stannosis is a form of pneumoconiosis. There has been no

evidence of disability or special complicating factors.

Eye and skin irritation. Natural ventilation in large open areas. Local Exhaust Ventilation or Airline Respirators


Titanium Dioxide (TiO2)

10 mg/m3 Slight lung fibrosis may form. (Ti) is a

suspected carcinogen. Irritation of mucous membranes, eyes,

nose and throat. Natural ventilation in large open areas. Local Exhaust. Respirators

may be required. Mechanical

Ventilation and/or Airline respirators

Vanadium (V) 0.05 mg/m3 Can cause "green tongue", paleness,

physical deterioration of the body. Irritation to the respiratory tract

Soar throat, coughing, bronchitis and chest pains. Shortness of breath and

eye irritation may occur.

Natural ventilation in large open areas. Local Exhaust. Respirators may be required.



of 37

Appendix 11.16

PERSONAL PROTECTIVE EQUIPMENT REQUIRMENTS FOR WELDING, CUTTING, SOLDERING AND BRAZING*

*Reference Respiratory Protection Procedure and PPE Procedure and all applicable craft specific procedures for more details.

HAZARD/TASK RESPIRATOR CLOTHING GLOVES EYES/FACE FOOTWEAR HAT OTHER

CUTTING – UV RADIATION

See Cutting –

Fumes & Gases

Goggles or

Welding Hood MINIMUM

OXYGEN-ACETYLENE:

Light(Plate < 1” thick)

Medium(Plate 1”-6” thick)

Heavy(Plate > 6” thick)

FRC Leather

Leather

Leather or Welding Welding

Welding

SHADE NUMBER

3 4

5

Leather Leather

Leather

Hard Hard

Hard

AIR CARBON/ARC(Gouging):

Light ( < 500 Arc Current)

Heavy (500-1000 Arc Current)

Leather

Leather

Welding

Welding

10

11

Leather

Leather

Hard

Hard

Flash Curtains or

Equivalent Shielding

Hearing Protection

Device(s) PLASMA ARC:

Light < 300 Arc Current

Medium (300-400 Arc Current)

Heavy (400-800 Arc Current)

Leather

Leather

Leather

Welding

Welding

Welding

8

9

10

Leather

Leather

Leather

Hard

Hard

Hard

WELDING – UV RADIATION

OXYGEN-ACETYLENE WELDING:

Light(Plate <1/8” thick)

Medium (Plate 1/8” – ½” thick)

Heavy (Plate > ½” thick)

See Welding – Fumes & Gases

Leather

Leather

Leather

Welding

Welding

Welding

Welding Hood

MINIMUM

SHADE NUMBER 4

5

6

Leather

Leather

Leather

Hard

Hard

Hard

Flash Curtains or

Equivalent Shielding

SHIELDED METAL ARC WELDING

(Rod or Electrode):

Rod < 3/32” & < 60 Arc Current

Rod 3-5/32” & 60-160 Arc Current Rod 5-8/32” & 160-250 Arc Current

Rod > 8/32” & 250-550 Arc Current

Leather

Leather

Leather Leather

Welding

Welding

Welding Welding

7

8 10

11

Leather

Leather

Leather Leather

Hard

Hard

Hard Hard


of 37

HAZARD/TASK RESPIRATOR CLOTHING GLOVES EYES/FACE FOOTWEAR HAT OTHER

WELDING-UV RADIATION

Welding Hood

MINIMUM SHADE

NUMBER

Flash Curtains

or Equivalent Shielding

GAS METAL ARC WELDING (MIG):

< 60 Arc Current 60-100 Arc Current

160-250 Arc Current

250-500 Arc Current

See Welding –

Fumes & Gases

FRC FRC

Leather

Leather

Welding Welding

Welding

Welding

10 10

10

10

Leather Leather

Leather

Leather

Hard Hard

Hard

Hard

GAS TUNGSTEN ARC WELDING (TIG):

< 50 Arc Current

50-150 Arc Current

150-500 Arc Current

FRC

FRC

Leather

Welding

Welding

Welding

10

10

10

Leather

Leather

Leather

Hard

Hard

Hard

PLASMA ARC WELDING:

< 20 Arc Current

20-100 Arc Current 100-400 Arc Current

400-800 Arc Current

Leather

Leather Leather

Leather

Welding

Welding Welding

Welding

6

8 10

11

Leather

Leather Leather

Leather

Hard

Hard Hard

Hard

TORCH BRAZING FRC Leather 3 Leather Hard

TORCH SOLDERING FRC Leather 2

Leather

Hard

CARBON ARC WELDING Leather Welding 14

Leather Hard

Respirator Type Respirator Cartridges

1 – Air Purifying, Half Face 4 – OV / AG or Multi Gas

2 – Air Purifying, Full Face 5 – P100

3 – Supplied Air 6 – OV / AG / P100 or Multi Gas P100


of 37

HAZARD / TASK RESPIRATOR RESPIRATOR RESPIRATOR

WELDING – FUMES & GASES

SHOP

FIELD

CONFINED SPACES

Good Ventilation

Poor Ventilation

Good Ventilation

Poor Ventilation

Good Ventilation

Poor Ventilation

OXYGEN-ACETYLENE

Carbon Steel

Other Alloys

None

None

(1) (5)

(1) (5)

None

None, except for

Galvanized (1)(5)

(1)(5)

(1)(5)

(1)(6)

(1)(6)

(3)

(3)

SHIELDED METAL ARC WELDING (Rod or

Electrode)

Carbon Steel Other Alloys

None None

(1)(5) (1)(5)

None None

(1)(5) (1)(6)

(1)(5) (3)

(3) (3)

GAS METAL ARC WELDING (MIG)

Carbon Steel

Other Alloys

None

None

(1)(5)

(1)(5)

None

None

(1)(5)

(1)(6)

(1)(5)

(3)

(3)

(3)

GAS TUNGSTEN ARC WELDING (TIG)

Carbon Steel Other Alloys

None

None

(1)(5)

(1)(5)

None

None

(1)(5)

(1)(6)

(1)(5)

(3)

(3)

(3)

Respirator Type Respirator Cartridges

1 – Air Purifying, Half Face 4 – OV / AG or Multi Gas

2 – Air Purifying, Full Face 5 – P100

3 – Supplied Air 6 – OV / AG / P100 or Multi Gas P100

NOTE: All Hot work (Cutting, Grinding, Welding) on alloy metals must comply with the Hexavalent

Chromium Standard (Under Development)

ehs procedure: s-07-01-s page 1 of 37

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