Welding and Cutting S.O.P. 3F
Welding and Cutting S.O.P. 3F
Welding and Cutting S.O.P. 3F
TABLE OF CONTENTS
I. Scope and Purpose II. Related Procedures and Resources III. Personnel Responsibility IV. Personal Protective Equipment V. Fire Prevention and Protection VI. Prohibited Practices VII. Ventilation VIII. Confined Spaces IX. Handling, Storage and Operation of Compressed Gas Cylinders X. Arc Welding Requirements XI. Capacitor Discharge Stud Welder Attachment 3F.1a, Radiant Energy Filter Lenses (Welding Type) Attachment 3F.1b, Radiant Energy Filter Lenses (Welding and Cutting Plate Thickness)
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III.
PERSONNEL RESPONSIBILITY
A. Supervisor 1. It is the supervisors responsibility to read and understand this policy, which will provide him/her with the knowledge to recognize hazards and safe work practices to be followed during welding and cutting operations. 2. To enforce the procedures in this policy, which will ensure compliance with this S.O.P. 3. To ensure employees receive training on required topics. 4. To conduct documented monthly inspection and mark all welding cables, leads, hoses and attachments associated with their use on a quarterly basis using Appendix Form 2C.2a, Quarterly Inspections Color Code Chart. The supervisor may designate an employee to conduct these inspections. Employee 1. It is the employees responsibility to follow the safe work practices outlined in this S.O.P. 2. To report any recognized hazards associated with welding and cutting to his/her supervisor. 3. To conduct daily visual inspections of all welding cables, leads and hoses and attachments prior to using them. Logistical Support 1. It is the responsibility of Logistics Support to conduct documented inspections upon receipt and shipping of welding cables, leads, hoses and attachments.
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NOTE: All welding cables, leads and hoses shall be marked immediately before being shipped for next field job. The Operators Manual and any grounding equipment (i.e., grounding rods, clamps, wire, etc.) shall be shipped to field jobs with the welding machine.
IV.
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Wearing jewelry is prohibited as per S.O.P. 3G (IV)(F), e.g., watches, necklaces, and body rings of any type. Personnel needing Medical ID tags shall take necessary action against hazardous energy, i.e., electric shock. Minimum Safety Equipment - Fitters: 1. Long sleeve shirts (not of polyester or nylon) or welding leathers. 2. Welders gloves. 3. Safety glasses with side shields. 4. Sturdy work shoes as per S.O.P. 3G (V). 5. Wearing jewelry is prohibited as per S.O.P. 3G (IV)(F), e.g., watches, necklaces, and body rings of any type. Personnel needing Medical ID tags shall take necessary action against hazardous energy, i.e., electric shock.
NOTE: Periodically check welding hoods to ensure light-tight since welding operations emit intense ultraviolet radiation. Additional PPE, such as Respiratory Protection, flash protection, or goggles may be required in some areas.
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B.
VI.
PROHIBITED PRACTICES
A. No welding, cutting, or other hot work shall be performed on used drums, barrels, Welding and Cutting S.O.P. 3F
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tanks or other containers until they have been cleaned so thoroughly as to make absolutely certain that there are no flammable materials present or any substance such as greases, tars, acids or other materials, which subjected to heat, might produce flammable or toxic vapors. Any pipelines or connections to the drum or vessel shall be disconnected or blanked. NOTE: The owner or their representatives shall approve welding or cutting task on equipment, vessels, valves, nipples or piping that holds the potential of affecting industrial processes with in the paper/pulp, power, marine or petrochemical industry.
VII.
VENTILATION
A. Ventilation for General Welding and Cutting 1. Consult with a safety representative of the company to determine ventilation requirements. The following factors shall be considered: a. Dimension of space in which welding and cutting is to be done (with special regard to height of ceiling). b. Number of welders and cutters. c. Possible evolution of hazardous fumes, gases or dust according to the metals involved. d. Atmospheric conditions. e. Heat generated. f. Presence of volatile solvents. 2. Mechanical ventilation shall be provided when welding or cutting under the following conditions: a. A space of less than 10,000 cu. ft. per welder. b. A room having a ceiling height of less than 16 ft. c. Confined spaces or where the welding space contains partitions, balconies or other structural barriers to the extent that they significantly obstruct cross ventilation. 3. Natural ventilation is considered sufficient for welding or cutting operations where restrictions in section (VII)(A)(1) are not present. Beryllium 1. Welding or cutting indoors, outdoors or in confined spaces involving beryllium, containing base or filler metals, shall be done using local exhaust ventilation and air-line respirators unless atmospheric tests have established that the workers exposure is within the acceptable concentrations defined by the United States of America Standards Institute or the American Conference of Governmental Industrial Hygienist. 2. Workers in the immediate vicinity of the welding or cutting operations shall be protected as necessary by local exhaust ventilation or airline respirators. Cadmium 1. Welding or cutting indoors, outdoors or in confined spaces involving cadmium-bearing or cadmium-coated base metals shall be done using local exhaust ventilation and air-line respirators unless atmospheric tests Welding and Cutting S.O.P. 3F
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have established that the workers exposure is within the acceptable concentrations defined by the United States of America Standards Institute or the American Conference of Governmental Industrial Hygienist. Outdoors such operations shall be done using respiratory protective equipment such as fume respirators approved by the U S Bureau of Mines. Welding involving cadmium-bearing filler metals shall be done using freely movable hoods, airline respirators or hose masks.
Lead 1. Welding and cutting on suspected lead containing surfaces and/or material is prohibited. The following shall be utilized if the metal or surface preparations are unknown or if there is reasonable suspicion of containing lead. a. Contact client for material verification. b. Request past sample data. c. Sample 2. Lead containing material shall be abated a minimum of 18 inches from any surface preparation containing lead. Personnel are required to follow S.O.P. 7A, Abrasive Blasting and S.O.P. 8C, Lead Abatement.
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closed. Valve protection caps shall always be in place, hand tight, except when cylinders are in use or connected for use. 3. Cylinders shall not be placed where they may become part of an electric circuit. Avoid contact with third rails, trolley wires, etc. Cylinders shall be kept away from radiators, piping systems, layout tables, etc., that may be used for grounding electric circuits. Any practice such as the tapping of an electrode against a cylinder to strike an arc is prohibited. 4. To keep cylinders from being knocked over while in use, suitable cylinder truck, chain or steadying device shall be used. 5. Slings or electric magnets shall not be used when transporting cylinders by a crane or derrick. Valve caps, shall always be in place where cylinders are designed to accept a cap. 6. When cutting is performed above other workers, suitable protection shall be provided to prevent injury from falling sparks, slag or molten metal to those below the cutting operation, e.g., welding blankets. General Storage of Cylinders 1. Cylinders shall be kept away from sources of heat. 2. Cylinders shall be stored in well protected, well ventilated, dry locations, at least 20 feet away from highly combustible materials, e.g., oil, gasoline, etc. 3. Cylinders shall be sorted and in assigned places away from elevators, stairs or gangways, with appropriate signage designating the area as cylinder storage. 4. Storage spaces shall be located where cylinders will not be knocked over or damaged by passing or falling objects, or subject to tampering with by unauthorized personnel. 5. Cylinders of oxygen and fuel-gas shall be used in rotation as received from the supplier. 6. Empty cylinders shall have their valve closed. Storage of Fuel-Gas Cylinders 1. Acetylene is unstable and potentially explosive under certain conditions. Precautions when dealing with it include: a. Limit regulators to a maximum of 12-psi delivery pressures. This must be accomplished thorough the use of commercially available regulators. b. Always use and store in the vertical position. c. At no time shall the withdrawal rate of an individual acetylene cylinder exceed 1/7th of the cylinder contents per hour. If additional flow capacity is required, as in multi-flame heating nozzle use, it may be necessary to use a different fuel gas. d. Any time regulators are pressured up; the handle must be in place on the acetylene bottle. e. Open cylinders a maximum of one complete turn. 2. MAPP gas is a stabilized mixture of methyl-acetylene and has 2. Welding and Cutting S.O.P. 3F
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considerably fewer tendencies to backfire than acetylene. 3. Maximum allowable use pressure is 94 psig. Storage of Oxygen Cylinders 1. Pure oxygen accelerates combustion. Oil, grease, and other flammables become highly explosive in the presence of oxygen. To avoid this condition, dedicated regulators must be used for oxygen cylinders. Setting Up Equipment 1. Ensure all connections are free of dirt, dust, oil, or grease. 2. Ensure there is no tension on the regulator adjusting screws. 3. Ensure the use of a dedicated regulator for oxygen, as stated above. 4. Slowly open fuel gas cylinder valve (maximum of one (1) turn for acetylene, completely open for MAPP gas). 5. Check all connections for leaks. Lighting the Torch 1. Open the oxygen valve on the torch handle and adjust the oxygen regulator to the desired pressure. 2. Allow gas to flow (10 seconds for every 50 feet of hose). 3. Close oxygen valve on the torch. 4. With the tension released on the regulator adjustment screw, open cylinder fuel valve (maximum one (1) turn for acetylene, full open for MAPP gas). 5. Open the fuel gas valve on the torch and adjust the fuel gas regulator to the desired setting. 6. Allow gas to flow (10 seconds for every 50 feet of hose). 7. Close the torch fuel control valve. 8. Holding the torch in one hand and the striker in the other; open the torch fuel valve about one-half turn and ignite the gas. 9. Keep opening the fuel valve until the flame stops smoking and leaves the end of the tip about 1/8 inch, then slightly reduce the fuel supply to bring the flame back to the tip 10. Open torch oxygen valve until a bright neutral flame is observed.
NOTE: If backfire or flashback occurs, immediately turn off the oxygen valve then the fuel valves. Repeat above steps. G. Shutting off the Torch 1. Shut off the torch oxygen valve then the fuel valve. 2. Close both cylinder valves. 3. Open the torch oxygen valve and release the pressure in the system, then close valve. 4. Release the adjusting screw on the regulator. 5. Repeat steps 3 and 4 for the fuel system. General Maintenance Welding and Cutting Operations 1. Cylinders, cylinder valves, couplings, and regulators shall be kept free from oily or greasy substances. 2. Oxygen cylinders shall not be handled with oily hands or gloves. 3. Oxygen must never be permitted to strike oily surface, greasy clothes, or Welding and Cutting S.O.P. 3F
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enter a fuel oil or other storage tank. No welding, cutting or other hot work shall be performed on used drums, barrels, tanks or other containers until they have been thoroughly cleaned, as to make certain that there are no flammable materials present or any substances that when subjected to heat may produce flammable or toxic vapors.
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C.
frame or other satisfactory ground. Alternatively it may be done by grounding the work lead at or near the welding machine. Care shall be taken, however, to avoid double grounding as otherwise welding current may flow through a connection intended only for safety grounding and may be of higher magnitude than the grounding conductor can safely carry. 3. Welding current preferably shall be returned to the welding machine by a single cable from the work to the welding machine. Connection of a cable from the welding machine to a common conductor or structure on which the work rests, or to which the work is connected, is a permissible procedure. 4. Conduits containing electrical conductors shall not be used for completing a work lead circuit. Pipe lines shall not be used as a permanent part of a work lead circuit, but may be used during construction, extension or repair providing current is not carried through threaded joints, flanged bolted joints or caulked joints and that special precautions are used to avoid sparking at connection of the work lead cable. 5. Chains, wire ropes, cranes, hoists and elevators shall not be used to carry welding current. 6. During construction or modification, a building or any other fabricated metal structure that is used for a welding current return circuit, shall be checked to determined whether proper electrical contact exists at all joints. Sparking or heating at any point shall cause rejection of the structure as a return circuit. 7. All ground connections shall be checked to determine that they are mechanically strong and electrically adequate for the required current. 8. When it becomes necessary to carry cables some distance from the machines, if practicable they shall be substantially supported overhead. If this cannot be done, and cables are laid on the floor or ground, they shall be protected in such a manner that they will not be damaged, entangled or interfere with safe passage. 9. For individual welding machines, the rated current-carrying capacity of the supply conductors shall not be less than the rated primary current of the welding machines. Operation and Maintenance 1. Before starting operations, all connections to the machine shall be checked to make certain they are properly made. The work lead shall be firmly attached to the work. Coiled welding cable shall be spread out before use to avoid serious overheating and damage to insulation. 2. Grounding of the welding machine frame shall be checked with special attention given to safety ground connections of portable machines. 3. There shall be no leaks of cooling water, shielding gas or engine fuel. 4. Printed rules and instructions covering operation of equipment, supplied by the manufacturers, shall be strictly followed. 5. When the welder has occasion to leave his work or stop work for any appreciable time, or when the machine is to be moved, the power supply Welding and Cutting S.O.P. 3F
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switch in the equipment shall be open. The equipment shall be disconnected from the source of power when not in use. 6. Metal and carbon electrodes shall be removed from holders when not in use to eliminate danger of electrical contact with persons or conducting objects. Tungsten electrodes shall be removed or retracted within holders. Electrodes in wire form, in semi-automatic holders shall be retracted or cut off to remove possibility of contact. Electrode holders when not in use shall be placed so that they cannot make electrical contact with persons, conducting objects, fuel or compressed gas tanks. 7. The operator shall report any equipment defect or safety hazard to his/her supervisor. 8. Welding equipment used in the open shall be protected from inclement weather conditions. Protective cover shall not obstruct the ventilation necessary to prevent overheating of the machine. 9. Work and electrode lead cables shall be frequently inspected for wear and damage. Cables with damaged insulation or exposed bare conductors shall be replaced. Joining lengths of work and electrode cables shall be done by the use of connecting means specifically intended for the purpose. The connecting means shall have insulation adequate for the service conditions. 10. Welding cables shall be kept dry and free from grease and oil. Electric Shock 1. Avoidance of electric shock is largely within the control of the welder, therefore, it is especially important that he be thoroughly instructed in detail how to avoid shock Because most contacts required for welding voltages have not caused severe injury or electric shock, parts having these voltages are liable to be handled carelessly. These voltages are nevertheless sufficiently high that, under some circumstances, they may be dangerous to life. Even mild shocks, not dangerous in themselves from normal working voltage or from high frequency stabilizers, can cause involuntary muscular contraction, leading to injurious falls from high places. Generally the path and amount of current flowing through the body determine the severity of shock. The voltage and contact resistance of the area of skin involved determine this. Clothing damp from perspiration or wet working conditions may so reduce contact resistance as to increase an imperceptible current to a value high enough to cause such violent muscular contraction as to prevent the welder form letting go of the live part. 2. The welder shall never permit the live metal parts of an electrode holder to touch his bare skin or any wet covering on his body. Adequately dry gloves are also recommended. He shall not use electrode holders for manual shielded metal-arc welding without well-insulated jaws in good repair. Whenever changing electrodes in gas tungsten-arc electrode holders, or whenever threading coiled electrodes into gas metal-arc equipment, the welding machine supplying power to the arc, must always be turned off. Special precautions shall be taken to prevent shock-induced Welding and Cutting S.O.P. 3F
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falls when the welder is working above ground level (refer to S.O.P. 3O, Fall Hazard Management). Cables with splices within 10 ft. of the holder shall not be used.
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attaching Ground Clamp to a clean area of the work piece. Metal Preparation 1. Prior to welding, surface area will be thoroughly cleaned to accommodate CD weld pins.
S.O.P. 3F
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Attachment 3F.1a
7 8 10 11
7 10 10 10
8 8 10
(Light) (Heavy)
10 11
6 8 10 11
8 9 10
3 2 14
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Attachment 3F.1a
4 5 6
Under 1 1 to 6 Over 6
3 4 5
Footnote(*) As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxy-fuel gas welding or cutting where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line in the visible light of the (spectrum) operation. Footnote(**) These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the work-piece.