Pannier Corporation

Health and Safety Handbook

Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
11/13/1995 25 5/20/2013 1 of 16

Welding and Hot Work Safety Plan

Scope: This Welding and Hot Work Safety Plan (known as the "Plan") addresses welding,
cutting, brazing, and related hot work operations capable of initiating fires or
explosions, creating toxic fumes, or generating heat or molten flying objects that could
injure workers. Examples of hot work processes covered under this Plan include:

• Welding (arc, oxygen-fuel gas, and resistance)

• Cutting (arc, oxygen, and torch)

• Open-flame soldering

• Brazing

• Grinding

• Heat treatment

• Hot riveting

• Other applications that may generate a spark, flame, or heat

This Plan does not cover additional requirements for hot work operations in confined
spaces or lockout/tagout procedures during hot work. See the Confined Space Entry Plan and
Lockout/Tagout Plan for more information about such operations.

Policy: It is the policy of Pannier Corporation to protect all personnel and property from
fire, explosion, and other recognized hazards of welding, cutting, brazing, and related
hot work operations.

PLAN ADMINISTRATION

The Program Contact Information table provides the roles and contact information for the
administration of this Plan.

Program Contact Information

[Modify the table as applicable to your organization.]

Task Contact Person Contact Information
Plan Administrator Bob Barker 412-492-1400 Ext. 315
Supervisor Rick Smith 412-492-1400 Ext. 344
Plan Administrator. The Plan Administrator or designee is responsible for the safe
operation of welding and related hot work activities, and developing and maintaining this
written Plan. The Administrator or designee will:

• Conduct hazard assessments for all work areas where hot work is performed and welding,
cutting, and brazing equipment is used and stored, and ensure that hazard assessments
conducted by contractors or consultants submit them to the Administrator or designee.

• Establish areas for cutting and welding, and establish procedures for cutting and
welding in other areas on the basis of fire potential of the facilities.

• Designate an individual responsible for authorizing cutting and welding operations in

areas not specifically designed for such processes.
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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• Ensure that cutters, welders, and their supervisors are suitably trained in the safe
operation of their equipment and the safe use of the process.

• Advise all contractors about flammable materials or hazardous conditions of which they
may not be aware.

Supervisor. The Supervisor will:

• Be responsible for the safe handling of the cutting or welding equipment and the safe
use of the cutting or welding process.

• Determine whether combustible materials are present or likely to be present in the work
location.

• Protect combustibles from ignition according to safe practices described in this Plan.

• Secure authorization for the cutting or welding operations from the Administrator or
designated representative.

• Ensure that the cutter, welder, or hot work operator secures the approval of the
Supervisor that conditions are safe before going ahead.

• Determine that fire protection and extinguishing equipment are properly located at the
site.

• Ensure fire watch personnel are available at the site when required.

Operators of welding, cutting, or other hot work equipment. The cutter, welder, or hot
work operator will:

• Conduct hot work only after specific written approval from the Administrator or
designee.

• Handle all hot work and related equipment safely and perform work so as not to endanger
lives and property.

• Cease hot work operations if unsafe conditions develop.

• Notify the Administrator or designee for reassessment of the situation in the event of
suspected unsafe conditions or concerns expressed by affected persons.

Plan Review and Update

This Plan will be reviewed and updated:

• Annually

• Whenever there is a change in federal or state rules related to welding, cutting,

brazing, or other hot work operations

• Whenever there is a change in facility operations related to the use, handling, or

storage of welding equipment and supplies

• Whenever equipment operators demonstrate a lack of understanding or skill to perform

welding or other hot work operations safely

DEFINITIONS
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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Fire watch means an individual or individuals whose primary responsibility is the

surveillance of all exposed areas to ensure that safe conditions are maintained during hot
work.

Hot work means any work involving burning, welding, cutting, brazing, or similar
operations capable of initiating fires, explosions, noxious fumes, or molten flying
objects.

Hot work permit means written authorization to perform hot work operations (for example,
riveting, welding, cutting, burning, and heating) capable of providing a source of
ignition.

HAZARD ASSESSMENT

The Administrator or designee will ensure that a hazard assessment is conducted in each
work area where welding or other hot work operations are or may be performed. The
assessment will identify sources of hazards that could expose employees to high heat,
light (optical) radiation, fumes, molten flying objects, and combustion from sparks.

Each hazard assessment will identify hazards, recommend controls, and provide guidance on
appropriate personal protective equipment (PPE) selections when a hazard control is not
feasible or satisfactory.

The Administrator or designee may use the attached Job Hazard Analysis Worksheet and PPE
Hazard Assessment Certificate for guidance when conducting the assessment(s).

Hazard Assessment Procedure

Following is the process for evaluating the operations and tasks that present potential
hazards to employees conducting or working near welding or other hot work operations:

1. Conduct a survey of each work area to assess if hazards are present, or are likely to
be present, for which hazard controls or PPE is needed. The Administrator will also
provide worksite evaluations of any operation at the request of a supervisor or employee.

2. Review injury and illness records, the layout of the work areas, and the placement of
workers in the work areas.

3. Collect and organize the data if available for each work area, and estimate the
potential for injuries according to the basic hazard categories and potential sources of
injury and illness.

4. Determine the type, level of risk, and seriousness of potential injury from each of the
hazards found in the work areas, and evaluate the possibility of exposure to several
hazards.

5. Categorize and record the hazards.

6. Determine what type of engineering or administrative control and/or PPE will protect
against the hazards.

7. Incorporate the results of the assessment and recommendations for protection into this
Plan and supplementary documents.

GENERAL REQUIREMENTS FOR HOT WORK PERSONNEL

Hot Work Operator

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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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The hot work operator will:

• Be trained in the safe operation of his or her equipment and the safe use of the
process.

• Have an awareness of the inherent risks involved and understand the emergency procedures
in the event of a fire.

• Handle the equipment safely and use it as described in this Plan and according to
manufacturer's instructions so as not to endanger life or property.

• Get Administrator or designee approval before starting hot work operations and comply
with the requirements of this Plan or hot work permit.

• Cease hot work operations if unsafe conditions develop and notify the supervisor or the
Administrator for reassessment of the situation.

Fire Watch Personnel

Fire watch personnel will:

• Be present during hot work operations and remain for a minimum of 30 minutes after
completion of hot work in order to detect and extinguish smoldering fires.

• Be aware of the inherent hazards of the worksite and of the hot work.

• Ensure that safe conditions are maintained during hot work operations.

• Have the authority to stop the hot work operations if unsafe conditions develop.

• Have fire-extinguishing equipment readily available and be trained in its use.

• Be familiar with the facilities and procedures for sounding an alarm in the event of a
fire.

• Watch for fires in all exposed areas surrounding the hot work operation and try to
extinguish them only when the fires are obviously within the capacity of the equipment and
fire-fighting skills available.

• Immediately contact the Supervisor and/or the Administrator if he or she determines that
the fire may grow beyond control.

HOT WORK AREAS

Designated Area

A designated area will be a specific area approved for welding or other hot work, such as
a maintenance shop or a detached outside location that is of noncombustible or fire-
resistive construction, essentially free of combustible and flammable contents, and
suitably segregated from adjacent areas. These designations are generally long-term for
facilities in which specific hot work operations are repeatedly performed. A fire watch is
not normally required in a Designated Area.

Hot Work Permit-Required Area

A permit-required area will be a nondesignated area that is made fire-safe by removing or

protecting combustibles from ignition sources and where protective controls and
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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ventilation are adequate to control worker exposure to heat, intense light, fumes, and
flying objects.

HOT WORK PERMIT

Authorization. Only designees authorized by the Administrator may issue hot work permits.

Before hot work operations begin in a nondesignated area, a completed hot work permit is
required. Based on local conditions, the Administrator or designee must determine the
length of the period for which the hot work permit is valid.

Posting. A signed and dated copy of the hot work permit must be posted at the entrance to
the area where hot work operations are conducted under the permit.

A copy of the standard Hot Work Permit form is attached to this Plan. A copy of the form
may be modified to include additional controls for special or site-specific activities not
normally covered under the standard hot work permit.

General Hot Work Permit Requirements

The following standard safe work practices and site conditions must be confirmed by the
Administrator or designee before permitting hot work to begin:

• All hot work and related equipment (e.g., welding equipment, shields, PPE, fire
extinguishers) must be in satisfactory operating condition and in good repair.

• The floor must be swept clean for a radius of 35 feet (ft) if combustible materials such
as paper or wood shavings are on the floor.

• Combustible floors except wood on concrete must be kept wet or be covered with damp
sand. Where floors have been wet down, personnel operating arc welding or cutting
equipment must be protected from possible shock or be protected by noncombustible or fire-
retardant shields.

• All combustible materials must be moved at least 35 ft away from the hot work operation.
If relocation is impractical, combustibles must be protected with fire-retardant covers,
shields, or curtains. Edges of covers at the floor must be tight to prevent sparks from
going under them, including where several covers overlap when protecting a large pile.

• Openings or cracks in walls, floors, or ducts within 35 ft of the site must be tightly
covered with fire-retardant or noncombustible material to prevent the passage of sparks to
adjacent areas.

• If hot work is done near walls, partitions, ceilings, or roofs of combustible

construction, fire-retardant shields or guards must be provided to prevent ignition.

• If hot work is to be done on a wall, partition, ceiling, or roof, precautions must be

taken to prevent ignition of combustibles on the other side by relocating combustibles. If
it is impractical to relocate combustibles, a fire watch on the opposite side from the
work must be posted.

• Hot work must not be attempted on a partition, wall, ceiling, or roof that has a
combustible covering or insulation, or on walls or partitions of combustible sandwich-type
panel construction.

• Hot work that is performed on pipes or other metal that is in contact with combustible
walls, partitions, ceilings, roofs, or other combustibles must not be undertaken if the
work is close enough to cause ignition by conduction.
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
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• Fully charged and operable fire extinguishers that are appropriate for the type of
possible fire must be available immediately at the work area. These extinguishers should
be supplied by the group performing the hot work. The fire extinguishers normally located
in a building are not considered to fulfill this requirement.

• Special precautions must be taken to avoid accidental operation of automatic fire

detection or suppression systems (for example, special extinguishing systems or
sprinklers).

• Nearby personnel must be suitably protected against heat, sparks, and slag.

FIRE PREVENTION AND PROTECTION

All welding and other hot work operations will be conducted in compliance with the
National Fire Protection Association (NFPA) Standard 51B, Standard for Fire Prevention
During Welding, Cutting, and Other Hot Work.

If fire hazards cannot be taken to a safe place or guards cannot be used to confine heat,
sparks, slag and protect the immovable fire hazards, the welding and cutting shall not be
permitted.

General Procedures

Following procedures must be completed before welding or other hot work operations begin:

• All movable fire hazards within 35 ft of a welding or other hot work operation must be
moved to a safe place if the object to be welded or cut cannot readily be moved.

• If the object to be welded or cut cannot be moved and if all the fire hazards cannot be
removed, then guards must be used to confine the heat, sparks, and slag, and to protect
the immovable fire hazards.

• Combustible material must be protected from exposure to sparks wherever there are floor
openings or cracks in the flooring, cracks or holes in walls, open doorways, and open or
broken windows that cannot be closed.

• Fire extinguishers or extinguishing equipment must be ready and available for instant
use; such equipment may consist of pails of water, buckets of sand, or hose or portable
extinguishers, depending on the nature and quantity of the combustible material exposed.

Prohibited Conditions for Hot Work

Hot work must not be permitted in the following areas until the conditions prohibiting hot
work have been modified:

• In the presence of explosive atmospheres, or in situations where explosive atmospheres

may develop inside contaminated or improperly prepared tanks or equipment which previously
contained flammable liquids

• In areas with an accumulation of combustible debris, dust, lint, and oily deposits

• In areas near the storage of exposed, readily ignitable materials such as combustibles

• On a container such as a barrel, drum, or tank that contained materials that will emit
toxic fumes when heated

• In a confined space, until the space has been inspected and determined to be safe
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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Administrative Precautions

Plant operations that might expose combustibles to ignition must not be scheduled to start
during welding and other hot work operations.

Conditions for Fire Watch

Fire watchers are required whenever welding or cutting is performed in locations where
other than a minor fire might develop, or any of the following conditions exist:

• Appreciable combustible material is closer than 35 feet (ft) (10.7 meters (m)) to the
point of operation.

• Appreciable combustibles are more than 35 ft (10.7 m) away but can be easily ignited by
sparks.

• Wall or floor openings within a 35-foot (10.7 m) radius expose combustible material in
adjacent areas including concealed spaces in walls or floors.

• Combustible materials are adjacent to the opposite side of metal partitions, walls,
ceilings, or roofs and are likely to be ignited by conduction or radiation.

Housekeeping

Welders must place welding cable and other equipment so that it is clear of passageways,
ladders, and stairways.

INSPECTIONS

Before welding or other hot work operations are permitted, the work area must be inspected
by the Administrator or designee responsible for authorizing such operations. The
inspector must indicate in writing (e.g., checklist or hot work permit) that:

• Hot work equipment is in good condition.

• Compressed gas cylinders are stored and handled according to safety procedures outlined
in this Plan or supplemental documents.

• Electrical systems associated with hot work operations are in good condition and
operated according to safety procedures outlined in this Plan or supplemental documents.

• Flammable and combustible materials such as trash, rags, and open containers of solvents
have been removed from the area.

• Flammable, combustible, or toxic residues have been removed or are adequately covered.

• All movable fire hazards in the vicinity have been removed from the hot work area.

• Ventilation is adequate to maintain a safe atmosphere during hot work.

• Adjacent spaces have been inspected and meet requirements for hot work.

• Operators and other affected workers are wearing required PPE

• Fire watch personnel are on duty when required

• Flammable, combustible, or toxic coatings (preservative coatings or insulation) have

been removed from hot work surfaces.
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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• Toxic preservatives on surfaces where hot work is performed are stripped back at least 4
inches (in.); otherwise airline respirators must be used.

Hot work permit inspection requirements. The inspector must following any additional
inspection requirements prescribed in a hot work permit.

Recordkeeping. Inspection records must be maintained according to the Recordkeeping

requirements of this Plan.

PPE

PPE is required for all workers who use hot work equipment and/or perform hot work
operations. All employees and contractors operating welding equipment must wear eye
protection.

Eye and face protection devices must meet the specifications of the American National
Standards Institute (ANSI) Z87.1, Occupational and Educational Eye and Face Protection
Devices, for all filter lenses and plates.

General PPE Requirements

The degree of PPE will vary with size, nature, and location of work to be performed.

Hot work permit areas. The operator of any hot work equipment and work areas covered under
a hot work permit must be equipped with protective devices and/or PPE as indicated in the
permit before any work begins.

Designated areas (hot work permit not required). The operator of any hot work equipment in
work areas designated for hot work must be equipped with protective devices and/or apparel
as indicated below:

[Modify the following PPE requirements as applicable to your designated areas where a hot
work permit is not required.]

• Portable and/or mechanical ventilation capable of keeping the levels of fumes, dust, and
gases below the thresholds established in regulations for permissible exposure limits
(PELs) for hazardous and toxic substances. If local exhaust or general ventilation is not
available and fume, dust, and gas generation is high, respirators must be used.

• Respiratory protection where required. NOTE: No employee will be issued or required to

use a respirator until that employee has satisfied the criteria for medical evaluation,
donning, doffing, and fit testing in the Respiratory Protection Plan.

• Gloves, apron, and/or jacket that are made of a material that is an insulator from heat
and electricity.

• Welder's helmets equipped with proper filter plate and cover lenses. See the Filter Lens
Shade Number Table for more information.

• Screens to protect persons not properly protected from the visual effects of viewing arc
welding or cutting and during gas or oxygen cutting or welding.

• Lifelines and harnesses for work in confined spaces as prescribed in the Confined Space
Entry Plan.

Arc Welding or Cutting PPE

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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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Helmets or hand shields must be used during all arc welding or arc cutting operations
except submerged arc welding. Helpers or attendants must be provided with proper eye
protection.

Gas Welding or Oxygen Cutting PPE

Goggles or other suitable eye protection must be used during all gas welding or oxygen
cutting operations. Spectacles with side shields and suitable filter lenses are permitted
for use during gas welding operations on light work, for torch brazing, or for inspection.

Resistance Welding PPE

Operators and attendants of resistance welding or resistance brazing equipment must use
transparent face shields or goggles to protect their faces or eyes.

Filter Lens Shade Number Table

Welding operation Shade No.

Shielded metal-arc welding-- 1/16-, 3/32-, 1/8-, 5/32-in. electrodes 10
Gas-shielded arc welding (nonferrous)-- 1/16-, 3/32-, 1/8-, 5/32-in. electrodes 11
Gas-shielded arc welding (ferrous)-- 1/16-, 3/32-, 1/8-, 5/32-in. electrodes 12
Shielded metal-arc welding: 3/16-, 7/32-, 1/4-in. electrodes 12
Shielded metal-arc welding: 5/16-, 3/8-in. electrodes 14
Atomic hydrogen welding 10 - 14
Carbon arc welding 14
Soldering 2
Torch brazing 3 or 4
Light cutting, up to 1 in. 3 or 4
Medium cutting, 1 in. to 6 in. 4 or 5
Heavy cutting, 6 in. and over 5 or 6
Gas welding (light) up to 1/8 in. 4 or 5
Gas welding (medium) 1/8 in. to 1/2 in. 5 or 6
Gas welding (heavy) 1/2 in. and over 6 or 8
HAZARD NOTIFICATION

Employers must include the following information on health hazard notices:

• All filler metals and fusible granular materials must carry the following notice, as a
minimum, on tags, boxes, or other containers:

"CAUTION--Welding may produce fumes and gases hazardous to health. Avoid breathing these
fumes and gases. Use adequate ventilation. See ANSI Z49."

• Filler metals containing cadmium in significant amounts must carry the following notice
on tags, boxes, or other containers:

"WARNING--CONTAINS CADMIUM--POISONOUS FUMES MAY BE FORMED ON HEATING--Do not breathe

fumes. Use only with adequate ventilation such as fume collectors, exhaust ventilators, or
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
Original Date: Section: Revision date: Page:
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air-supplied respirators. See ANSI Z49.1. If chest pain, cough, or fever develops after
use call physician immediately."

VENTILATION

Natural Ventilation

Natural ventilation may be used for welding or cutting operations where the space
restrictions for mechanical ventilation are not present.

Mechanical Ventilation General Requirements

Mechanical ventilation will be provided when welding or cutting is done on metals and
other compounds other than those specified in this section (e.g., fluorine, lead, zinc)
and when the following conditions apply:

• A space of less than 10,000 cubic (cu) ft (284 cu meters (m)) per welder

• A room having a ceiling height of less than 16 ft (5 m)

• In confined spaces or where the welding space contains partitions, balconies, or other
structural barriers to the extent that they significantly obstruct cross ventilation

Mechanical Ventilation Specifications

A fixed enclosure (booth) with a top and not less than two sides which surround the
welding or cutting operations and with a rate of airflow sufficient to maintain a velocity
away from the welder of not less than 100 linear ft (30 m) per minute will be used in
areas where hot work is performed. A 3-in. (7.6-centimeter(cm)) wide flanged suction
opening will be used with an airflow control velocity accomplished according to the
specifications in the Fixed Enclosure Duct Diameter Table.

Fixed Enclosure Duct Diameter Table

Welding Zone Minimum Air Flow (cu ft/min.) Duct Diameter (in.)
4 to 6 in. from arc or torch 150 3.0
6 to 8 in. from arc or torch 275 3.5
8 to 10 in. from arc or torch 425 4.5
10 to 12 in. from arc or torch 600 5.5
Fluorine Compounds

Local exhaust ventilation or airline respirators are required for fixed-location

production welding and for all production welding on stainless steels where air samples
taken at the welding location indicate that the fluorides liberated are above the maximum
allowable concentration.

Hazard Notification

Brazing and gas welding fluxes containing fluorine compounds must have a cautionary
wording to indicate that they contain fluorine compounds, such as the following:

"CAUTION--CONTAINS FLUORIDES--This flux, when heated, gives off fumes that may irritate
eyes, nose, and throat.

1. Avoid fumes and use only in well-ventilated spaces.

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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
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2. Avoid contact of flux with eyes or skin.

3. Do not take internally."

Fluorine Compounds in Confined Spaces

In confined spaces, welding or cutting involving fluxes, coverings, or other materials

which contain fluorine compounds must be done in compliance with the ventilation
requirements of the Confined Space Entry Plan.

Zinc

Indoors, welding or cutting involving zinc-bearing base or filler metals coated with zinc-
bearing materials must be done in compliance with the Mechanical Ventilation
Specifications section of this Plan.

Zinc in Confined Spaces

In confined spaces welding or cutting involving zinc-bearing base or filler metals or

metals coated with zinc-bearing materials must be done in compliance with the ventilation
requirements of the Confined Space Entry Plan.

Lead

Indoors, welding involving lead-base metals must be done in compliance with the Mechanical
Ventilation Specifications section of this Plan.

Indoor Operations

Indoors, welding or cutting operations involving metals containing lead other than as an
impurity or metals coated with lead-bearing materials, including paint, must be done using
local exhaust ventilation or airline respirators.

Outdoor Operations

Outdoor operations require the use of approved respirators in accordance with the
Respiratory Protection Plan. In all cases, workers in the immediate vicinity of the
cutting operation must be protected by local exhaust ventilation or airline respirators.

Lead in Confined Spaces

In confined spaces, welding involving lead-base metals must be done using local exhaust
ventilation or airline respirators and in compliance with the confined space requirements
of the Confined Space Entry Plan.

Beryllium

Welding or cutting at any location involving beryllium-containing base or filler metals

must be done using local exhaust ventilation and airline respirators unless atmospheric
tests under the most adverse conditions have established that the workers' exposure is
within the PEL for beryllium. In all cases, workers in the immediate vicinity of the
welding or cutting operations must be protected as necessary by local exhaust ventilation
or airline respirators.

Cadmium

Indoor Operations
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
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Indoors, welding or cutting operations involving cadmium-bearing or cadmium-coated base

metals must be done using local exhaust ventilation or airline respirators unless
atmospheric tests under the most adverse conditions show that employee exposure is within
the PEL for cadmium.

Outdoor Operations

Outdoor operations require approved respirators such as fume respirators and in accordance
with the Respiratory Protection Plan.

Cadmium in Confined Spaces

Welding or brazing work in confined spaces involving cadmium-bearing filler metals must be
done using ventilation as prescribed by the Mechanical Ventilation Specifications section
of this Plan and the ventilation requirements of the Confined Space Entry Plan.

Mercury

Indoor and Confined Space Operations

In confined spaces or indoors, welding or cutting operations involving metals coated with
mercury-bearing materials, including paint, must be done using local exhaust ventilation
or airline respirators unless atmospheric tests under the most adverse conditions show
that employee exposure is within the PEL for mercury.

Outdoor Operations

When done outdoors, welding or cutting operations involving metals coated with mercury-
bearing materials, including paint, must be done using approved respirators in accordance
with the Respiratory Protection Plan.

Cleaning Compounds

Manufacturer's instructions and other precautions must be followed when cleaning materials
are used. Degreasing and other cleaning operations involving chlorinated hydrocarbons must
be located so that no vapors from these operations will reach or be drawn into the
atmosphere surrounding any welding operation. In addition, trichloroethylene and
perchloroethylene will be kept out of atmospheres penetrated by the ultraviolet radiation
of gas-shielded welding operations.

Cutting of Stainless Steel

Oxygen cutting with either a chemical flux or iron powder or gas-shielded arc cutting of
stainless steel must be done using mechanical ventilation adequate to remove the fumes
generated.

FALL PROTECTION

Operators of hot work equipment or helpers working on platforms, scaffolds, or runways

must be protected against falling from heights above 4 ft in accordance with the
facility's Fall Protection Program. Such protection may include guardrails, safety
harnesses, or other equally effective safeguards.

SPECIAL OPERATIONS

Confined Spaces
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Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
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For the purposes of identifying a confined space in welding, cutting, and brazing
operations, a confined space is a relatively small or restricted space such as a tank,
boiler, pressure vessel, or compartment. See the Confined Space Entry Plan for detailed
information about work in a confined space.

Fire prevention in confined spaces

When arc welding is to be suspended for any substantial period, such as during lunch or
overnight, all electrodes must be removed from the holders and the holders carefully
located so that accidental contact cannot occur and the machine be disconnected from the
power source.

Whenever the torch is not to be used for a substantial period such as during lunch hour or
overnight, the torch valves must be closed and the fuel-gas and oxygen supply to the torch
positively shut off at some point outside the confined area. Where practicable, the torch
and hose must also be removed from the confined space.

Work in confined spaces

Ventilation is a prerequisite to work in confined spaces. For ventilation requirements see

the General Provisions subsection in this analysis.

Gas cylinders and welding machines must be left outside the confined space when welding or
cutting is performed.

Before operations are started, heavy portable equipment mounted on wheels must be securely
blocked to prevent accidental movement.

Where a welder must enter a confined space through a manhole or other small opening, means
must be provided for quickly removing him in case of emergency.

When safety belts and lifelines are used for this purpose, they must be attached to the
welder's body so that his body cannot be jammed in a small exit opening.

An attendant with a preplanned rescue procedure must be stationed outside to observe the
welder at all times and be capable of putting rescue operations into effect. However, a
tapping procedure on the walls of tanks as a means of communication in lieu of direct
observation of the welder by the attendant is an acceptable way to communicate.

After welding operations are completed, the welder must mark the hot metal or provide some
other means of warning other workers about the hot metal.

Ventilation in confined spaces

All welding and cutting operations carried on in confined spaces must be adequately
ventilated to prevent the accumulation of toxic materials or possible oxygen deficiency.
This applies not only to the welder but also to helpers and other personnel in the
immediate vicinity. Air replacement must be clean and safe to breathe. Oxygen must never
be used for ventilation.

Respirators in confined spaces

In circumstances for which it is impossible to provide such ventilation, airline

respirators or hose masks approved for this purpose by NIOSH must be used.

In areas immediately hazardous to life, a full-facepiece, pressure-demand, self-contained

breathing apparatus or a combination full-face piece, pressure-demand supplied-air
respirator with an auxiliary, self-contained air supply approved by NIOSH must be used.
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Health and Safety Handbook
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Welding, Cutting, Hot Work
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Where welding operations are carried on in confined spaces and where welders and helpers
are provided with hose masks, hose masks with blowers, or self-contained breathing
equipment, a worker must be stationed on the outside of such confined spaces to insure the
safety of those working within.

Fuel-Gas Welding

Employers must adopt procedures to prevent mixtures of fuel gases and air or oxygen that
may explode. Mixtures of air or oxygen with flammable gases prior to consumption except at
the burner or in a standard torch, are not allowed unless approved for the purpose.

Portable cylinders. All portable cylinders used for the storage and shipment of compressed
gases must be constructed and maintained in accordance with the regulations of the U.S.
Department of Transportation, 49 CFR parts 171–179.

Compressed gas cylinders must be legibly marked with either the chemical or the trade name
of the gas. Markings must be a stencil, stamp, or label, and must not be readily
removable.

Whenever practical, the marking must be located on the shoulder of the cylinder.

Oxy-acetylene Welding

Oxy-acetylene welders must:

• Check to make sure the safety fuse plug or disk is functioning.

• Never use oxygen or fuel gas directly from the cylinder. There has to be a regulator
attached to the valve.

• Stand to one side of the regulator (in case it malfunctions), open the cylinder valve
slowly, and do no more than 1½ turns.

• Use 3 - 7 psi for oxygen and 1 - 12 psi for acetylene, but never over 15 psi.

• Purge oxygen and acetylene lines and light the acetylene using a striker, not a lighter.

• Store oxygen and acetylene separately, secured in an upright position, with valves
closed, and at least 20 ft or more from combustibles.

Arc Welding

Operators and supervisors of arc welding equipment and operations must strictly follow the
printed rules and instructions covering operation of equipment supplied by the
manufacturers. Supervisors must ensure that operators follow the procedures for fire
prevention and protection, protection of personnel, and health protection and ventilation.

Arc welders must:

• Ensure welding machines are grounded.

• Avoid wet or damp areas to prevent electric shock.

• Check that connections are tight.

• Ensure cables are maintained and conductors are well insulated.

• Ensure cable splices are not within 10 ft of a holder.

 Pannier Corporation
Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
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• Use flash screens to protect others in the area from the flash.

Resistance Welding

Periodic inspection must be made by qualified maintenance personnel, and a certification

record maintained. The certification record must include the date of inspection, the
signature of the person who performed the inspection and the serial number, or other
identifier, for the equipment inspected. The operator must be instructed to report any
equipment defects to his supervisor and the use of the equipment must be discontinued
until safety repairs have been completed.

Workers designated to operate resistance-welding equipment must have been properly

instructed and judged competent to operate such equipment.

EMERGENCY RESPONSE

Injured Person

In case of an accident that results in a serious injury (i.e., requires medical

attention):

1. Attend the injured person(s), give standard first aid, make the situation safe, and
comfort the injured.

2. Call 9-911 from a company phone, or other nearest location.

3. Notify the Health and Safety Director or immediate supervisor.

4. Send a person, if available, to the office to coordinate help.

5. Wait for the emergency medical service to arrive.

REPORTING ACCIDENTS AND INJURIES

Any person who observes or causes an injury to a worker or damage to property or equipment
must immediately report the incident to a supervisor.

Accident Investigation

If an employee sustains a work-related injury, the employee or a co-worker will

immediately notify the Supervisor of the work-related injury or illness, and the
supervisor will ensure the injured or ill employee receives prompt medical treatment. The
employee will complete the employee part of the accident report form. If the date and time
of the injury or illness cannot be determined, such as an injury caused by cumulative or
repeated stress, the date of the last time that the employee worked is entered on the
form.

Use the attached Accident Investigation Report when conducting accident investigations.

TRAINING

Fire Watchers

Fire watchers must have fire extinguishing equipment readily available and be trained in
its use. They must be familiar with the equipment and procedures for sounding an alarm in
the event of a fire. They must watch for fires in all exposed areas, try to extinguish
them only when obviously within the capacity of the equipment available, or otherwise
 Pannier Corporation
Health and Safety Handbook
Marking System Group
Welding, Cutting, Hot Work
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sound the alarm. A fire watch must be maintained for at least a half hour after completion
of welding or cutting operations to detect and extinguish possible smoldering fires.

Oxygen-Fuel Gas Welders and Cutters

Workers in charge of the oxygen or fuel-gas supply equipment, including generators, and
oxygen or fuel-gas distribution piping systems must be instructed and judged competent by
their employers for this important work before being left in charge. Skilled mechanics
must be properly instructed to repair regulators or parts of regulators, including gages.

Arc Welders and Cutters

Workers who operate arc-welding equipment must be instructed and qualified to operate and
maintain such equipment.

Resistance Welders

Workers designated to operate resistance-welding equipment must be properly instructed and

judged competent to operate such equipment.

RECORDKEEPING

The Administrator or designee will maintain all records related to this Plan. Unless
otherwise noted, the records will be kept at Pannier Corporation, Glenshaw plant. All
records will be available for regulatory agency review on request.

The Administrator or designee will maintain the following written records:

• Job hazard assessments

• An updated list of designated locations allowed to perform welding or other hot work
operations without requiring a permit

• Hot work permits

• Inspection reports and checklists

• Accident or incident reports and investigations

• Training records

Record retention time. All records, including employee training records (e.g., curricula,
written or electronic materials, sign-in sheets, individual employee records) will be
retained for 3 years.