HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 1 / 10
Revision history
Rev Date Description of Change
Authorisation for Approval Authority:
Owner Developer Reviewer Approver
Summary
This guideline outlines the parameters for the safe use of welding and cutting
operations by Project and subcontractor employees.
Page 1 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 2 / 10
1.0 PURPOSE
This guideline outlines the parameters for the safe use of welding and cutting
operations by Project and subcontractor employees.
2.0 DEFINITIONS
Flame Resistant Material - A material that burns slowly or is self-
extinguishing after the external source of ignition is removed.
Qualified Inspector - A crafts person, who, by possession of a recognized
degree, certificate, or professional standing, or who by extensive knowledge,
training, and experience, has successfully demonstrated his or her ability or
competency to inspect equipment.
Qualified Operator -A crafts person, who, by possession of a recognized
degree, certificate, or professional standing, or who by extensive knowledge,
training, and experience, has successfully demonstrated his or her ability or
competency.
Fire Protection - Each employee engaged in welding, cutting or burning when
flammable materials are within thirty five feet (10.6 meters) must have a 9kg
(20lb) fire extinguisher within 3 meters (10 feet) of the operation. The
employee must ensure that the extinguisher is in proper working order.
Fire Watch - A subcontractor employee trained in the use of fire extinguishers
and maintaining safe working conditions in the area of hot work operations.
3.0 GENERAL
Qualified Operators -All operators of oxy-fuel equipment must be
knowledgeable in the proper care, maintenance, and use of oxy-fuel
equipment. This includes compressed gas cylinders, regulators, torches, hoses,
flashback arresters, check valves, PPE and fire prevention practices.
Fire Prevention - Before starting to burn or weld, the work area around and
below must be inspected to ensure that sparks or molten metal won’t fall on
workers or combustible materials. If an employee is unable to provide the
necessary safeguards, he should contact his supervisor for direction.
Fire Watch – An employee trained in the use of fire extinguishers, advising
personnel who might be injured by falling molten metal or debris to relocate,
and preparation of areas for hot work, including the following: Fire watch(s)
shall be required whenever welding or cutting is performed in locations where
the possibility of a fire exists, or any if the following conditions exist:
Combustible material, in building construction or contents, closer than
10.5m (35 feet) to the point of operation.
Combustibles are more than 10.5m (35 feet) away but are easily ignited by
sparks.
Page 2 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 3 / 10
Wall or floor openings within a 10.5m (35 feet) radius expose combustible
material in adjacent areas including concealed spaces in walls or floors.
Combustible materials located at the opposite side of metal partitions,
walls, ceilings, or roofs and are likely to be ignited by the conduction of
heat.
Fire Watch Responsibility:
Have fire extinguishing equipment readily available and be trained in its
use.
Be familiar in the emergency alarm system in the event of a fire.
Watch for fires in all exposed areas, try to extinguish them only when
obviously within the capacity of the equipment available, or otherwise
sound the alarm.
The Fire Watch shall be maintained for at least a half hour after completion of
welding or cutting operations to detect and extinguish possible smouldering
fires.
The Fire Watch is also responsible for:
Determining with his or her supervisor, all sources of combustible material
in the vicinity of the hot work.
Knowing the location of all fire fighting equipment in the area and have the
necessary fire fighting equipment within 3m (10ft) of the hot work.
Maintaining safe working conditions in the area and to stop work if
conditions change or if doubt arises concerning the existing conditions,
such as:
Gases or vapors accumulate in the area.
Fire or emergency in the area.
Opening of existing lines, vessels, pumps, etc.
To keep constant communications with workmen in the area.
The Fire Watch must be at the work site with a fire extinguisher, and if
available, a charged fire hose, ready to use while hot work is being performed.
The Fire Watch shall thoroughly examine the work area after hot work is
completed to insure that no smouldering materials are present.
The Fire Watch shall monitor the activities to ensure that job-specific permit
restrictions are being met (if applicable).
Fire blankets if required.
Sewer sealed, if required, shall be inspected by the safety personnel.
Page 3 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 4 / 10
To notify the Safety Personnel and the Project Safety Department in the
event secured work conditions change resulting in a work stoppage.
Supervisors Responsibility:
The supervisor shall instruct the Fire Watch in their duties and see that they
are posted in the proper locations. (Some jobs may require more than one
fire watch). He shall maintain contact with the Fire Watch and shall oversee
all hot work performed.
Note: Welding or burning in a hazardous area may require a Hot Work Permit.
In areas where flammable materials are stored and are unable to be moved to
allow overhead or nearby cutting or welding operations, a Fire Watch shall be
provided.
4.0 VENTILATION AND PROTECTION
Welding, cutting and heating in the open air can normally be performed
without mechanical ventilation equipment. However, when an unsafe
accumulation of contaminants exists because of unusual physical or
atmospheric conditions, suitable mechanical ventilation or respiratory
protective equipment must be used.
5.0 CONFINED SPACES
General, mechanical, or local exhaust ventilation must be provided when
welding, cutting, or heating in a confined space.
When sufficient ventilation cannot be obtained without blocking the means of
access, an employee in a confined space must be protected by an air-line
respirator. An employee outside the confined space is assigned to maintain
communication with those working within it and to aid them in an emergency.
6.0 METAL OF TOXIC SIGNIFICANCE
Welding, cutting, or heating in an enclosed space involving the following
metals must be performed with general, mechanical, or local exhaust
ventilation.
Zinc-bearing base or filler materials or metals coated with zinc-bearing
materials
Lead based metals
Cadmium-bearing filler materials
Chromium-bearing metals or metals coated with chromium-bearing
materials
Welding, cutting or heating in an enclosed space involving the following metals
must be performed with local exhaust ventilation, or the employees must be
protected by air-line respirators.
Page 4 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 5 / 10
Metals containing lead (other than as an impurity) or metals coated with
lead-bearing materials.
Cadmium-bearing or coated base materials.
Metals coated with mercury-bearing metals.
Beryllium-containing base or filler metals. Because of its high toxicity, work
involving beryllium must be done with both local exhaust ventilation and an
air-line respirator.
An employee doing welding, cutting, or heating of metals of toxic significance
in the open air must be protected by an approved filter-type respirator.
An employee doping welding, cutting, or heating of a beryllium metal in the
open air must use an air-line respirator.
Other employees exposed to the same atmosphere as the welder or
burner must be protected in the same manner.
7.0 Inert-Gas, Metal Arc Welding
Inert gas, metal-arc welding processes involve the production of ultraviolet
radiation of intensities from 5 to 30 times that produced during shielded, metal
arc welding. These ultra-violet rays decompose chlorinated solvents and
liberate toxic fumes and gases. The use of chlorinated solvents must be kept at
least 6om (200ft) (unless shielded) from the exposed arc, and surfaces
prepared with chlorinated solvents must be thoroughly dry before welding is
permitted on such surfaces.
When inert-gas, metal arc welding is being performed on stainless steel, an
enclosed space must have local exhaust ventilation, or the employee must be
protected by an air-line respirator to protect against dangerous concentrations
of nitrogen dioxide.
7.1 Preservative Coatings
In enclosed spaces, all surfaces covered with toxic preservatives must be
stripped of the toxic coatings for a distance of at least 10cm (4”) from the area
of heat application, or the employee must be protected by an air-line
respirator.
Each materials Material Safety Data Sheet (MSDS) shall be reviewed to
determine the appropriate ventilation and respiratory protection required.
7.2 Additional Requirements
When arc-welding is being done near other workmen, they must be
protected from the arc rays by non-combustible screens or they must wear
proper eye protection.
Page 5 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 6 / 10
Do not use any type of cigarette lighters or matches to light torches. Spark
type igniters must be used. Torches must not be used to light smoking
materials.
Appropriate fire resistant gloves must be worn when burning or welding.
When a special wrench is required to operate the acetylene cylinder valve,
the wrench must be kept in position on the valve. The use of crescent
wrenches for this purpose is not recommended.
Keep all welding leads and cutting torch hoses off floors, walkways and
stairways. The use of wire to support leads, hoses and cords is prohibited.
Rope is recommended and will prevent damage to the hose or leads.
8.0 OXY-FUEL CUTTING OPERATIONS
8.1 Compressed Gas Cylinders
Compressed gas cylinders shall be kept in an upright position and be secured
in an approved cart or a permanent object by a chain or similar method to
prevent displacement. Natural fibre and/or synthetic rope should not be used
due to possible reaction in some environments.
When cylinders are not in use for extended periods, or when being transported
or hoisted by motorized equipment, the regulators shall be removed and valve
protection caps firmly secured on the cylinders.
Cylinders shall not be hoisted by wrapping ropes, slings or chokers around
them, they shall be secured in an approved rack or cylinder truck.
Cylinders shall not be placed where they may become exposed to an electrical
arc or sparks, slag, flame, or other heat sources.
Cylinders shall not be taken into confined spaces.
Oxygen and fuel gas cylinders in storage shall be separated by at least 6m
(20ft) or by a 1.5m (5ft) high fire wall with a one hour fire resistance rating. All
cylinders must be stored in an upright position and adequately secured to
prevent them falling over.
Storage area shall be clearly identified as to the content of the cylinder and
whether empty or full. Smoking, spark producing work and open flame
activities are not allowed within 6m (20ft) of any cylinder storage area. Post
signs prohibiting these activities in cylinder storage area.
Flash back arresters and check valves shall be installed on both oxygen and
fuel gas hoses. Check valves are to be placed at the torch end and the flash-
back arresters are to be placed at the regulator end of the hoses.
Visually inspect all hoses before each use. Hose splices and repairs shall be
made with approved splicing kits and fitting and only by qualified employees.
Page 6 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 7 / 10
Water hose clamps are never to be used at splices or as hose connections at
the torch and regulator.
Hoses shall not be placed where they will become a tripping hazard, ran over
by vehicle traffic or crushed in doorways unless guarded or barricaded.
Hoses shall not be stored in unventilated containers such as gang boxes or
cabinets.
Regulators shall have approved and functional gauges on both the low and
high side.
Torches shall be lighted only with approved friction type lighters.
All gas welding and cutting equipment, hoses and cylinders shall be kept clear
of oil, grease and other hydrocarbons. Oxygen and oil, grease, or other
hydrocarbons can result in a serious explosion.
Approved personal protective equipment shall be worn as per the PPE Working
Instruction.
8.2 Burning/Torch Cutting Operations
Check valves and flame arresters - Directly attach reverse-flow check valves to
the barrel of the cutting torch and flame arresters to the regulator. These
attachments stop a flashback flame, extinguish it, and cut off the flow of
gases.
When extinguishing the flame, close the acetylene and oxygen valves in the
order recommended by the torch manufacturer. If the oxygen valve is closed
first, carbon soot will be deposited in the air. However, this ensures that the
acetylene valve is turned off first, no soot is formed, but there is no assurance
that the fuel gas valve is closed and that it is not leaking.
To discontinue welding or cutting for a few minutes, closing only the torch
valves is permissible. If the welding or cutting is to be stopped for a longer
period (during lunch or overnight), proceed as follows:
• Close the oxygen and acetylene cylinder valves;
• Open the torch valves to relieve all gas pressure from the hose and
regulators;
• Close the torch valves and release the regulator pressure adjusting screws.
Never merely turn off the gas supply at the torch. This leaves the hose
pressurized. Always cut the supply from the cylinder, bleed the lines, and, with
the lines open, back off the regulator. The lines should then be coiled carefully,
avoiding kinks.
Page 7 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 8 / 10
9.0 STORING THE EQUIPMENT
At the end of the shift, or when the work is complete, remove the regulator
from the cylinders, replace the protective cylinder caps and cap the regulator
threaded nipples to prevent dirt and foreign material from entering the system.
Store the torch, hoses, and regulators in a clean, dry, oil free storage box that
is well ventilated. “No Smoking - No Open Flame” signs must be attached to
all four sides and top of the storage box.
10.0 INSPECTION
A qualified inspector must inspect all welding machines prior to their initial use
on site and at least quarterly (every three months) thereafter. This inspection
shall be indicated by use of the colour coding system. Operators using the
welding machine must ensure the colour coding remains legible between
inspections. Welding machines with illegible colour codes shall be considered
unsafe and removed from service.
10.1 Daily Inspection
The operator must inspect the equipment prior to each use. In particular, the
operator should look for leaks, burns, worn areas, and other defects.
10.2 Quarterly Inspection and Tests
A qualified inspector must inspect and test all components of oxy-fuel
equipment prior to their initial use on site and at least quarterly thereafter.
This inspection shall be indicated by the colour coding system. Operators using
the tools must ensure the colour coding system remains legible between
inspections. Tools with illegible colour coding shall be considered unsafe and
removed from service.
11.0 ELECTRIC ARC WELDING
11.1 Leads
Inspect welding leads prior to use to ensure that the insulation is not damaged
and that the conductor is not exposed. Repair or discard damaged cord sets.
To eliminate the possibility of partially exposing a connection while installing
the leads, male and female connectors may need to be taped or otherwise
restrained from separating. Welding leads shall not be tied in a knot.
Arc welding cables shall be kept clear of walkways and shall not be exposed to
vehicular traffic. Welding leads are not to be suspended from an elevated
position except for jobs of one hour or less.
The welding cable must be free of defects, splices or repairs within 3m (10ft) of
the electrode holder.
Ground leads for electric arc welding shall be located as close to the welding
areas as possible to minimize secondary arcs.
When electrode holders are left unattended, the electrodes shall be removed.
Page 8 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 9 / 10
11.2 Portable Welding Machines
When a portable welding machine includes a receptacle for electrical power,
the receptacle must have a Ground Fault Circuit Interrupter (GFCI) if the
voltage is alternating current. If the voltage is direct current, the receptacle
must be removed.
All portable welding machines must be grounded.
12.0 WELDING BOXES/ENCLOSURES
Where work is performed in hazardous areas and welding sparks and hot slag
from welding and burning operations can ignite hazardous materials below or
near the work area (and the materials or the work cannot be moved), then
welding boxes or similar enclosures shall be built. Requirements include:
• The floors shall be solid with doubled fire blanket covering the floor.
• All sides shall be covered with fire blanket to a minimum of 1.1m (42”) high
unless the enclosure has solid non-flammable walls.
• A 9kg (20 pound) fire extinguisher inside the box.
• The box sealed to the point of no slag or sparks escaping (i.e., higher walls,
a roof, additional layers of fire blanket, etc., installed if required by the
work).
• Welding machines must be located in non-restricted areas, leads pulled
into the work area and, where required, the area checked for flammable
vapours.
• Forced artificial ventilation is required.
13.0 FIRE EXTINGUISHERS & PERSONAL PROTECTION
Suitable fire extinguishing equipment shall be maintained in a state of
readiness for instant use.
Goggles, helmets, and shields that give maximum eye protection for each
welding and cutting process shall be worn by operator, welders, and their
helpers. Welders shall be provided with flame-resistant gauntlet gloves and
aprons.
For overhead work, capes or shoulder covers of leather or other suitable
material should be available. Skull caps of leather or flame-resistant fabric may
be worn under helmets to prevent head burns. Also, for overhead welding, ear
protection (wool or rubber plugs, or wire screen protectors) is sometimes
desirable. For protection against sharp or heavy falling objects, hard hats or
other head protection should be worn.
Operators and other persons working with inert-gas-shielded arc welding
should keep all parts of the body which could be exposed to the ultraviolet and
Page 9 of 10
HSE Department Réf:
GUIDE Date:
Rev: 01
11/12
WELDING AND CUTTING 10 / 10
infrared radiation covered to protect against skin burns and other types of
injuries. Dark clothing, particularly a dark shirt, is preferable to light-coloured
clothing in order to reduce reflection to the operator's face underneath the
helmet.
Thermal insulated underwear for cold-weather protection should be made of
down filled or waffle-weave cotton and wool. Quilted nylon-shell, polyester
filled underwear, although it does not ignite any easier than cotton, will burn
and melt to form a hot plastic mass which adheres to the skin and may cause
serious injuries. Thermal underwear is designed only to be worn under other
clothing and should not be exposed to open flames, sparks, or other sources of
ignition.
Page 10 of 10
