SOP

WELDING & CUTTING PROCEDURE

DOCUMENT TYPE SOP

DOCUMENT TITLE WELDING & CUTTING PROCEDURE
DOCUMENT NUMBER PB-CONS-SOP-015

A IFR 27/05/2016 First Issue for Review GIL RS

Rev Status Issue Date Description Prepared Checked

Approvals

Remarks
A,B,C,… Revision for all preliminary version
0 First official version
1,2,3,… Revision for official version
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Revision Sheet

REVISION DATE DESCRIPTION OF CHANGE

A 27/05/2016 First Issue for Review

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Contents
1 PURPOSE ...................................................................................................................................................... 4
2 SCOPE ........................................................................................................................................................... 4
3 GENERAL INFORMATION ............................................................................................................................. 4
4 FIRE SUPPRESSION & PROTECTION.............................................................................................................. 6
5 HOT WORK PERMIT...................................................................................................................................... 7
6 OXY-FUEL WELDING & CUTTING .................................................................................................................. 7
6.1 General Precautions............................................................................................................................. 7
6.2 Handling Compressed Gas Cylinders ................................................................................................... 8
6.3 Placing Cylinders .................................................................................................................................. 8
6.4 Use of Fuel Gas..................................................................................................................................... 8
6.5 Regulators and Gauges ........................................................................................................................ 9
6.6 Oil and Grease Hazards ........................................................................................................................ 9
6.7 Hoses .................................................................................................................................................. 10
6.8 Torches ............................................................................................................................................... 10
7 ELECTRIC ARC WELDING AND CUTTING..................................................................................................... 11
7.1 Manual Electrode Holders ................................................................................................................. 11
7.2 Welding Cables and Connectors ........................................................................................................ 11
7.3 Operating ........................................................................................................................................... 11
7.4 Shielding ............................................................................................................................................. 12
8 INERT GAS METAL ARC WELDING .............................................................................................................. 12
9 RESISTANCE WELDING ............................................................................................................................... 12
Appendix A. PERSONAL PROTECTION STANDARD GUIDE ................................................................................. 14
Appendix B. WELDING & CUTTING PERMIT ...................................................................................................... 16

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1 PURPOSE

This Procedure provides general work practices and requirement for welding and cutting, grinding or
similar work. The following instructions and work practices have been established in accordance with
the Client requirement.

2 SCOPE

This procedure shall apply to all employees responsible for planning, supervising, and conducting
welding and cutting operations.

3 GENERAL INFORMATION

A. Supervisors and workers performing welding, cutting, and/or brazing operations shall be
trained in hazard recognition, evaluation, and control; fire protection; and safe work
practices; and shall adhere to requirements in this procedure.

B. Welding/Cutting Areas: Whenever possible, welding and/or cutting operations should be

performed in areas that are isolated and designated for such uses. Welding or cutting must
not be performed in the following areas:

1. In the presence of explosive atmospheres;

2. In areas near the storage of quantities of exposed, ignitable materials;
3. In sprinklered buildings; or,
4. In areas not authorized by management or by a hot work permit.

C. Whenever welding operations are interrupted for a substantial period of time (e.g., lunch or
overnight) or completed, "hot" metal areas must be identified, and the equipment must be
shut off with any valves closed.

D. Equipment: Personnel are required to use approved welding, cutting, and grinding
equipment and follow the manufacturer’s instructions. Such equipment shall be maintained
in safe working order at all times. Personnel shall report any equipment defect or safety
hazard to a supervisor, and the use of such equipment must be discontinued until it is
repaired by qualified personnel.

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E. Site Preparation: Prior to beginning welding or cutting operations, workers must:

1. Check the work area (35' radius) to ensure that no fire hazards including oily or
greasy materials are present;
2. Remove all combustible materials within 35’ not necessary for the operation. Any
combustible material that cannot be removed, such as wood platforms, should be
covered with a flame-resistant material;
3. Check that all equipment is in good working condition;
4. Inform workers in the immediate area and display warning signs at the worksite to
alert others of the potential hazards;
5. Install welding shields/curtains to protect other workers from the sparks and intense
light associated with welding/cutting operations; and
6. When performing welding, cutting, and/or brazing operations in areas on or around
Acutely Hazardous Materials which are included in a Process Safety Management
(PSM) Program, a hot work permit is required.

F. Ventilation: Cutting or welding operations must be performed in areas with adequate

ventilation to keep fumes and gases within safe limits.

1. Local exhaust ventilation must be used when potentially hazardous materials are
being worked on. (Examples of potentially hazardous materials include, but are not
limited to, chromium, fluorides, zinc, beryllium, cadmium, lead, and mercury).
2. Adequate exhaust ventilation must be used when using inert-gas welding, plasma-
arc cutting or carbon-arc cutting.
3. The metal surface shall be free of all chlorinated solvents during any welding or
cutting operations.

G. Personal Protective Equipment: Approved personal protective equipment (PPE) shall be

worn by all employees performing or assisting in welding and/or cutting operations.

1. Examples of PPE include eye protection, helmets and hand shields, flame resistant
gloves, limb/body protection, and respiratory protection.
2. While performing overhead or vertical welding, personnel must wear leather
personal protective equipment (shoulder, head, and ear covers).
3. All welders should wear flame-resistant aprons, coveralls, gauntlet gloves and shirts
with sleeves of sufficient length and construction to protect the arms from heat, UV
radiation, and sparks.
4. Wool and leather clothing are preferred because they are more resistant to
deterioration and flame than cotton or synthetics. Synthetic fiber clothing should
not be worn unless it is specifically manufactured to be fire retardant.
5. Clothing should be kept reasonably free of oil or grease.
6. Front pockets and upturned sleeves or cuffs should be prohibited. Sleeves and
collars should be kept buttoned and high boots should be worn under pant legs (or
leggings worn) to prevent hot metal slag or sparks from contacting the shin.
7. Personnel must wear respiratory protection when ventilation is not sufficient to
prevent exposure above permissible limits. (When performing cutting or welding
operations involving coatings which generate toxic substances upon heating, or
working with materials that contain beryllium, cadmium, lead, or mercury,
personnel must wear supplied-air respirators).

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8. Workers welding on metal alloys should wear work uniforms, coveralls, or similar
full-body coverings that are laundered each day. Lockers or other closed areas
should be provided to store work and street clothing separately.
9. Other personnel in welding/cutting areas not protected by noncombustible or
flameproof screens or shields must wear appropriate goggles.

H. Confined Space Operations: Proper precautions must be taken by personnel who are
required to perform welding or cutting operations in a confined space area. Refer to the
Confined Space Pre-Entry Procedure, and contact the Entry Supervisor prior to performing
welding or cutting operations in a confined space.

I. Prior to welding tanks, cylinders, or other containers, supervisory personnel must complete
a hot work permit and shall verify that such containers do not contain, or have not
contained, any flammable, toxic, or explosive materials. If containers have contained
flammable, toxic, or explosive materials, they must be emptied, flushed, or otherwise
purged and sampled prior to welding.

J. Fire Protection: Fire protection equipment must be maintained ready for use at all times
that welding or cutting operations are being performed.

1. Utility trucks supporting welding/cutting operations must be equipped with

firefighting and fire protection equipment, including a fire extinguisher of at least 10
A:B:C rating.
2. If welding is to be performed in areas where a fire hazard may exist, fire watch
practices must be established and implemented. (See Appendix A Hot Work Permit.)
3. When performing welding or cutting operations on coated surfaces that are highly
flammable (determined by a flammability test), the coating must be stripped from
the area to prevent ignition.

K. All surfaces covered with toxic preservatives, including coatings which generate toxic
substances upon heating, must be stripped for a distance of at least 4 inches from the area
of heat application.

L. Contractors performing welding and cutting operations must be made aware of the risks
involved in the operations, and shall obtain approval from District prior to performing such
operations.

4 FIRE SUPPRESSION & PROTECTION

A. Suitable fire protection equipment must be maintained ready for use at all times that
welding or cutting operations are being performed. If welding is to be performed in non-
approved areas, supervisory personnel must complete a hot work permit.

B. A Fire watch and a hot work permit are required when welding or cutting is performed
where:

1. Combustibles are closer than 35' to the point of operation, or where there are
appreciable combustibles easily ignited by sparks;
2. Wall, floor, or other openings within 35' radius that expose combustible materials;
or
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3. Combustible materials are adjacent to the opposite side of metal walls, partitions,
ceilings, or roofs and are likely to be ignited by conduction or radiation.

C. If required, duties of the Fire Watch include:

1. Using fire extinguishing equipment to extinguish fires within the capacity of

equipment available;
2. Sounding an alarm in the event of a fire;
3. Watching for fires in all exposed areas;
4. Maintaining a fire watch for at least 1/2 hour (30 minutes) after completion of
welding or cutting operations; and
5. Reporting any injury, including suspected flash burns, to their supervisor.

5 HOT WORK PERMIT

Prior to performing welding/cutting operations in the following circumstances, a hot work permit
must be completed and approved by the appropriate supervisor.

A. In locations that have not been designated as welding locations.

B. In confined spaces.

C. Welding or cutting tanks, cylinders, or other containers.

D. In areas where a fire hazard may exist (example: weeds, wood products, fabrics, etc).

E. In areas included in the Process Safety Management Program (if applicable).

F. In areas where combustibles are closer than 35' to the point of operation.

G. In areas where combustible materials are adjacent to the opposite side of metal walls,
partitions, ceilings, or roofs and areas likely to be ignited by conduction or radiation.

Copies of open permits must be maintained at the job site and in the supervisor’s office. Upon job
completion, closed permits should be maintained for three (3) years.

6 OXY-FUEL WELDING & CUTTING

6.1 General Precautions

 Prior to beginning welding or cutting operations, workers must check that the cylinders,
regulators, backflow prevention device, flame arrestors, hoses, clamps, and torches are in
good working condition.
 Oil or grease must not come into contact with oxygen cylinders, valves, regulators or other
fittings. Do not handle oxygen cylinders or apparatus with oily hands or gloves, or greasy
materials. Do not let oxygen contact oily or greasy surfaces or clothes, or enter a fuel oil or
other storage tank.

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 Fuel gas and oxidizers must pass through a pressure-reducing regulator prior to being used.
Pressure reducing regulators must only be used at or below the rated pressures and must be
specific to the type of gas being used. Prior to connecting a pressure regulator, cylinder
valves should be "cracked" to clear the dust or dirt that might otherwise enter the regulator.
This procedure shall be performed away from other welding work or sparks.
 Prior to removing a regulator from a cylinder, personnel must close all cylinder valves, and
release the gas from the regulator.
 Cylinders must be kept far enough away from the actual welding or cutting operation so that
sparks, hot slag, or flame will not reach them, or fire-resistant shields must be provided.

6.2 Handling Compressed Gas Cylinders

Follow these procedures when handling gas cylinders:

 Valve protection caps must be in place and secured.
 Cylinders will be moved by tilting and rolling them on their bottom edges. They must not be
intentionally dropped, struck, or permitted to strike each other violently.
 Cylinders must be either firmly secured on a special carrier intended for this purpose or
regulators must be removed and valve protection caps put in place before cylinders are
moved.
 A suitable cylinder truck, chain, or other steadying device must be used to keep cylinders
from being knocked over while in use.
 Oxygen cylinders must be stored separated from fuel gas cylinders or combustible materials
by a minimum distance of 20 feet or by a five-foot high non-combustible barrier with a fire-
resistive rating of one-half hour. Cylinders must not be stored near elevators, stairs or
gangways. Assigned storage must prevent cylinders from being knocked over or damaged.

6.3 Placing Cylinders

Cylinders must be kept far enough away from the actual welding or cutting operation so that sparks,
hot slag, or flame will not reach them. When this is impractical, fire resistant shields must be used.

Cylinders must be placed where they cannot become part of an electrical circuit. Electrodes must
not be struck against a cylinder to strike an arc.

Fuel gas cylinders must be placed with valve end up whenever they are in use. They must not be
placed in a location where they would be subject to open flame, hot metal, or other sources of
artificial heat.

6.4 Use of Fuel Gas

Before a regulator to a cylinder valve is connected, the valve must be opened slightly and closed
immediately. (This action is generally to clear the valve of dust or dirt that might otherwise enter the
regulator.) The person cracking the valve must stand to one side of the outlet not in front of it. The
valve of a fuel gas cylinder must not be cracked where the gas would reach welding work, sparks,
flame, or other possible sources of ignition.

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The cylinder valve must always be opened slowly to prevent damage to the regulator.

For quick closing, valves on fuel gas cylinders must not be opened more than 1 ½ turns. When a
special wrench is required, it must be left in position on the stem of the valve while the cylinder is in
use so that the fuel gas flow can be shut off quickly in case of an emergency.

Nothing must be placed on top of a fuel gas cylinder, when in use, which may damage the safety
device or interfere with the quick closing of the valve.

Fuel gas must not be used without reducing the pressure through a regulator attached to the
cylinder valve.

Before a regulator is removed from a cylinder valve, the cylinder valve must always be closed and
the gas released from the regulator.

If, when the valve on a fuel gas cylinder is opened, there is found to be a leak around the valve stem,
the valve must be closed and the gland nut tightened. If this action does not stop the leak, the use of
the cylinder must be discontinued, and it must be properly tagged and removed from the work area.

In the event that fuel gas is leaking from the cylinder valve, rather than from the valve stem, and the
gas cannot be shut off, the cylinder must be properly tagged and removed from the work area. If a
regulator attached to a cylinder valve will effectively stop a leak through the valve seat, the cylinder
need not be removed from the work area.

If a leak develops at a fuse plug or other safety device, the cylinder must be removed from the hot
work area. Cylinders not having fixed hand wheels must have keys, handles, or non-adjustable
wrenches on valve stems while in service.

Torches must be inspected before use for leaking shutoff valves, hose couplings, and tip
connections. Defective torches may not be used.

Torches must be lit by friction lighters or other approved devices, and not by matches or from hot
work.

6.5 Regulators and Gauges

Oxygen and fuel gas pressure regulators, including their related gauges, must be in proper working
order while in use.

6.6 Oil and Grease Hazards

Oxygen cylinders and fittings must be kept away from oil or grease. Cylinders, cylinder caps and
valves, couplings, regulators, hose, and apparatus must be kept free from oil or greasy substances
and must not be handled with oily hands or gloves. Oxygen must never be directed at oily surfaces,
greasy clothes, or within a fuel oil or other storage tank or vessel.

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6.7 Hoses

Fuel gas hose and oxygen hose must be easily distinguishable from each other. The contrast may be
made by different colors or by surface characteristics readily distinguishable by the sense of touch.
Oxygen and fuel gas hoses must not be interchangeable. A single hose having more than one gas
passage must not be used.
When parallel sections of oxygen and fuel gas hose are taped together, not more than 4 inches out
of 12 inches may be covered by tape.
All hoses carrying acetylene, oxygen, natural or manufactured fuel gas, or any gas or substance that
may ignite or enter into combustion, or be in any way harmful to employees, must be inspected at
the beginning of each working shift. Defective hoses must be removed from service.

Hoses which have been subject to flashback, or which show evidence of severe wear or damage,
must be tested to twice the normal pressure to which it is subject, but in no case less than 300 psi.
Defective hose, or hose in doubtful condition, must not be used. Hose couplings must be of the type
that cannot be unlocked or disconnected by means of a straight pull without rotary motion.

Boxes used for the storage of gas hoses must be ventilated. Hoses, cables, and other equipment
must be kept clear of passageways, ladders and stairs.

6.8 Torches

The operator must clean clogged torch tip openings with suitable cleaning wires, drills, or other
devices designed for such purpose. Torches must be inspected by the operator at the beginning of
each working shift for leaking shutoff valves, hose couplings, and tip connections. Do not use
defective torches.

Light torches with friction lighters or other approved devices, and not by matches or from hot work.

Personnel must follow the manufacturer's operating procedures for lighting the torch. Generally
accepted practices for start up and shut down follow:

A. Start Up

1. Open the oxygen valve on the torch handle and adjust the oxygen regulator to the
desired delivery range.
2. Close the torch handle oxygen valve.
3. Open the fuel valve on the torch handle and adjust the fuel regulator to the required
delivery range.
4. Close the torch fuel control valve.
5. Hold the torch in one hand and the spark lighter in the other. Open the torch fuel
valve approximately one-half turn and ignite the gas.
6. Point the torch away from people and combustible materials.
7. Keep opening the fuel valve until the flame stops smoking and bring the flame back
to the tip.
8. Open the torch oxygen valve until a bright neutral flame is reached.

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B. Shut Down

When shutting down the system, first shut off the oxygen, then the fuel gas. Drain the gas
pressures from the system.

7 ELECTRIC ARC WELDING AND CUTTING

7.1 Manual Electrode Holders

Only manual electrode holders which are specifically designed for arc welding and cutting, and are of
a capacity capable of safely handling the maximum rated current required by the electrodes, may be
used.

Any current-carrying parts passing through the portion of the holder that the operator grips in his
hand, and the outer surfaces of the jaws of the holder, must be fully insulated against the maximum
voltage encountered to ground.

7.2 Welding Cables and Connectors

Cables in need of repair may not be used. When a cable, other than the cable lead becomes worn to
the extent of exposing bare conductors, the portion thus exposed must be protected by means of
rubber and friction tape or other equivalent insulation.

7.3 Operating

A. Prior to beginning welding or cutting operations, workers must:

1. Check that the machine, all electrode holders and cable are capable of carrying the
maximum current, are properly insulated and grounded, and have been maintained
in good working condition.
2. Check that any cable splices have been performed with insulating quality equal to
that of the cable, and that there are no splices within 10 feet of the electrode.
3. The area must be free of chlorinated solvent vapors within 50 feet of the exposed
arc; surfaces prepared with chlorinated solvents shall be thoroughly dry before
welding is performed on them.

B. When arc welding is performed in wet or high humidity conditions, personnel must use
additional protection against electric shock (e.g., rubber pads or boots).

C. To protect workers or other personnel from the arc rays, noncombustible or flameproof
screens or shields shall be used, or personnel in the area shall wear appropriate goggles.

D. Manual electrode holders must be specific to welding and cutting, and capable of handling
the maximum current required for the operation. All current carrying parts gripped by the
user must be insulated against the maximum voltage to ground.

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E. Arc welding and cutting cables must be insulated, flexible, and capable of handling the
maximum current required by the operation, taking into account the duty cycles, and must
not have bare or worn conductors. Cables must be free of repair or splice from 10' of the
electrode holder unless insulated connectors or splices with insulating quality equal to that
of the cable are provided. Exposed metal parts must be insulated.

F. Ground return cables must have current carrying capacity equal to or exceeding the total
maximum output capacities of the welding or cutting unit. Do not use electrical conduits or
structures or pipelines containing gas or flammable liquids as part of the grounding circuit
system.

G. Arc welding and cutting machine frames must be grounded, either through a third wire in
the cable containing the circuit conductor or through a separate wire at the source of the
current. Grounding circuit resistance must be low enough to permit sufficient current to
flow to cause the fuse or circuit breaker to interrupt the current.

H. When machines are not in use, the power supply switch shall be shut off and the electrodes
removed and the holders placed to prevent employee injury.

7.4 Shielding

Whenever practical, all arc welding and cutting operations must be shielded by non-combustible or
flameproof screens, which will protect employees and other persons working in the vicinity from the
direct rays of the arc.

8 INERT GAS METAL ARC WELDING

When performing inert-gas metal-arc welding, extreme caution shall be used; inert gases can easily
displace oxygen. The following safeguards must be followed.

A. The area must be free of chlorinated solvent vapors within 50 feet of exposed arc; surfaces
prepared with chlorinated solvents shall be thoroughly dry before welding is performed on
them.

B. Employees exposed to radiation must have their skin completely covered.

C. If welding on stainless steel, personnel must be protected by local exhaust ventilation or by

wearing supplied-air respirators.

9 RESISTANCE WELDING

A. Prior to performing resistance welding operations, personnel must inspect the machine to
ensure:

1. All machine guards are in position and in proper working condition; and
2. Emergency stop button(s) are in working condition.

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B. Resistance welding equipment must be periodically inspected by qualified personnel, and a

certification record maintained. The record shall include the date of the inspection, the
signature of the person who performed the inspection, and the serial number or other
equipment identification.

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Appendix A. PERSONAL PROTECTION STANDARD GUIDE

List of Eye & Face Protection Selection Guide:

1 GOGGLES, flexible fitting, regular ventilation
2 GOGGLES, flexible fitting, hooded ventilation
3 GOGGLES, cushioned fitting, rigid body
4 SPECTACLES, metal frame, with side shields
5 SPECTACLES, plastic frame with side shields
6 SPECTACLES, metal-plastic frame, with side shields
7 WELDING GOGGLES, eyecup type, tinted lenses
7A CHIPPING GOGGLES, eyecup type, clear safety lenses
8 WELDING GOGGLES, coverspec type tinted lenses
8A CHIPPING GOGGLES, coverspec type, clear safety lenses
9 WELDING GOGGLES, coverspec type, tinted plate lens
10 FACE SHIELD (available with plastic or mesh window)
11 WELDING HELMETS

Applications as follow:

Application for shield as follow:

Welding Operation Shade #
Shielded metal-arc welding 10
1/16 to 5/32-inch diameter electrodes
Shielded metal-arc welding 12
3/16 to ¼-inch diameter electrodes
Shielded metal-arc welding 14
5/16 to 3/8-inch diameter electrodes
Gas-shielded arc welding (non-ferrous) 11
1/16 to 5/32-inch diameter electrodes

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Gas-shielded arc welding (ferrous) 12

1/16 to 5/32-inch diameter electrodes
Atomic hydrogen welding 10 – 14
Carbon-arc welding 14
Soldering 2
Torch brazing 3 or 4
Light cutting 3 or 4
Up to 1 inch
Medium cutting 4 or 5
1 to 6 inches
Heavy cutting 5 or 6
Over 6 inches
Gas welding (light) 4 or 5
Up to 1/8-inch
Gas welding (medium) 5 or 6
1/8 to 1/2 –inch
Gas welding (heavy) 6 or 9
Over 1/2 –inch

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Appendix B. WELDING & CUTTING PERMIT

Date of Permit: Date of Work Begins: Date of Completion:

Issued for Contractor Name:
Foreman/Supervisor Name: Emergency Contact Number:
Phone Number: Hours of Operation:
Location of Site where Work is to be performed :O in door O out door

Description of Work to be performed:

Equipment:
O Electric Arc
O Acetylene
O Calcium Carbide
O Gas Cylinders
O Others ……………………………………………….

Safety Requirement:
OFire Alarm ORequired, type ………… O Available
ORequired, type ………… O Available
OCylinder Storage ORequired, type ………… O Available
ORequired, type ………… O Available

Inspection Date: Inspection Time:

Prepared by Reviewed by Approved by

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