HERSHEY ENTERTAINMENT & RESORTS COMPANY
WELDING AND CUTTING PROCEDURES
The Company established Welding and Cutting Procedures guidelines to be followed whenever any of
our employees work with welding and cutting equipment. The procedures here establish uniform
requirements designed to ensure that welding and cutting safety training, operation, and maintenance
practices are communicated to and understood by affected employees. These requirements also are
designed to ensure that procedures are in place to safeguard the health and safety of all employees.
This program is designed to comply with the requirements for welding and cutting operations located
in 29 CFR 1910.251 through .255. This program also complies with the following standards or
regulations.
Standard or Regulation:
ANSI A13.1-1956
ANSI B31.3-1967
ANSI C33.2-1956
ANSI Z48.1-1954
ANSI Z49.1-1967
ANSI Z54.1-1963
ANSI B57.1-1965
ANSI Z87.1-1968
API Std. 1104-1968
API Std. PSD No.-1963
ASTM B88-66a
AWS A6.1-1966
CGA- E-8
CGA- SB-13
CGA- SB-11
CGA- E-1
NEMA EW-1-1962
NFPA 51B-1962
NFPA 80-1970
29 CFR 1910.132
29 CFR 1910.217
29 CFR 1910.219
29 CFR 1910.Subpart S
29 CFR 1910.1000
42 CFR 84
49 CFR 171-179
Name:
American National Standard Scheme for the Identification of Piping Systems
American National Standard Code for Pressure Piping
Safety Standard for Transformer-Type Arc-Welding Machines
American National Standard Method for Marking Portable Compressed Gas Containers to
Identify the Material Contained
Safety in Welding and Cutting
American National Standard Safety Standard for Non-Medical X-ray and Sealed GammaRay Sources
American National Standard Compressed Gas Cylinder Valve Outlet and Inlet
Connections
American National Standard Practice for Occupational and Educational Eye and Face
Standard for Welding Pipe Lines and Related Facilities
Welding or Hot Tapping on Equipment Containing Flammables
Standard Specification for Seamless Copper Water Tube
Recommended Safe Practices for Gas-Shielded Arc Welding
Standard for Gas Flow meters
Use of Regulator on Compressed Gas Cylinders Over 3000 psi.
Use of Rubber Welding Hose
Standard for Fitted Hose for Welding and Cutting Equipment
Requirements for Electric Arc Welding Apparatus
Standard for Fire Prevention in Use of Cutting and Welding Processes
Standard for the Installation of Fire Doors and Windows
Personal Protective Equipment-General Requirements
Mechanical Power Presses
Mechanical Power-Transmission Apparatus
Electrical
Air Contaminants
Approval of Respiratory Protective Devices
Hazardous Materials Regulations
Administrative Duties
The Corporate Safety Manager is responsible for developing and maintaining Welding and Cutting
Procedures. These procedures are kept at the safety office.
Welding and Cutting Equipment
The Company uses the following welding and cutting equipment:
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Make, Model, & Serial no.
Purox, “E”
Type
Cutting Torch
Quantity
1
Thermodine, Power Plus TA
10/270
Purox, “E”
Generator
1
Cutting Torch
1
Lincoln, 250 G9 PRO
Victor Torch
Generator
Cutting Torch
1
2
Lincoln TIG - 300
Thermal Dynamics, Pak Master
XL Plus
Lincoln Electric, Wire Feeder
Compressed Oxygen Cylinders
Generator
Mini Generator
2
1
Welder
Oxygen
1
8
Compressed Acetylene Cylinders
Acetylene
6
Compressed Argon Cylinders
Argon
3
Purpose
Cutting,
Welding
TIG Welding
Location
Field Truck
Cutting,
Welding
Welding
Cutting,
Welding
TIG Welding
Welding
Trailer
Welding
Welding,
Cutting
Welding,
Cutting
Welding
Maintenance Building
Throughout Department
Field Truck
Trailer
Maintenance Building
Maintenance Building
Maintenance Building
Throughout Department
Throughout Department
Affected Employees
While all employees have a general obligation to work safely with and around welding and cutting
operations, the following job titles have specific responsibilities:
Job Title
Welders
Mechanic
Department
Maintenance Department
Maintenance Department
Training
It is the policy of the Company to permit only trained and authorized personnel to operate welding and
cutting equipment. The Corporate Safety Manager will identify all new employees in the employee
orientation program and make arrangements with department management to schedule training.
The following person(s) will conduct initial training and evaluation:
• Supervisor of Maintenance
• Corporate Safety Manager
This instructor(s) has the necessary knowledge, training, and experience to train new welding and
cutting equipment operators. His or her qualifications include:
Initial Training
During an operator’s initial training, the instructor(s) combines both classroom instruction and
practical training. Classroom instruction includes the following formats:
•
•
Lecture
Discussion
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Written material
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Classroom instruction, itself, covers the following topics:
• Welding, cutting, and brazing hazards
(including fire hazards)
• Welding, cutting, and brazing types
• Testing methods
• Ventilation procedures
• Personal protective equipment
(PPE)
• Housekeeping measures
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•
•
•
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Safe operation and maintenance of
welding, cutting, and brazing equipment
Inspection procedures for equipment,
Alarm systems
Fire fighting equipment and use
Safe work practices for welding within
confined spaces
Practical training includes these formats:
1. Demonstrations performed by the trainer
2. Practical exercises performed by the trainee
All welders and cutters are trained and tested on the equipment they will be operating before they
begin their job. Practical training covers the following:
• Ventilation procedures
• Welding, cutting, and brazing hazards
(including fire hazards)
• Alarm systems
• Welding, cutting, and brazing types
• Fire fighting equipment and use
• Safe operation and maintenance of
• Personal protective equipment (PPE)
welding, cutting, and brazing equipment
• Housekeeping measures
• Inspection procedures for equipment
• Safe work practices for welding within
• Testing methods
confined spaces
During training, our company covers the operational hazards of the welding and cutting operations,
including:
1. Hazards associated with the particular make and model of the welding and cutting equipment;
2. Hazards of the workplace; and
3. General hazards that apply to the operation of all or most welding and cutting equipment.
See Appendix A for Company-specific hazards of our welding and cutting equipment and our workplace.
Each potential welder or cutter who has received training in any of the elements of our training program
for the types of equipment which that employee will be authorized to operate and for the type of
workplace in which the welding and cutting equipment will be operated need not be retrained in those
elements before initial assignment in our workplace if the company has evaluated and found that the
employee is competent to operate the equipment safely.
Training is done:
1. In-house training. See the attached current copy of the training material and the course outline.
2. Training by an outside vendor. See the attached information about the outside company and their
training materials.
Training Certification
After an employee has completed the training program, the instructor will determine whether the potential
welder or cutter can safely perform the job. At this point, the trainee will take a performance test or
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practical exercise through which the instructor(s) will decide if the training has been adequate. All
welding and cutting trainees are tested on the equipment they will be operating.
The Corporate Safety Manager is responsible for keeping records certifying each employee who has
successfully completed training and testing. Each certificate includes the name of the employee, the
date(s) of the training, the date of the evaluation, and the identity of the person who did the training and
evaluation.
Performance Evaluation
Each certified welder or cutter is evaluated to verify that the welder or cutter has retained and uses the
knowledge and skills needed to operate safely. The Corporate Safety Manager does this evaluation.
Refresher Training
Refresher training required if:
1. The welder/cutter is involved in an accident or near miss incident;
2. The welder/cutter has been observed performing unsafely;
3. When the welder/cutter is assigned to a different type of equipment;
4. It is determined during an evaluation that the welder/cutter needs additional training; or
5. When there are changes in the workplace that could affect safe operation of equipment, retraining
is performed.
Current Welders and Cutters
Under no circumstances may an employee operate welding or cutting equipment until he/she has
successfully completed the Company’s welding and cutting training program. All new welders or cutters
must undergo a performance evaluation, regardless of their level of experience. The following table lists
employees who are currently authorized welders and cutters at this company:
Department or work area
Maintenance
Maintenance
Employee name/title
Sam Holley/Welder
Paul Reiber/ Welder
Equipment make and model
All
All
All employees have a responsibility to work safely with and around welding and cutting operations.
Operating Procedures
Welding and cutting can create certain hazards that only safe work practices can prevent. The Company
has created a set of operating procedures to promote safe work practices and to eliminate certain hazards
associated with welding and cutting. These operating procedures include:
Electrical Equipment
• Employees should not arc weld while standing on damp surfaces or in damp clothing.
• Employees should properly ground, install, and operate equipment.
• Employees should not use defective equipment.
• Employees should use well-insulated electrode holders and cables.
• Employees should insulate themselves from both the work and the metal electrode and holder.
• Employees should not wrap a welding cable around your body.
• Employees should wear dry gloves and rubber-soled shoes.
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• Employees should not use damaged or bare cables and connectors.
• In case of electric shock, Employees should not touch a victim. Employees should turn off the
current at the control box and then call for help. After the power is off, employees may perform
cardiopulmonary resuscitation (CPR) if necessary.
Personal Protective Equipment
• Proper eye protection i.e., helmets, hand shields, goggles, and spectacles, must be provided.
• Proper protective clothing must be provided.
• First-aid equipment shall be available at all times.
• Air line respirators will be provided for confined space jobs when sufficient ventilation cannot
be provided without blocking the exit.
• When known or unknown toxic materials are present in a job, respirators will be provided that
match the hazard for all employees. The hazards include zinc or zinc-bearing base or filler
metals, lead base metals, cadmium-bearing filler metals, chromium-bearing or chromium-coated
metals, mercury, nitrogen dioxide, and beryllium. Due to beryllium’s extreme danger, both
ventilation and air-line respirators will be used.
• Where screens are not sufficient to protect welders and passersby from arc radiation, the
Company will provide eye protection with appropriate helmets, filter lens goggles, or hand
shields. The helmets and shields will be maintained in good repair.
• When a toxic preservative is detected on a surface in a confined space, air line respirators will be
provided (or the toxic coating will be stripped from at lest four inches around the heated area.)
Compressed Gas Cylinders
• Handling, storage, and use of compressed gases around the workplace represent a number of
potential hazards. Questions regarding the handling, storage and use of compressed gases are by
supervisors and/or the Compressed Gas Association Pamphlet P-1-1965.
• Approved practices include:
1. Employees should keep valve protection cap in place at all times when a cylinder is not in
use.
2. Employees should use care in handling and storage of cylinders, safety valves, relief
valves, etc., to prevent damage.
3. When cylinders are hoisted, employees should secure them on a cradle, slingboard, or
pallet.
4. Employees should move cylinders by tilting and rolling them on their bottom edges. Care
in handling is required.
5. Employees should secure cylinders in an upright position at all times, especially when
moving them by machine.
6. Employees should use carriers or carts provided for the purpose when cylinders are in use.
7. Employees should when in use, isolate cylinders from welding or cutting or suitable shield
them. Care will be taken to prevent them from becoming part of an electrical circuit.
8. Employees should maintain a distance of at least 20 feet or provide a non-combustible
barrier at least five feet high in separating fuel gas cylinders form oxygen cylinders. This
applies to indoor and outdoor storage.
9. The supervisor will designate: well-ventilated storage areas for cylinders inside buildings.
Care will be taken to keep storage areas out of traffic areas or other situations where they
could be knocked over, damaged, or tampered with; locations for fuel gas and oxygen
manifolds in well-ventilated areas.
10. Before a regulator is removed, employees should check that the valve is closed and the gas
released form the regulator.
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11. Employees should keep cylinders, cylinder valves, couplings, regulators, hoses, and
apparatus free of oily or greasy substances.
12. Employees should keep empty compressed gas cylinders appropriately marked and their
valves closed.
13. Employees should store full and empty cylinders apart.
14. Employees should group cylinders by type of gas.
15. Employees should use old stock before newer stock.
• Prohibited practices include:
1. Employees should not use of valve protection caps for lifting cylinders.
2. Employees should not use of damaged or defective cylinders. The plant manager will
provide appropriate tags and designate an appropriate storage area for these cylinders.
3. Employees should not use a wrench or hammer to open cylinder valves.
4. Employees should not attempt to repair a cylinder valve. The supplier should be contacted.
5. Employees should not mix gases.
6.Employees should not use a magnet or choker sling when hoisting cylinders.
7.Employees should not use a bar to pry cylinders form frozen ground. Warm, not boiling,
water is used to thaw cylinders.
8.Employees should not take oxygen, acetylene, or other fuel gas or manifolds with these
gases into confined spaces.
9.Employees should not store cylinders near elevators, stairs, or gangways.
• Using cylinders as rollers or supports.
Fire Prevention
1. The supervisor will assess fire hazards within the Company.
2. If the object to be welded or cut cannot readily be moved, all movable fire hazards in the vicinity
shall be taken to a safe place.
3. If the object to be welded or cut cannot be moved and if all the fire hazards cannot be removed,
then guards shall be used to confine the heat, sparks, and slag, and to protect the immovable fire
hazards.
4. If the requirements stated in two and three above cannot be followed then welding and cutting
shall not be performed.
5. Wherever there are floor openings or cracks in the flooring that cannot be closed, employees
should take precautions so that no readily combustible materials on the floor below will be
exposed to sparks, which might drop through the floor. The same precautions shall be observed
with regard to cracks or holes in walls, open doorways, and open or broken windows.
6. Suitable fire extinguishing equipment shall be provided and maintained in a state of readiness for
instant use. Such equipment may consist of pails of water, buckets of sand, hose or portable
extinguishers depending upon the nature and quantity of the combustible material exposed.
7. Before cutting or welding is permitted, the employee responsible for authorizing cutting and
welding operations shall inspect the area. The employee shall designate precautions to be
followed in granting authorization to proceed preferable in the form of a written permit.
8. Special precautions shall be taken for floors covered with combustible materials; combustibles
within 35 feet of the work area; ducts that might carry sparks; combustible walls; combustibles on
the other side of a noncombustible wall; combustible coverings; pipes in contact with combustible
walls; storage of readily ignitable materials; drums barrels, tanks other containers that may contain
flammable materials; pipes leading to a drum or vessel; and all hollow spaces, cavities or
containers.
9. The Company will designate an employee to be responsible for authorizing welding operations in
areas not designed for such processes.
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10. The Company will advise all contractors about flammable materials or hazardous conditions.
11. Cutting or welding shall not be permitted in the following situations:
In areas not authorized by management.
In sprinklered buildings while such protection is impaired.
In the presence of explosive atmospheres (mixtures of flammable gases, vapors, liquids, or
dusts with air), or explosive atmospheres that may develop inside unclean or improperly
prepared tanks or equipment which have previously contained such materials, or that may
develop in areas with an accumulation of combustible dusts.
Fire Watchers
Fire watchers shall be required when:
• Welding or cutting is performed in locations where other than a minor fire might develop, or
any of the following conditions exist.
• There is an appreciable combustible material, in building construction or contents, closer than
35 feet (10.7m) to the point of operation.
• There is appreciable combustibles are more than 35 feet (10.7m) away but are easily ignited by
sparks.
• Wall or floor openings within a 35-foot (10.7m) 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.
• Fire watchers shall have fire extinguishing equipment readily available and be trained in its
use.
• Fire watchers will be trained on the specific fire hazards.
• Fire watchers must remain at the site at least a half-hour after completion of welding or cutting
operations to detect and extinguish possible smoldering fires.
Gas Welding and Cutting
Safe practices in using fuel gas include:
• Before a regulator to a cylinder valve is connected, employees should “crack” the valve to
clear it of dust or dirt. Employees should stand to one side of the outlet, not in front of it.
Employees should not do this where the gas would reach welding work, sparks, flame, or other
possible sources of ignition.
• Employees should open cylinder valves slowly to prevent damage to the regulator. For quick
closing, do not open valves on fuel gas cylinders more than 1 ½ turns. When a special wrench
is required, leave it in position on the valve stem while the cylinder is in use. In the case of
manifold or coupled cylinders, make sure at least one such wrench is always available for
immediate use.
• Employees should not place anything on top of a fuel gas cylinder, when in use, which may
damage the safety device or interfere with quick closing.
• Employees should not use fuel gas directly from cylinders through torches or other devices
equipped with shutoff valves without reducing the pressure through a suitable regulator.
• Before a regulator is removed from a cylinder valve, employees should always close the
cylinder valve and release the gas from the regulator.
• If the gas leaks around the valve stem, employees should close the valve and tighten the gland
nut. If this does not work, employees should not use the cylinder, but properly tag it and
remove it from the work area.
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If fuel gas leaks from the cylinder valve and the gas cannot be shut off, employees should
properly tag and remove the cylinder from the work area. If a regulator will effectively stop a
leak through the valve seat, the cylinder can be used.
Employees should not use oxygen for personal cooling, cleaning off of surfaces, ventilation, or
blowing dust from clothing.
Employees should not weld or cut an acetylene or oxygen pipeline, including the attachment of
hangers or supports, until the line has been purged.
Employees should only use pressure-reducing regulators for gas and pressures for which they
are intended.
Employees should not attempt to repair a regulator or parts of a regulator. Have a skilled
mechanic do so.
Safe practices in using torches include:
• Employees should clean clogged tip openings only with suitable cleaning wires, drills, or other
devices designed for such purpose.
• Employees should inspect at the beginning and end of each shift for leaking shutoff valves,
hose couplings, and tip connections. Do not use defective torches.
• Employees should light only with friction lighters or other approved devices. Do not use
matches or hot work.
Safe practices in using regulators and gauges include:
• Employees should make sure oxygen and fuel gas pressure regulators, including their related
gauges are in proper working order.
• Employees should keep oxygen cylinders and fittings away from oil or grease. Oxygen shall
not be directed at oily surfaces, greasy clothes, or within a fuel oil or other storage tank or
vessel.
Arc Welding and Cutting
• When arc welding is performed in wet conditions, or under conditions of high humidity,
special protection against electric shock shall be supplied.
• Employees should not dip a hot electrode into water.
• Employees should use holders, cable, and other apparatus specifically designed for the
purpose, matched to the job and other components and in good repair.
• When leaving electrode holders unattended, electrodes must be removed and holders placed so
that accidental electrical contact is not made.
• Employees should use non-combustible or flame-proof screens to protect employees and
passersby from arc rays whenever possible.
• Employees assigned to operate or maintain gas-shielded arc welding equipment shall be
acquainted with the requirements of American Welding Society, A6.1-1966, Recommended
Safe Practices for Gas-Shielded Arc Welding.
• 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; magnetic work clamps
shall be freed from adherent metal particles of spatter on contact surfaces. Coiled welding
cable shall be spread out before use to avoid serious overheating and damage to insulation.
• Grounding of the welding machine frame shall be checked. Special attention shall be given to
safety ground connections of portable machines.
• There shall be no leaks of cooling water, shielding gas, or engine fuel.
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•
•
•
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•
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It shall be determined that proper switching equipment for shutting down the machine is
provided.
Printed rules and instructions covering operation of equipment supplied by the manufacturers
shall be strictly followed.
Electrode holder when not in use shall be so placed that they cannot make electrical contact
with persons, conducting objects, fuel, or compressed gas tanks.
Cables with splices within 10 feet (3m) of the holder shall not be used. The welder should not
coil or loop welding electrode cable around parts of his or her body.
The operator should report any equipment defect or safety hazard to his supervisor and the use
of the equipment shall be discontinued until its safety has been assured. Only qualified
personnel shall make repairs.
Machines that have become wet shall be thoroughly dried and tested before being used.
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 be insulation adequate for the service
conditions.
Ventilation
• The supervisor will determine the number, location, and capacity of ventilation devices.
• Ventilation will be sufficient to protect passersby as well as the welder.
• Oxygen shall never be used for ventilation.
• Employees should not rely on general ventilation as the only means of protection when air
contaminants are toxic.
• Where ventilation is not sufficient to provide clean, breathable air, respirators will be specified
according to specifications listed in the Personal Protective Equipment row of this table.
Confined Spaces
• Employees should evaluate the space, the hazardous atmosphere, the floor surface, and the
interior surface for flammability, combustibility, or toxic fumes that could result from the
welding process.
• Employees should perform atmospheric testing for testing for oxygen deficiency, and for toxic
and flammable or combustible gases before and during entry. If the tests show that flammable
or combustible gases are present, the space must be ventilated until safe to enter. If the
atmosphere is toxic and cannot be cleared through ventilation, appropriate respiratory
equipment must be used. All energy sources that could cause employee injury must be
disconnected and locked in the “off” position before entry.
• Gas cylinders and welding machines shall be left on the outside of the confined space. Before
operations are started, heavy portable equipment mounted on wheels shall be securely blocked
to prevent accidental movement.
• Where a welder must enter a confined space through a manhole or other small opening, means
shall be provided for quickly removing him in case of emergency. When safety belts and
lifelines are used for this purpose they shall be so attached to the welder’s body so that his or
her body cannot be jammed in a small exit opening. An attendant with a preplanned rescue
procedure shall be stationed outside to maintain communication with the welder at all times
and be capable of putting rescue operations into effect.
• When arc welding is to be suspended for any substantial period of time, such as during lunch
or overnight, all electrodes shall be removed from the holders carefully located so that
accidental contact cannot occur and the machine disconnected from the power source.
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In order to eliminate the possibility of gas escaping through leaks of improperly closed valves,
when gas welding or cutting, the torch valves shall be closed and the fuel-gas and oxygen
supply to the torch positively shut off at some point outside the confined area whenever the
torch is not to be used for a substantial period of time, such as during lunch hour or overnight.
Where practicable the torch and hose shall also be removed from the confined space.
After welding operations are completed, the welder shall mark the hot metal or provide some
other means of warning other workers.
Flammable, Toxic, or Hazardous Materials
• The Company will designate an employee who is responsible for testing the flammability of
unknown coatings.
• When a coating is found to be highly flammable, it will be stripped from the area to prevent
fire.
Slip, Trip, and Fall Protection
• A welder or helper working on platforms, scaffolds, or runways shall be protected against
falling. This may be accomplished by the use of railings, safety belts, lifelines, or some other
equally effective safeguards.
• Welders shall place welding cable and other equipment so that it is clear of passageways,
ladders, and stairways.
• Employees should maintain a clear welding or cutting area to prevent slips, trips, and falls.
Inspections
A number of inspections are required under the welding and cutting regulations. To make inspections
efficient, the Company has compiled a list of inspection items to be checked before welding or cutting:
Welding Inspection Items Include:
• Are only authorized and trained personnel permitted to use welding, cutting or brazing equipment?
See 29 CFR 1910.252(a)(2)(xii)(C)
• Does each operator have a copy of the appropriate operating instructions and are they directed to
follow them? See 29 CFR 1910.253(a)(4),(d)(6),(f)(7)(A)
• Are pressure-reducing regulators used only for the gas and pressures for which they are intended?
See 29 CFR 1910.253(e)(6)(i)
• Is grounding of the machine frame and safety ground connections of portable machines checked
periodically? See 29 CFR 1910.254(d)(3);255(b)(9),(c)(6)
• Are only approved apparatus (torches, regulators, pressure-reducing valves, acetylene generators,
manifolds) used? See 29 CFR 1910.253(a)(3)
• Is a check made for adequate ventilation in and where welding or cutting is performed? See 29
CFR 1910.252(c)(1)(iii),(2)(i)
• When working in confined places, are environmental monitoring tests taken and means provided
for quick removal of welders in case of an emergency? See 29 CFR 1910.252(c)(4)
Welding Equipment Inspection Items Include:
• Is necessary personal protective equipment available? See 29 CFR 1910.252(b)(2)
• Are only approved apparatus used? See 29 CFR 1910.253(a)(3)
• Is open circuit (No Load) voltage of arc welding and cutting machines as low as possible and not
in excess of the recommended limits? See 29 CFR 1910.254(b)(3)(i)-(iv)
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Is grounding of the welding machine frame and safety ground connections of portable machines
checked periodically? See 29 CFR 1910.254(d)(9),(c)(6)
Equipment Marking Inspection Items Include:
• Is red used to identify acetylene (and other fuel-gas) hose, green for oxygen hose, and black for
inert gas and air hose? See 29 CFR 1910.253(e)(5)(i)
• Are empty compressed gas cylinders appropriately marked and their valves closed? See 29 CFR
1910.101(b)(1)(ii),(2)(iii),(5)(ii)(H)
Compressed Gas Cylinder Management Inspection Items Include:
• Are compressed gas cylinders regularly examined for obvious signs of defects, deep rusting, or
leakage? See29 CFR 1910.254(d)(4);255(e)
• Is care used in handling and storage of cylinders, safety valves, relief valves, etc., to prevent
damage? See 29 CFR 1910.253(b)(2)(II),(5)(iii)(B)
• Are liquefied gases stored and shipped valve-end up with valve covers in place? See 29 CFR
1910.253(b)(5)(iii)(A)
• Before a regulator is removed, is the valve closed and gas released from the regulator? See 29
CFR 1910.253(b)(5)(iii)(D)
• Are cylinders, cylinder valves, couplings, regulators, hoses, and apparatus kept free of oily or
greasy substances? See 29 CFR 1910.253(b)(5)(i)
• Are the cylinders kept away from elevators, stairs, or gangways? See 29 CFR 1910.253(b)(2)(ii)
• Is it prohibited to use cylinders as rollers or supports? See 29 CFR 1910.253(b)(5)(ii)(B)
• Is care taken not to drop or strike cylinders? See 29 CFR 1910.253 (b)(5)(ii)(B)
• Unless secured on special trucks, are regulators removed and valve-protection caps put in place
before moving cylinders? See 29 CFR 1910.253(b)(5)(ii)(D)
• Do cylinders without fixed hand wheels have keys, handles, or non-adjustable wrenches on stem
valves when in service? See 29 CFR 1910.253(b)(5)(ii)(E)
• Are empty compressed gas cylinders appropriately marked and their valves closed? See 29 CFR
1910.253(b)(1)(ii), (2)(iii), (5)(ii)(H)
• Are fuel gas cylinders and oxygen cylinders separated by distance, fire resistant barriers, etc.,
while in storage? See 29 CFR 1910.253(b)(4)(iii)
Air emission Inspection Items Include:
• If welding creates hazardous air emissions, is the welding area appropriately marked to indicate
this?
• If welding creates hazardous air emissions, have ventilation or local exhaust systems been
provided to keep fumes below the maximum allowable concentrations?
Aisle Inspection Items Include:
• Are aisles marked?
• Are aisle widths maintained?
• Are aisles in good condition?
• Are aisles and passageways properly illuminated?
• Are aisles kept clean and free of obstructions?
Fire Alarm System Inspection Items Include:
• If you have a non-supervised fire alarm system, is it tested bimonthly?
• If you have a supervised employee alarm system, is it tested yearly?
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Portable Fire Extinguisher Inspection Items Include:
• Are appropriate fire extinguishers mounted, located, and identified so that they are readily
accessible to employees?
• Are all fire extinguishers inspected and recharged regularly, and noted on the inspection tag?
• Are portable fire extinguishers provided in adequate number and type?
Fire Prevention Inspection Items Include:
• Are precautions taken to prevent the mixture of air or oxygen with flammable gases, except at a
burner or in a standard torch?
• Are signs reading “DANGER NO SMOKING, MATCHES, OR OPEN LIGHTS” or the
equivalent, posted in welding areas?
• Are provisions made to never crack a fuel-gas cylinder valve near source of ignition?
• When welding is done on metal walls, are precautions taken to protect combustibles on the other
side?
• Before hot work is begun, are used drums, barrels, tanks, and other containers so thoroughly
cleaned that no substances remain that could explode, ignite, or produce toxic vapors?
• If welding gases are stored, does a 5-foot noncombustible barrier separate oxygen and acetylene?
• Are compressed gas cylinders kept away from sources of heat?
• Is combustible scrap, debris, and waste stored safely and removed from the work site promptly?
• Are fire watchers assigned when welding or cutting if performed in locations where a serious fire
might develop?
• Are provisions made for personnel to perform fire watch duties under appropriate circumstances?
Personal Protective Equipment Inspection Items Include:
• Are all employees required to use personal protective equipment (PPE) as needed?
• Is PPE functional and in good repair? Does it have ANSI or ASTM specifications marked on it?
• Are employees exposed to the hazards created by welding, cutting, or brazing operations protected
with personal protective equipment and clothing?
• Is personal protective equipment provided and are all employees required to use PPE as needed to
protect against eye and face injury?
• Are protective goggles or face shields provided and worn where there is any danger of flying
particles or corrosive materials?
• Are approved safety glasses required to be worn at all times in areas where there is a risk of eye
injuries such as punctures, abrasions, contusions, or burns?
• Are appropriate safety glasses, face shields, etc., used while using hand tools or equipment, which
might produce flying materials, or be subject to breakage?
• Are employees who need corrective lenses in working environments having harmful exposures
required to wear only approved safety glasses, protective goggles, or use other medically approved
precautionary procedures?
• Is appropriate foot protection required where there is a risk of foot injury?
• Is appropriate hand protection required where there is the risk of hand injury?
• Are hard hats provided and worn where danger of falling objects exist?
• Are hard hats inspected periodically for damage to the shell and suspension system?
H E & R 2005
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Maintenance
Any deficiencies found in the Company welding and cutting equipment are repaired, or defective parts
replaced, before continued use. However, no modifications or additions that affect the capacity of safe
operation of the equipment may be made without the manufacturer’s written approval. If such
modifications or changes are made, the capacity, operation, and maintenance instruction plates, tags, or
decals, must be changed accordingly. In no case may the original safety factor of the equipment be
reduced.
While defective parts may be found, we prefer to invest time and effort into the proper upkeep or our
equipment, which results in day-to-day reliability. The Company compiles with the manufacturer’s
recommended maintenance schedules, and complete the proper records, which not only increases the
longevity of welding and cutting equipment but also its day to day reliability.
The Corporate Safety Manager completes(s) a receiving or delivery inspection whenever the Company
purchases welding and cutting equipment.
Welders follow the manufacturer’s operator instruction manual for daily or weekly maintenance. See
attached manufacturer’s operator instruction manual(s).
Periodic maintenance (those completed monthly or less frequently) is done by a factory-trained expert, or
a dealer.
Signs and Labels
The Company uses the following signs:
1. After welding operations are completed, all welders must mark the hot metal or provide some
other means of warning other workers.
2. A warning should be placed near cylinders having leaking fuse plugs or other leaking safety
devices not to approach them with a lighted cigarette or other source of ignition. Such cylinders
should be plainly tagged; the supplier should be promptly notified and his instructions followed as
to their return.
3. The following sign shall be conspicuously posted at each manifold:
Low-Pressure Manifold
Do Not Connect High-Pressure Cylinder
Maximum Pressure-250 psig (1.7 MPa)
4. Aboveground piping systems shall be marked in accordance with the American National Standard
Scheme for the Identification of Piping Systems, ANSI A13.1-1956, which is incorporated by
reference as specified in 29 CFR 1910.6.
5. Station outlets shall be marked to indicate the name of the gas.
6. Acetylene generators shall be of approved construction and shall be plainly marked with the
maximum rate of acetylene in cubic feet per hour for which they are designed; the weight and size
of carbide necessary for a single charge; the manufacturer’s name and address; and the name or
number of they type of generator.
7. Operating instructions shall be posted in a conspicuous place near the generator or kept in a
suitable place available for ready reference.
H E & R 2005
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The Company uses the following labels:
1. Lenses shall bear some permanent distinctive marking by which the source and shade may be
readily identified.
2. Precautionary labels. A number of potentially hazardous materials are employed in fluxes,
coatings, coverings, and filler metals used in welding and cutting or are released to the atmosphere
during welding and cutting. The suppliers of welding materials shall determine the hazard, if any,
associated with the use of their materials in welding, cutting, etc.
3. All filler metals and fusible granular materials shall 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 Z49.1-1967 Safety in Welding and Cutting published by the American
Welding Society.
4. Brazing (welding) filler metals containing cadmium in significant amounts shall 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
air-supplied respirators. See ANSI Z49.1-1967. If chest pains, cough, or fever develops after use call
physician immediately.
5. Brazing and gas welding fluxes containing fluorine compounds shall have a cautionary wording to
indicate that they contain fluorine compounds. One such cautionary wording recommended by the
American Welding Society for brazing and gas welding fluxes reads as follows:
CAUTION
CONTAINS FLUORIDES
This flux when heated gives off fumes that may irritate eyes, nose and throat.
Avoid fumes-use only in well-ventilated spaces.
Avoid contact of flux with eyes or skin.
Do not take internally.
6. Compressed gas cylinders shall be legibly marked, for the purpose of identifying the gas
content, with either the chemical or the trade name of the gas. Such marking shall by means of
stenciling, stamping, or labeling, and shall not be readily removable. Whenever practical, the
marking shall be located on the shoulder of the cylinder. This method conforms to the
American National Standard Method for Marking Portable Compressed Gas Containers to
Identify the Material Contained, ANSI Z48.1-1954, which is incorporated by reference as
specified in 29 CFR 1910.6.
7. Gages on oxygen regulators shall be marked “USE NO OIL.”
8. The total hourly output of a generator shall not exceed the rate for which it is approved and
marked. Unless specifically approved for higher ratings, carbide-feed generators shall be rated
at 1 cubic foot per hour per pound of carbide required for a single complete charge.
9. Packages containing calcium carbide shall be conspicuously marked “Calcium CarbideDangerous If Not Kept Dry” or with equivalent warning.
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10. Terminals for welding leads should be protected from accidental electrical contact by personnel
or by metal objects, i.e., vehicles, crane hooks, etc. Protection may be obtained by use of :
Dead-front receptacles for plug connections; recessed openings with non-removable hinged
covers; or heavy insulating sleeving or taping or other equivalent electrical and mechanical
protection. If a welding lead terminal which is intended to be used exclusively for connection
to the work is connected to the grounded enclosure, it must be done by a conductor at least two
AWG sizes smaller than the grounding conductor and the terminal shall be marked to indicate
that it is grounded.
Record Keeping
The Corporate Safety Manager is responsible for maintaining the following records:
1. Authorization permits: before cutting or welding is permitted, the employee responsible for
authorizing cutting and welding operations shall inspect the area. The employee shall designate
precautions to be followed in granting authorization to proceed preferably in the form of a
written permit.
2. Rules and instructions for operation and maintenance of oxygen or fuel-gas supply
equipment: Employees in charge of the oxygen or fuel-gas supply equipment, including
generators, and oxygen or fuel-gas distribution piping systems shall be instructed and judged
competent by the Company for this important work before being left in charge. Rules and
instructions covering the operation and maintenance of oxygen or fuel-gas supply equipment
including generators, and oxygen of fuel-gas distribution piping systems shall be readily
available.
3. Trouble reports: Cylinder valves shall not be tampered with nor should any attempt be made
to repair them. If trouble is experienced, the supplier should be sent a report promptly
indicating the character of the trouble and the cylinders serial number. Supplier’s instructions
as to its disposition shall be followed.
4. Operating instructions: Operating instructions shall be posted in a conspicuous place near the
generator or kept in a suitable place available for ready reference.
5. Certification records for resistance welding equipment: Periodic inspection shall be made
by qualified maintenance personnel, and a certification record maintained. The certification
record shall 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
shall be instructed to report any equipment defects to his or her supervisor and the use of the
equipment shall be discontinued until safety repairs have been completed.
These records are maintained in the Safety Office.
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Appendix A
Company-specific hazards of our welding and cutting equipment and our workplace include:
Location
Maintenance
Equipment
Oxyacetylene
Hazard
Fire
Maintenance
Oxyacetylene
Fumes
Maintenance
Maintenance
Oxyacetylene
Oxyacetylene
Intense Heat
Gas Leaks
Maintenance
Maintenance
Oxyacetylene
Oxyacetylene
Electrical Shock
Byproduct
Maintenance
Oxyacetylene
Spackle
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Protection Method
• Fire blankets
• Fire Extinguishers
• Shields
• Respirators
• Hoods
• Protective Clothing
• Proper care of cylinders
• Inspection of cylinders
• Inspection of hoses
• Proper lockout/tagout
• Respirators
• Protective clothing
• Protective clothing
Rev. 2012
Appendix B
List of welding and cutting equipment:
Make, Model, & Serial no.
Purox, “E”
Type
Cutting Torch
Thermodine, Power Plus TA
10/270
Purox, “E”
Generator
1
Cutting Torch
1
Lincoln, 250 G9 PRO
Victor Torch
Generator
Cutting Torch
1
2
Lincoln TIG - 300
Generator
2
Thermal Dynamics, Pak
Master XL Plus
Lincoln Electric, Wire
Feeder
Compressed Oxygen
Cylinders
Compressed Acetylene
Cylinders
Compressed Argon
Cylinders
Mini Generator
1
Purpose
Cutting,
Welding
TIG
Welding
Cutting,
Welding
Welding
Cutting,
Welding
TIG
Welding
Welding
Welder
1
Welding
Oxygen
8
Acetylene
6
Argon
3
Welding,
Cutting
Welding,
Cutting
Welding
H E & R 2005
Quantity
1
17
Location
Field Truck
Field Truck
Trailer
Trailer
Maintenance
Building
Maintenance
Building
Maintenance
Building
Maintenance
Building
Throughout
Department
Throughout
Department
Throughout
Department
Rev. 2012