Welding Control Procedure

1
1.1

SMSP 5016

Procedure Description
This procedure describes how welding is controlled by the department.

2
2.1 2.2

Required Documentation
Technical information on welding equipment is held in the Technical Library Inspections of electrical equipment are held on file in the Technical Library.

3
3.1

Selection of New Welding Equipment

All proposed new welding equipment shall be risk assessed prior to its purchase to ensure its suitability. The Engineering Supervisor shall assess the welding capability and the electrical requirements. As a minimum the review shall ensure that the equipment is: 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 Suitable for its use Suitable for the environment in which it shall be used Ergonomically designed Adjustable to suit the operator CE certified Approved to the appropriate standard given in tables 1,3 & 4. Supplied with correctly coloured hoses, as shown in table 2. Free from fittings with a copper content above 90% (which allows explosive copper acetylide to form).

3.2

On delivery, new welding equipment shall be inspected to ensure the requirements have been met. Equipment shall be inspected and entered on the Equipment Register with a test certificate.

4
4.1

Authorisation
Only persons who have been trained and authorised shall use welding or gas cutting equipment

5
5.1

Risk Assessments
Risk assessments shall be done on work out with the scope of this procedure. Such assessments shall be done on the advice of competent welding personnel.

6
6.1 6.2

General
The Engineering Supervisor shall arrange welding operations as required. Welding procedures that control the quality and physical parameter of the actual welding is not detailed in this procedure. No welding or cutting operations shall be performed on charged pipes, tanks or vessels until risk assessed and made safe. Gas equipment shall be ignited only with the use of proper torch lighters. Date: 01/12/08 Page: 1 of 6

6.3

6.4

2nd Edition Rev 11

Welding Control Procedure

7
7.1

SMSP 5016

PPE
The following PPE shall be used in welding and cutting operations: 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 Goggles Screens Masks Leather Gauntlets Leather Aprons Leather Jackets

8
8.1

Eye Protection When Arc Welding

All welders and persons assisting welders shall ensure that they use the provided eye protection for UV light and sparks from arc welding. Before using electric arc equipment welders shall position welding screens and signs to protect others in the vicinity. Where this is not practical, for reasons of ventilation or access, the welder shall inform those persons of his/hers intent. In such cases the welder shall also inform those persons when they have finished.

8.2

9
9.1

Hot Surfaces & Fire Risk

Welders shall: 9.1.1 9.1.2 Inform those in the vicinity that welding/cutting is about to take place. Remove flammable materials from the risk of burning where possible or screened them where this is not practical. Not leave hot surfaces unattended. Prevent falling off-cuts, rod stubs and sparks showering persons or items below with sparks and hot metal. Take precaution that the spread of heat does not damage the surroundings. Not hang blowpipes from cylinders and regulators while alight. Ensure that fire extinguishers are available. Not coil hoses or leads around their body.

9.1.3 9.1.4

9.1.5 9.1.6 9.1.7 9.1.8

10
10.1 10.2

Ventilation
Oxygen shall not be used for ventilation Breathing apparatus shall be used when welding or cutting metals coated with any of the following unless alternative proven effective ventilation can be used: 10.2.1 Metallic Lead 10.2.2 Zinc

2nd Edition Rev 11

Date: 01/12/08 Page: 2 of 6

Welding Control Procedure

10.2.3 Lead Paints 10.2.4 Cadmium 10.2.5 Others as required in COSHH assessments 10.3

SMSP 5016

Where possible extraction of gases shall be used rather than blowing; which only dilutes the gases.

11
11.1

Confined Spaces
Welding in a confined space shall be done in accordance with the confined space procedure. Electrical welding plant to be used in a confined space shall be comply with table 3. DC equipment shall be used in preference to AC. If used, AC equipment shall be fitted with voltage regulators; which restricts the no load voltage to 40V before the electrode makes contact with the work piece.

11.2

12
12.1

Doubler Plates
Care shall be exercised when welding in the space between doubler or ware plates to exclude the possibility of flammable substances, if necessary seek advice.

13
13.1

Repairs to Small Containers

Small containers, which have contained a flammable substance, shall be thoroughly steam cleaned before use. No other method of cleaning shall be acceptable. The container shall be certified as gas free before any hot work is done on it. A constant supply of fresh air shall circulate any container on which hot work is being done.

13.2 13.3

14
14.1

Equipment Inspection
All welding equipment shall be routinely inspected for safety according to the planned maintenance schedule. Persons deemed competent by the Engineering Supervisor shall inspect gas equipment. Persons deemed competent by the Engineering Supervisor shall inspect electrical equipment. Welders shall satisfy themselves that equipment is safe and suitable for a task before using it.

14.2

14.3

14.4

15
15.1 15.2 15.3 15.4

Gas Cylinder Storage

Full and empty cylinders shall be segregated and clearly marked as such. Cylinders shall be stored clear from flammable materials or sources of heat. Cylinders shall be stored vertically. Cylinders shall be stored at least 1m back from property boundaries.

2nd Edition Rev 11

Date: 01/12/08 Page: 3 of 6

Welding Control Procedure

15.5

SMSP 5016

Where cylinders are stored outside they shall be kept out of direct sunlight and protected from rain and seaspray. Oxygen and acetylene cylinders shall be stored separately.

15.6

16
16.1 16.2

Gas Cylinder Handling

Cylinders shall not be dropped or allowed to fall over. Cylinders shall be hoisted only in purpose built lifting frames.

17
17.1 17.2

Fittings for Gas Equipment

Packing shall not be used in valve joints. No temporary repairs shall be attempted. Faulty valve joints on cylinders shall be placed outside in an area clear from persons and marked to indicate the hazard. The Engineering Supervisor shall be informed immediately. Only standard valve keys shall be used. Leaks at the valve are occasionally caused by grit and may be removed by opening the valve slowly and closing it quickly. The adjustable screw on regulator valves shall always be released before the cylinder is opened. The cylinder valve must be closed before the regulator is removed. Care shall be taken when using high-pressure equipment to ensure that all items of equipment are suitable for the pressure. Blowpipes will be replaced if blocked. NRVs shall be fitted to the inlet of all blowpipe inlets. Floating plate type NRVs shall not be used. Flame arresters with pressure or temperature cut-off valves shall be fitted to pressure regulator outlets on both oxygen and acetylene. Hoses shall not be used for any other purpose or with any other gas than that indicated by its colour. The supply of both gases shall be shut off before changing any item in a system. The protective coating of French chalk on new hoses shall be removed by blowing threw with air (not oxygen) before use. Gas fittings shall not be lubricated with grease, oil etc for fear of explosion.

17.3 17.4

17.5

17.6

17.7 17.8

17.9

17.10

17.11 17.12

17.13

18
18.1 18.2

Electrical Requirements
Jewellery shall not be worn while using electrical welding equipment. When changing welding rods, welders should not place the electrodes between the legs or particularly under the arm. The area can be damp and may allow a fatal current to pass through the heart. Similarly when working in wet conditions or when the body is in direct electrical contact with the earthed work piece it is recommended that the welder should either isolate the rod holder or shut down the plant between rod changes. Welders should be aware that only milliamps of current is required to cause the heart to stop. Those in a supervisory role are responsible for providing safe site conditions for welders. Date: 01/12/08 Page: 4 of 6

2nd Edition Rev 11

Welding Control Procedure

18.3

SMSP 5016

When not in use electrode holders shall be placed in or hung on an approved insulating container or hook. All welding machines shall be of a type that has a transformer that is isolated and double/reinforced insulated (see table 3) Welding machines, which are to be used outside, shall have an IP rating of at least IP54 Where welding is to be done on equipment that is connected to electrical supplies, the supplies shall be isolated before welding is done. Welding machines shall be kept as close to the work as possible to reduce the lead length and allow the welder greater control over the process. Where more than one person is using the same welding unit the polarity of each feed and return leads shall be kept the same. Where two or more leads are used in a confined space the corresponding leads shall be paired. The crossing of any leads shall be avoided. Leads shall be extended to circumnavigate areas containing oil, chemicals etc. A welding return lead shall be provided from the neutral/earth for each welding supply of an AC welding transformer or the negative terminal of a DC unit to the workpiece. The connection shall be made as near as possible to the place where the welding is being done. Buildings earthing system shall not be used as a return path. Welding equipment that operates on different phases shall not be used in the same area. The Engineering Supervisor shall be informed of any proposed alteration or new welding systems to ensure electrical safety. When refuelling generator sets the engine shall be turned off. Care shall be taken not to place generator sets next to walls or in areas where the air cannot circulate properly to allow proper cooling.

18.4

18.5

18.6

18.7

18.8

18.9

18.10 18.11

18.12

18.13 18.14

19
19.1

Earthing and Bonding

The work piece shall be bonded to earth by means of a heavy section conductor and a good electrical connection made with clamps or bolted connections. The low voltage AC winding on welding transformers shall not be earthed. Only the transformer casing shall be earthed. For DC generators no earth connection shall be made to either pole of the output. Only the machine frame shall be earthed. Earth bonding shall not be done on fuel lines, propellers, shafts or bearings.

19.2

19.3

19.4

20
20.1

Stray Currents
When two items are to be welded together, neither of the items being permanently fixed, both items shall be electrically connected to the welding return. Electrode holders shall have a protective guard disc between the handle and the consumable. Electrode holders shall be renewed immediately if damaged. Date: 01/12/08 Page: 5 of 6

20.2

20.3

2nd Edition Rev 11

Welding Control Procedure

20.4

SMSP 5016

Electrode holders shall be placed on an insulated area or supports when not in use.

Table 1: Gas Equipment Standards Gas Equipment Gas Cylinders: Regulators < 200bar Regulators > 200bar < 300bar: Manifold Gas Supplies Pressure Gauges Hoses Connections Quick Action Hose Connections Combined Hose Assemblies Blowpipes Air Aspirate Blowpipes (LPG) at controlled pressure supplied by containers fitted with regulators Blowpipes at the uncontrolled vapour pressure of the gas Safety Devices Small Portable Gas Welding Packs

Standard BS5045 BS5741 or BSEN585 or ISO2503 BS7650 ISO7291 BS1780 or BSEN562 or ISO5171 BSEN559 or ISO3821 BS1389 or ISO3253 BSEN561 or ISO7289 BS1389 BS6503 ISO9012 BS3879 BS6158 or ISO5175 BS6942

Table 2: Hose Colours Gas Acetylene LPG Oxygen Compressed Air

Hose Colour Red Orange Blue Black

Table 3: Electrical Equipment standards Electrical Equipment Power Sources (General)

Standard (BS638 and BS7418) or (EN50.060 and EN60.974 ) or IEC974 BS638 Part 10 BS638 Part 4

Equipment (Confined Spaces) Welding Cables

Table 4: PPE PPE Eye Protectors Protective Clothing Filters and cover lenses Radiation Protection

Standard BS2092 BS2653 BS679 BS1542

2nd Edition Rev 11

Date: 01/12/08 Page: 6 of 6