SAMPLE SAFETY TRAINING AND

INSTRUCTION PROGRAM

WELDING & CUTTING

(EMPLOYER NAME) WELDING & CUTTING

DISCLAIMER

This sample safety program is intended solely as a

guide and template for employer reference and
use. This sample program is not intended to be
implemented as is, nor is it intended to comply with
any federal, state, or local regulation or
statute. Rather, the sample program is meant to
assist each employer in developing its own written
safety program based upon its specific needs and
requirements. An employer should review the OSHA
standards for specific requirements applicable to its
operations and make adjustments to this sample
program based upon those requirements. An
employer will need to modify the sample safety
program by adding information relevant to its
particular jobsites or facilities in order to develop an
effective, comprehensive program. The failure of an
employer to develop its own written safety program
designed for its own operations may result in a
violation of OSHA standards.

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(EMPLOYER NAME) WELDING & CUTTING

REGULATORY STANDARD:

29 CFR 1926.350 Subpart J, Welding and Cutting

29 CFR 1926.351 Arcs Welding and Cutting
29 CFR 1926.352 Fire Prevention
29 CFR 1926.353 Ventilation and Protection in Welding, Cutting and Heating
29 CFR 1926.354 Welding, Cutting and Heating on Preservative Coating
29 CFR 1926. 406 (C) Specific Purpose Equipment and Installation

OSHA Website: www.osha.gov Reference

Date: Nov. 2015

BASIS: The welding, cutting, and brazing processes expose workers to a variety of
hazards including; burns, fire, eye damage, possible lung irritation and damage,
electric shock, slips and falls. Numerous injuries and deaths occur each year from the
hazards associated with welding, cutting, and brazing operations in the American
workplace. Most of these injuries and deaths are preventable.

GENERAL: (EMPLOYER NAME) will ensure that work practices that involve
Welding, Cutting and Brazing equipment/operations are evaluated to determine if
proper safety precautions are instituted. The Occupational Safety and Health
Administration (OSHA) recommends that certain guidelines be adhered to regarding
these hazards. This standard practice instruction is intended to address the issues of;
evaluating and identifying the specific hazards where hot work is performed,
communicating information concerning these hazards, and establishing appropriate
procedures, and protective measures for our employees.

RESPONSIBILITY: (EMPLOYER NAME) is responsible for implementing all facets of

this program and has full authority to make necessary decisions to ensure success of
the program

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 (EMPLOYER NAME) WELDING & CUTTING

TABLE OF CONTENTS

1. Written Program 7. Selection and Use of Work Practices

2. Fire Prevention and Protection 8. Code of Safe Practices

3. Protection of Personnel 9. Job Site Training

4. Health Protection and Ventilation 10. Written Assessment

5. Industrial Applications 11. Compliance Checklist

6. Training 12. Job Hazard Analysis

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(EMPLOYER NAME) WELDING & CUTTING

1. WRITTEN PROGRAM.

(EMPLOYER NAME) will review and evaluate this standard practice instruction on an
annual basis, or when changes occur to the OSHA regulations, that prompt revision of
this document, or when facility operational changes occur that require a revision of
this document. Effective implementation of this program requires support from all
levels of management within (EMPLOYER NAME). This written program will be
communicated to all personnel that are affected by it. It encompasses the total
workplace, regardless of number of workers employed or the number of work shifts. It
is designed to establish clear goals, and objectives.

2. FIRE PREVENTION AND PROTECTION.

Fire and explosion pose a serious risk to our employees during welding, cutting, and
brazing operations. Sparks can travel as much as 35 feet, and spatter can bounce on
the floor or fall through openings creating hazards in other work areas of our facility.

2.1 Basic safety precautions. The below listed basic safety precautions will be
followed by company employee's performing welding, cutting, and brazing operations.
The basic precautions for fire prevention in welding or cutting work are:

2.1.1 Fire Hazards. 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.

2.1.2 Guards. 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.

2.1.3 Restrictions. If the requirements stated in paragraphs 2.1.1 and 2.1.2

cannot be followed then welding and cutting shall not be performed.

2.2 Special precautions. When the nature of the work to be performed requires the

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use of guarding devices certain additional precautions may be necessary:

2.2.1 Combustible material. Wherever there are floor openings or cracks in

the flooring that cannot be closed, precautions shall be taken 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.

2.2.2 Fire extinguishers. Suitable fire extinguishing equipment shall be

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.

2.2.3 Fire watch.

2.2.3.1 Fire watchers shall be required whenever welding or cutting is

performed in locations where other than a minor fire might develop, or
any of the following conditions exist:

2.2.3.1.1 Appreciable combustible material, in building

construction or contents, closer than 35 feet (10.7 m) to the point
of operation.

2.2.3.1.2 Appreciable combustibles are more than 35 feet

(10.7m) away but are easily ignited by sparks.

2.2.3.1.3 Wall or floor openings within a 35 foot (10.7 m) radius

expose combustible material in adjacent areas including
concealed spaces in walls or floors.

2.2.3.1.4 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.

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2.2.3.2 Fire watchers shall have fire extinguishing equipment readily

available and be trained in its use. They shall be familiar with facilities
for sounding an alarm in the event of a fire. They shall 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. A fire
watch shall be maintained for at least a half hour after completion of
welding or cutting operations to detect and extinguish possible
smoldering fires.

2.2.4 Authorization. Before cutting or welding is permitted, the area shall be

inspected by the individual responsible for authorizing cutting and welding
operations. He/she shall designate precautions to be followed in granting
authorization to proceed preferably in the form of a written hot work permit.

2.2.5 Floors. Where combustible materials such as paper clippings, wood

shavings, or textile fibers are on the floor, the floor shall be swept clean for a
radius of 35 feet (10.7 m). Combustible floors shall be kept wet, covered with
damp sand, or protected by fire-resistant shields. Where floors have been wet
down, personnel operating arc welding or cutting equipment shall be protected
from possible shock.

2.2.6 Prohibited areas. Cutting or welding shall not be permitted in the

following situations:

2.2.6.1 In areas not authorized by management.

2.2.6.2 In sprinklered buildings while such protection is impaired.

2.2.6.3 In the presence of explosive atmospheres (mixtures of

flammable gases, vapors, liquids, or dusts with air), or explosive
atmospheres that may develop inside uncleaned or improperly prepared
tanks or equipment which have previously contained such materials, or

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that may develop in areas with an accumulation of combustible dusts.

2.2.6.4 In areas near the storage of large quantities of exposed, readily

ignitable materials such as bulk sulfur, baled paper, or cotton.

2.2.7 Relocation of combustibles. Where practicable, all combustibles shall

be relocated at least 35 feet (10.7 m) from the work site. Where relocation is
impracticable, combustibles shall be protected with flame proofed covers or
otherwise shielded with metal or asbestos guards or curtains.

2.2.8 Ducts. Ducts and conveyor systems that might carry sparks to distant
combustibles shall be suitably protected or shut down.

2.2.9 Combustible walls. Where cutting or welding is done near walls,

partitions, ceiling or roof of combustible construction, fire-resistant shields or
guards shall be provided to prevent ignition.

2.2.10 Noncombustible walls. If welding is to be done on a metal wall,

partition, ceiling or roof, precautions shall be taken to prevent ignition of
combustibles on the other side, due to conduction or radiation, preferably by
relocating combustibles. Where combustibles are not relocated, a fire watch on
the opposite side from the work shall be provided.

2.2.11 Combustible cover. Welding shall not be attempted on a metal

partition, wall, ceiling or roof having a combustible covering nor on walls or
partitions of combustible sandwich-type panel construction.

2.2.12 Pipes. Cutting or welding on pipes or other metal in contact with

combustible walls, partitions, ceilings or roofs shall not be undertaken if the
work is close enough to cause ignition by conduction.

2.2.13 Management. Management shall recognize its responsibility for the

safe usage of cutting and welding equipment on its property and:

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2.2.13.1 Based on fire potentials of plant facilities, establish areas for

cutting and welding, and establish procedures for cutting and welding, in
other areas.

2.2.13.2 The (Title) will be responsible for authorizing cutting and

welding operations in areas not specifically designed for such
processes.

2.2.13.3 Ensure that cutters or welders and their supervisors are

suitably trained in the safe operation of their equipment and the safe use
of the process.

2.2.13.4 Advise all contractors about flammable materials or hazardous

conditions of which they may not be aware.

2.2.14 Supervisor. The first line supervisor:

2.2.14.1 Shall be responsible for the safe handling of the cutting or

welding equipment and the safe use of the cutting or welding process.

2.2.14.2 Shall determine the combustible materials and hazardous

areas present or likely to be present in the work location.

2.2.14.3 Shall protect combustibles from ignition by the following:

2.2.14.3.1 Have the work moved to a location free from

dangerous combustibles.

2.2.14.3.2 If the work cannot be moved, have the combustibles

moved to a safe distance from the work or have the combustibles
properly shielded against ignition.

2.2.14.3.3 See that cutting and welding are so scheduled that

plant operations that might expose combustibles to ignition are
not started during cutting or welding.

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2.2.14.4 Shall secure authorization for the cutting or welding operations

from the (Title).

2.2.14.5 Shall determine that the cutter or welder secures his approval
that conditions are safe before going ahead.

2.2.14.6 Shall determine that fire protection and extinguishing

equipment are properly located at the site.

2.2.14.7 Where fire watches are required, he/she shall see that they are
available at the site.

2.2.15 Fire prevention precautions. Cutting or welding shall be permitted only

in areas that are or have been made fire safe. When work cannot be moved
practically, as in most construction work, the area shall be made safe by
removing combustibles or protecting combustibles from ignition sources.

2.3 Welding or cutting containers.

2.3.1 Used containers. No welding, cutting, or other hot work shall be

performed on used drums, barrels, tanks or other containers until they have
been cleaned or filled with water so thoroughly as to make absolutely certain
that there are no flammable materials present or any substances such as
greases, tars, acids, or other materials which when subjected to heat, might
produce flammable or toxic vapors. Any pipe lines or connections to the drum
or vessel shall be disconnected or blanked. For welding, cutting and heating on
steel pipelines containing natural gas, the pertinent portions of regulations
issued by the Department of Transportation, Office of Pipeline Safety, 49 CFR
Part 192, Minimum Federal Safety Standards for Gas Pipelines, shall apply.

2.3.2 Venting and purging. All hollow spaces, cavities or containers shall be
vented to permit the escape of air or gases before preheating, cutting or

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(EMPLOYER NAME) WELDING & CUTTING

welding. Purging with inert gas is recommended.

2.3.3 Verification. Appropriate verification by testing for toxics and/or

flammable/combustible gases shall be done to verify the absence of such
hazards.

2.4 Confined spaces.

2.4.1 Accidental contact. 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 and the holders carefully located so that
accidental contact cannot occur and the machine be disconnected from the
power source.

2.4.2 Torch valve. In order to eliminate the possibility of gas escaping through
leaks or improperly closed valves, when gas welding or cutting, the torch
valves shall be closed and the gas 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.

2.4.3 Cylinders. Cylinders shall not be allowed inside the confined space.

3. PROTECTION OF PERSONNEL

3.1 General

3.1.1 Railings. Employee's working on platforms, scaffolds, or runways shall

be protected against falling. This may be accomplished by the use of railings,
positioning devise systems, fall arrest systems, life lines, or some other equally
effective safeguards.

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(EMPLOYER NAME) WELDING & CUTTING

3.1.2 Welding cables. Employee's shall place welding cables and other
equipment so that it is clear of passageways, ladders, and stairways and shall
be protected from vehicular and equipment traffic. Cables must be at least 7’
off the floor when suspended overhead. Cable connections shall be compatible
and shall be tight.

3.1.3 Cylinder Storage

3.1.3.1 Compressed gas cylinders shall be transported, moved, and

stored upright and properly secured .

3.1.3.2 Unless secured in a device specifically designed to secure and

move compressed gas cylinders, regulators shall be removed and caps
secured prior to movement.

3.1.3.3 When cylinders are stored, regulators shall be removed and

caps secured, and, fuel and oxygen cylinders separated by 20’ (or rated
fire wall). “Storage” means no anticipated use within 24 hours.

3.1.3.4 A suitable cylinder truck, chain, or other steadying device shall

be used to keep cylinders from being knocked over while in use.

3.1.3.5 Cylinders shall be secured in an upright position at all times

except, for short periods of time while cylinders are being hoisted or
carried.

3.1.3.6 Oxygen cylinders in storage shall be separated from fuel-gas

cylinders or combustible materials (especially oil or grease), a minimum
distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet
(1.5 m) high having a fire-resistance rating of at least one-half hour

3.1.3.7 Inside of buildings, cylinders shall be stored in a well-protected,

well-ventilated, dry location, at least 20 feet (6.1 m) from highly

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combustible materials such as oil or excelsior. Cylinders should be

stored in definitely assigned places away from elevators, stairs, or
gangways. Assigned storage places shall be located where cylinders will
not be knocked over or damaged by passing or falling objects, or subject
to tampering by unauthorized persons. Cylinders shall not be kept in
unventilated enclosures such as lockers and cupboards.

3.1.3.8 Cylinders shall 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 shall be provided.

3.1.3.9 Cylinders shall be placed where they cannot become part of an

electrical circuit. Electrodes shall not be struck against a cylinder to
strike an arc.

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

3.1.3.11 Cylinders containing oxygen or acetylene or other fuel gas shall

not be taken into confined spaces

3.1.4 Cylinder Handling

3.1.4.1 Cylinders shall be moved by titling and rolling the cylinder on its
bottom edge. Otherwise, cylinders shall be transported by approved
devices.

3.1.4.2 When work is finished, when cylinders are empty, or when

cylinders are moved at any time, the cylinder valve shall be closed.

3.1.4.3 Horizontal rolling is prohibited.

3.1.4.4 Cylinders shall not be lifted using slings or by the cylinder cap.

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Only approved devices shall be used for lifting cylinders.

3.1.4.5 When cylinders are transported by powered vehicle, they shall

be secured in a vertical position.

3.1.4.6 Bars shall not be used under values or valve protection caps to
pry cylinders loose from frozen. Warm, not boiling water, water shall be
used to thaw cylinders loose.

3.1.4.7 Cylinders, whether full or empty, shall not be used as rollers or

supports.

3.1.4.8 No damaged or defective cylinder shall be used.

3.1.4.9 No person other than the gas supplier shall attempt to mix gases
in a cylinder. No one except the owner of the cylinder or person
authorized by him, shall refill a cylinder. No one shall use a cylinder's
contents for purposes other than those intended by the supplier. All
cylinders used shall meet the Department of Transportation
requirements published in 49 CFR Part 178, Subpart C, Specification for
Cylinders.

3.1.4.10 Before a regulator to a cylinder valve is connected, the valve

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

3.1.4.11 The cylinder valve shall always be opened slowly to prevent

damage to the regulator. For quick closing, valves on fuel gas cylinders

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shall not be opened more than 1 1/2 turns. When a special wrench is
required, it shall 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. In the case of manifolded or coupled cylinders, at
least one such wrench shall always be available for immediate use.
Nothing shall 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.

3.1.4.12

3.1.5 Regulators

3.1.5.1 Regulators shall be kept clean, operational and free of grease

and oils.

3.1.5.2 Repairs to regulators shall only be made by authorized

personnel.

3.1.5.3 Open cylinder valves and quickly close them (“crack” the valve)
prior to attaching regulators. This allows debris to be cleared. Stand to
one side when cracking cylinder valves. DO NOT crack hydrogen
cylinders as hydrogen may self ignite.

3.1.6 Fuel gas and oxygen manifolds

3.1.6.1 Fuel gas and oxygen manifolds shall bear the name of the
substance they contain in letters at least 1-inch high which shall be
either painted on the manifold or on a sign permanently attached to it.

3.1.6.2 Fuel gas and oxygen manifolds shall be placed in safe, well
ventilated, and accessible locations. They shall not be located within
enclosed spaces.

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3.1.6.3 Manifold hose connections, including both ends of the supply

hose that lead to the manifold, shall be such that the hose cannot be
interchanged between fuel gas and oxygen manifolds and supply
header connections. Adapters shall not be used to permit the
interchange of hose. Hose connections shall be kept free of grease and
oil.

3.1.6.4 When not in use, manifold and header hose connections shall be
capped.

3.1.6.5 Nothing shall be placed on top of a manifold, when in use, which

will damage the manifold or interfere with the quick closing of the valves.

3.1.7 Hoses

3.1.7.1 Fuel gas hose and oxygen hose shall 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 shall not be interchangeable. A single hose
having more than one gas passage shall not be used.

3.1.7.2 When parallel sections of oxygen and fuel gas hose are taped
together, not more than 4 inches out of 12 inches shall be covered by
tape.

3.1.7.2 All hose in use, carrying acetylene, oxygen, natural or

manufactured fuel gas, or any gas or substance which may ignite or
enter into combustion, or be in any way harmful to employees, shall be
inspected at the beginning of each working shift. Defective hose shall be
removed from service.

3.1.7.3 Hose which has been subject to flashback, or which shows

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evidence of severe wear or damage, shall be tested to twice the normal

pressure to which it is subject, but in no case less than 300 p.s.i.
Defective hose, or hose in doubtful condition, shall not be used.

3.1.7.4 Hose couplings shall be of the type that cannot be unlocked or

disconnected by means of a straight pull without rotary motion.

3.1.7.5 Boxes used for the storage of gas hose shall be ventilated.

3.1.7.6 Hoses, cables, and other equipment shall be kept clear of

passageways, ladders and stairs.

3.1.8 Torches

3.1.8.1 Clogged torch tip openings shall be cleaned with suitable

cleaning wires, drills, or other devices designed for such purpose.

3.1.8.2. Torches in use shall be inspected at the beginning of each

working shift for leaking shutoff valves, hose couplings, and tip
connections. Defective torches shall not be used.

3.1.8.3 Torches shall be lighted by friction lighters or other approved

devices, and not by matches or from hot work.

3.1.8.4 Regulators and gauges. Oxygen and fuel gas pressure

regulators, including their related gauges, shall be in proper working
order while in use.

3.1.8.5 Oil and grease hazards. Oxygen cylinders and fittings shall be
kept away from oil or grease. Cylinders, cylinder caps and valves,
couplings, regulators, hose, and apparatus shall be kept free from oil or
greasy substances and shall not be handled with oily hands or gloves.
Oxygen shall not be directed at oily surfaces, greasy clothes, or within a
fuel oil or other storage tank or vessel.

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3.1.9 Arc Welding and Cutting

3.1.9.1 Manual Holders

3.1.9.1.1 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, shall be
used.

3.1.9.1.2 Any current-carrying parts passing through the portion of the

holder which the arc welder or cutter grips in his hand, and the outer
surfaces of the jaws of the holder, shall be fully insulated against the
maximum voltage encountered to ground.

3.1.9.2 Welding Cables and Connectors

3.1.9.2.1 All arc welding and cutting cables shall be of the completely
insulated, flexible type, capable of handling the maximum current
requirements of the work in progress, taking into account the duty cycle
under which the arc welder or cutter is working.

3.1.9.2.2 Only cable free from repair or splices for a minimum distance
of 10 feet from the cable end to which the electrode holder is connected
shall be used, except that cables with standard insulated connectors or
with splices whose insulating quality is equal to that of the cable are
permitted.

3.1.9.2.3 When it becomes necessary to connect or splice lengths of

cable one to another, substantial insulated connectors of a capacity at
least equivalent to that of the cable shall be used. If connections are
effected by means of cable lugs, they shall be securely fastened
together to give good electrical contact, and the exposed metal parts of

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the lugs shall be completely insulated.

3.1.9.2.4 Cables in need of repair shall not be used. When a cable,

other than the cable lead referred to in paragraph (b)(2) of this section,
becomes worn to the extent of exposing bare conductors, the portion
thus exposed shall be protected by means of rubber and friction tape or
other equivalent insulation.

3.1.9.3 Ground Returns and Machine Grounding

3.1.9.3.1 Pipelines containing gases or flammable liquids, or conduits

containing electrical circuits, shall not be used as a ground return. For
welding on natural gas pipelines, the technical portions of regulations
issued by the Department of Transportation, Office of Pipeline Safety,
49 CFR Part 192, Minimum Federal Safety Standards for Gas Pipelines,
shall apply.

3.1.9.3.2 When a structure or pipeline is employed as a ground return

circuit, it shall be determined that the required electrical contact exists at
all joints. The generation of an arc, sparks, or heat at any point shall
cause rejection of the structures as a ground circuit.

3.1.9.3.3 When a structure or pipeline is continuously employed as a

ground return circuit, all joints shall be bonded, and periodic inspections
shall be conducted to ensure that no condition of electrolysis or fire
hazard exists by virtue of such use.

3.1.9.3.4 The frames of all arc welding and cutting machines shall be
grounded either through a third wire in the cable containing the circuit
conductor or through a separate wire which is grounded at the source of
the current. Grounding circuits, other than by means of the structure,
shall be checked to ensure that the circuit between the ground and the

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grounded power conductor has resistance low enough to permit

sufficient current to flow to cause the fuse or circuit breaker to interrupt
the current.

3.1.9.3.5 All ground connections shall be inspected to ensure that they

are mechanically strong and electrically adequate for the required
current.

3.1.9.4 Operating Instructions

3.1.9.4.1 Employers shall instruct employees in the safe means of arc

welding and cutting as follows:

3.1.9.4.1.1 When electrode holders are to be left unattended, the

electrodes shall be removed and the holders shall be so placed
or protected that they cannot make electrical contact with
employees or conducting objects.

3.1.9.4.1.2 Hot electrode holders shall not be dipped in water; to

do so may expose the arc welder or cutter to electric shock.
When the arc welder or cutter has occasion to leave his work or
to stop work for any appreciable length of time, or when the arc
welding or cutting machine is to be moved, the power supply
switch to the equipment shall be opened.

3.1.9.4.1.4 Any faulty or defective equipment shall be reported to

the supervisor.

3.1.9.4.2 Electric welders-disconnecting means -

3.1.9.4.2.1 Motor-generator, AC transformer, and DC rectifier arc

welders. A disconnecting means shall be provided in the supply
circuit for each motor-generator arc welder, and for each AC

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transformer and DC rectifier arc welder which is not equipped

with a disconnect mounted as an integral part of the welder.

3.1.9.4.2.1 Resistance welders. A switch or circuit breaker shall

be provided by which each resistance welder and its control
equipment can be isolated from the supply circuit. The ampere
rating of this disconnecting means shall not be less than the
supply conductor capacity for additional requirements.

3.1.9.5 Shielding

3.1.9.5.1 Whenever practicable, all arc welding and cutting operations

shall be shielded by noncombustible or flameproof screens which will
protect employees and other persons working in the vicinity from the
direct rays of the arc.

3.2 Eye protection.

3.2.1 Selection.

3.2.1.1 Helmets or hand shields shall be used during all arc welding or
arc cutting operations, excluding submerged arc welding. Helpers or
attendants shall be provided with proper eye protection.

3.2.1.2 Goggles or other suitable eye protection shall be used during all
gas welding or oxygen cutting operations. Spectacles without side
shields, with suitable filter lenses are permitted for use during gas
welding operations on light work, for torch brazing or for inspection.

3.2.1.3 All operators and attendants of resistance welding or resistance

brazing equipment shall use transparent face shields or goggles,
depending on the particular job, to protect their faces or eyes, as
required.

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3.2.1.4 Eye protection in the form of suitable goggles shall be provided

where needed for brazing operations.

3.2.2 Specifications for protectors.

3.2.2.1 Helmets and hand shields shall be made of a material which is

an insulator for heat and electricity. Helmets, shields and goggles shall
be not readily flammable and shall be capable of withstanding
sterilization.

3.2.2.2 Helmets and hand shields shall be arranged to protect the face,
neck and ears from direct radiant energy from the arc.

3.2.2.3 Helmets shall be provided with filter plates and cover plates
designed for easy removal.

3.2.2.4 All parts shall be constructed of a material which will not readily
corrode or discolor the skin.

3.2.2.5 Goggles shall be ventilated to prevent fogging of the lenses as

much as practicable.

3.2.2.6 All glass for lenses shall be tempered, substantially free from
striae, air bubbles, waves and other flaws. Except when a lens is ground
to provide proper optical correction for defective vision, the front and
rear surfaces of lenses and windows shall be smooth and parallel.

3.2.2.7 Lenses shall bear some permanent distinctive marking by which

the source and shade may be readily identified.

3.2.2.8 The following is a guide for the selection of the proper shade
numbers. These recommendations may be varied to suit the individual's
needs.

Welding operation Shade No.

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(EMPLOYER NAME) WELDING & CUTTING

Shielded metal-arc welding:

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

Note: In gas welding or oxygen cutting where the torch produces a high yellow
light, it is desirable to use a filter or lens that absorbs the yellow or sodium line
in the visible light of the operation.

3.2.2.8 All filter lenses and plates purchased by (EMPLOYER NAME)

shall meet the test for transmission of radiant energy prescribed in ANSI
Z87.1--1968- Practice for Occupational and Educational Eye and Face
Protection.

3.2.3 Protection from arc welding rays. Where the work permits, the welder

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(EMPLOYER NAME) WELDING & CUTTING

should be enclosed in an individual booth painted with a finish of low reflectivity

such as zinc oxide (an important factor for absorbing ultraviolet radiations) and
lamp black, or shall be enclosed with noncombustible screens similarly painted.
Booths and screens shall permit circulation of air at floor level. Workers or
other persons adjacent to the welding areas shall be protected from the rays by
noncombustible or flameproof screens or shields or shall be required to wear
appropriate goggles.

Protective clothing. General requirements. Supervisors will ensure that

employees exposed to the hazards created by welding, cutting, or brazing
operations be protected by personal protective equipment in accordance with
the requirements. Appropriate protective clothing required for any welding
operation will vary with the size, nature and location of the work to be
performed.

3.4 Work in confined spaces.

3.4.1 General. As used herein confined space is intended to mean a relatively

small or restricted space such as a tank, boiler, pressure vessel, or small
compartment of a ship. The Company Confined Space Program shall be
followed.

3.4.2 Ventilation. Ventilation is a prerequisite to work in confined spaces. The

company confined space procedures will delineate ventilation requirements for
specific operations where welding or cutting is required.

3.4.3 Securing cylinders and machinery. When welding or cutting is being

performed in any confined spaces the gas cylinders and welding machines
shall be left on the outside. Before operations are started, heavy portable
equipment mounted on wheels shall be securely blocked to prevent accidental
movement.

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(EMPLOYER NAME) WELDING & CUTTING

3.4.4 Lifelines. 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 that his body cannot be
jammed in a small exit opening. An attendant with a preplanned rescue
procedure (see company confined space procedures) shall be stationed
outside to observe the welder at all times and be capable of putting rescue
operations into effect.

3.4.5 Electrode removal. 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 and the holders carefully located so that
accidental contact cannot occur and the machine disconnected from the power
source.

3.4.6 Gas cylinder shutoff. 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.

3.4.7 Warning signs. After welding operations are completed, the welder shall
mark the hot metal or provide some other means of warning other workers.

4. HEALTH PROTECTION AND VENTILATION.

4.1 General

4.1.1 Contamination. The requirements for contamination control have been

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(EMPLOYER NAME) WELDING & CUTTING

established on the basis of the following factors in arc and gas welding which
govern the amount of contamination to which welders may be exposed:

4.1.1.1 Dimensions of space in which welding is to be done (with

special regard to height of ceiling).

4.1.1.2 Number of welders.

4.1.1.3 Possible evolution of hazardous fumes, gases, or dust according

to the metals involved.

4.1.1.4 Material being welded or cut

4.1.1.5 Consumables

4.1.1.6 Rate of the welding and cutting

4.1.1.7 Air movement

4.1.1.8 Body position

4.1.1.9 Time

4.1.1.10 Protective equipment worn or not worn

4.1.2 Screens. When welding must be performed in a space entirely screened

on all sides, the screens shall be so arranged that no serious restriction of
ventilation exists. It is desirable to have the screens so mounted that they are
about 2 feet (0.61 m) above the floor unless the work is performed at so low a
level that the screen must be extended nearer to the floor to protect nearby
workers from the glare of welding.

4.1.3 Permissible Exposure Limits (PELs). Local exhaust or general

ventilating systems shall be provided and arranged to keep the amount of toxic
fumes, gases, or dusts below the PELs.

4.1.4 Precautionary labels. A number of potentially hazardous materials are

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(EMPLOYER NAME) WELDING & CUTTING

employed in fluxes, coatings, coverings, and filler metals used in welding and
cutting or are released to the atmosphere during welding and cutting.
Supervisors will ensure employee's under their control are familiar with the
Safety Data Sheets (SDS) applicable to the welding materials they are using.

4.2 Ventilation for general welding, cutting and Heating.

4.2.1 General. Mechanical ventilation shall be provided when welding or

cutting is done on metals to reduce the fumes at the source to below the PELs
or safe limits.

4.2.1.1 In a space of less than 10,000 cubic feet (284 m3) per welder.

4.2.1.2 In a room having a ceiling height of less than 16 feet (5 m).

4.2.1.3 In confined spaces or where the welding space contains

partitions, balconies, or other structural barriers to the extent that they
significantly obstruct cross ventilation.

4.2.1.4 Oxygen shall not be used for ventilation purposes, comfort

cooling, blowing dust from clothing, or for cleaning the work area.

4.2.2 Minimum rate. Such ventilation shall be at the minimum rate of 2,000
cubic feet (57 m3) per minute per welder, except where local exhaust hoods
and booths provide an equivalent or better rate, or airline respirators. Natural
ventilation is considered sufficient for welding or cutting operations where the
following restrictions are not present.

4.2.2.1 In a space of less than 10,000 cubic feet (284 m3) per welder.

4.2.2.2 In a room having a ceiling height of less than 16 feet (5 m).

4.2.2.3 In confined spaces or where the welding space contains

partitions, balconies, or other structural barriers to the extent that they
significantly obstruct cross ventilation.

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(EMPLOYER NAME) WELDING & CUTTING

4.3 Local exhaust hoods and booths. Mechanical local exhaust ventilation to
reduce fume exposure to below PELs maybe by means of either of the following:

4.3.1 Hoods. Freely movable hoods intended to be placed by the welder as

near as practicable to the work being welded and provided with a rate of air-
flow sufficient to maintain a velocity in the direction of the hood of 100 linear
feet (30 m) per minute in the zone of welding when the hood is at its most
remote distance from the point of welding. The rates of ventilation required to
accomplish this control velocity using a 3 inch (7.6 cm) wide flanged suction
opening are shown in the following table:

Duct
Minimum air flow *(1) cubic
diameter,
Welding zone feet/ minute
inches *(2)

4 to 6 inches from arc or torch 150 3

6 to 8 inches from arc or torch 275 3½

8 to 10 inches from arc or torch 425 4½

10 to 12 inches from arc or torch 600 5½

4.3.2 Local exhaust ventilation shall consist of freely movable hoods

intended to be placed by the welder or burner as close as practicable to
the work. This system shall be of sufficient capacity and so arranged as
to remove fumes and smoke at the source and keep the concentration
of them in the breathing zone within PELs or safe limits.

4.3.3 Contaminated air exhausted from a working space shall be

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discharged into the open air or otherwise clear of the source of intake
air.

4.3.4 All air replacing that withdrawn shall be clean and respirable.

4.3.2 Fixed enclosure. A fixed enclosure with a top and not less than
two sides which surround the welding or cutting operations and with a
rate of airflow sufficient to maintain a velocity away from the welder of
not less than 100 linear feet (30 m) per minute.

4.4 Ventilation in confined spaces.

4.4.1 Air replacement. All welding and cutting operations carried on in

confined spaces shall be adequately ventilated to prevent the accumulation of
toxic or flammable materials or possible oxygen deficiency. This applies not
only to the welder but also to helpers and other personnel in the immediate
vicinity. All replacement air shall be clean and respirable.

4.4.2 Airline respirators. In such circumstances where it is impossible to

provide such ventilation, airline respirators or hose masks approved by the
Mine Safety and Health Administration and the National Institute for
Occupational Safety and Health, shall be used. The respirator program applies
.

4.4.3 Self-contained units. In areas Immediately Dangerous to Life and

Health (IDLH), self-contained breathing equipment shall be used. The
breathing equipment shall be approved by the Mine Safety and Health
Administration and the National Institute for Occupational Safety and Health.

4.4.4 Outside helper. Where (Employer Name) welding operations are

carried on in confined spaces and where welders and helpers are provided with
hose masks, hose masks with blowers, or self-contained breathing equipment

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(EMPLOYER NAME) WELDING & CUTTING

approved by the Mine Safety and Health Administration and the National
Institute for Occupational Safety and Health, a worker shall be stationed on the
outside of such confined spaces to insure the safety of those working within.
This will done in accordance with the company confined space and respiratory
protection programs or practice instructions.

4.4.5 Oxygen for ventilation shall not be used

4.5 Fluorine compounds.

4.5.1 General. In confined spaces, welding or cutting involving fluxes,

coverings, or other materials which contain fluorine compounds shall be done
in accordance with the safety precautions and work practices delineated on the
SDS. A fluorine compound is one that contains fluorine, as an element in
chemical combination, not as a free gas.

4.5.2 PELs. The need for local exhaust ventilation or airline respirators for
welding or cutting in other than confined spaces will depend upon the individual
circumstances. However, experience has shown such protection to be
desirable for fixed-location production welding and for all production welding on
stainless steels. Where air samples taken at the welding location indicate that
the fluorides fumes are below the PEL, such protection is not necessary.

4.6 Zinc.

4.6.1 Confined spaces. In confined spaces welding or cutting involving zinc-

bearing base or filler metals or metals coated with zinc-bearing materials shall
be done in accordance with the "Ventilation in confined space" section of this
SPI.

4.6.2 Indoors. Indoors, welding or cutting involving zinc-bearing base or filler

metals coated with zinc-bearing materials shall be done.

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(EMPLOYER NAME) WELDING & CUTTING

4.7 Lead. Refer to (Employer Name) Lead Policy

4.7.1 Confined spaces. In confined spaces, welding involving lead-base

metals (erroneously called lead-burning) shall be done in accordance with the
"Ventilation in confined space".

4.7.2 Indoors. Indoors, welding involving lead-base metals shall be done in

accordance with the "Local exhaust hoods and booths" .

4.7.3 Local ventilation. In confined spaces or indoors, welding or cutting

involving metals containing lead, other than as an impurity, or involving metals
coated with lead-bearing materials, including paint shall be done using local
exhaust ventilation or airline respirators. Outdoors such operations shall be
done using respiratory protective equipment approved by the Mine Safety and
Health Administration and the National Institute for Occupational Safety and
Health. In all cases, workers in the immediate vicinity of the cutting operation
shall be protected as necessary by local exhaust ventilation or airline
respirators.

4.8 Beryllium. Welding or cutting indoors, outdoors, or in confined spaces involving

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

4.9 Cadmium.

4.9.1 General. Welding or cutting indoors or in confined spaces involving

cadmium-bearing or cadmium-coated base metals shall be done using local
exhaust ventilation or airline respirators unless atmospheric tests under the

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(EMPLOYER NAME) WELDING & CUTTING

most adverse conditions have established that the workers' exposure is within
the acceptable concentrations. Outdoors such operations shall be done using
respiratory protective equipment such as fume respirators.

4.9.2 Confined space. Welding (brazing) involving cadmium-bearing filler

metals shall be done using ventilation in accordance with the "Ventilation in
confined space" and the "Local exhaust hoods and booths" section of this SPI.

4.10 Mercury. Welding or cutting indoors or in a confined space involving metals

coated with mercury-bearing materials including paint, shall be done using local
exhaust ventilation or airline respirators unless atmospheric tests under the most
adverse conditions have established that the workers' exposure is within the
acceptable concentrations. Outdoors such operations shall be done using respiratory
protective equipment

4.11 Titanium and Zirconium. Titanium and zirconium are pyrophoric in nature and
precautions should be fully understood prior to grinding, cutting or welding on these
materials.

4.12 Hexavalent Chromium – refer to (Employer’s Name) Hexavalent Chromium

Program

4.13 Welding, cutting, and heating in way of preservative coatings

4.13.1 Before welding, cutting, or heating is commenced on any surface

covered by a preservative coating whose flammability is not known, a test shall
be made by a competent person to determine its flammability. Preservative
coatings shall be considered to be highly flammable when scrapings burn with
extreme rapidity.

4.13.2 Precautions shall be taken to prevent ignition of highly flammable

hardened preservative coatings. When coatings are determined to be highly

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flammable, they shall be stripped from the area to be heated to prevent

ignition.

4.13.3 Protection against toxic preservative coatings:

4.13.3.1 In enclosed spaces, all surfaces covered with toxic

preservatives shall be stripped of all toxic coatings for a distance of at
least 4 inches from the area of heat application, or the employees shall
be protected by air line respirators.

4.13.3.2 In the open air, employees shall be protected by a respirator.

4.13.3.3 The preservative coatings shall be removed a sufficient

distance from the area to be heated to ensure that the temperature of
the unstripped metal will not be appreciably raised. Artificial cooling of
the metal surrounding the heating area may be used to limit the size of
the area required to be cleaned.

4.14 Cleaning compounds.

4.14.1 Manufacturer's instructions. In the use of cleaning materials, because

of their possible toxicity or flammability, appropriate precautions such as
manufacturers instructions shall be followed.

4.14.2 Since the inert-gas metal-arc welding process involves the production of
ultra-violet radiation of intensities of 5 to 30 times that produced during
shielded metal-arc welding, the decomposition of chlorinated solvents by
ultraviolet rays, and the liberation of toxic fumes and gases, employees shall
not be permitted to engage in, or be exposed to the process until the following
special precautions have been taken: The use of chlorinated solvents shall be
kept at least 200 feet, unless shielded, from the exposed arc, and surfaces
prepared with chlorinated solvents shall be thoroughly dry before welding is

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permitted on such surfaces.

4.14.3 Degreasing. Degreasing and other cleaning operations involving

chlorinated hydrocarbons shall be so located that no vapors from these
operations will reach or be drawn into the atmosphere surrounding any welding
operation. In addition, trichloroethylene and perchlorethylene should be kept
out of atmospheres penetrated by the ultraviolet radiation of gas-shielded
welding operations.

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

4.16 Natural Gas Pipelines

Before any welding or cutting on lines containing natural gas, supervision shall ensure
all rhe requirements of Department of Transportation, Office of Pipeline Safety, 49
CFR Part 192, Minimum Federal Safety Standards for Gas Pipelines, are in place.

4.17 First-aid equipment. First-aid equipment shall be available at all times. All
injuries shall be reported to in accordance with as soon as possible for medical
attention. First aid shall be rendered until medical attention can be provided.

5. INDUSTRIAL APPLICATIONS

5.1 Transmission pipeline.

5.1.1 General. The requirements of the "Protection of personnel" and the

"Health protection and ventilation" sections of this SPI shall be observed.

5.1.2 Field shop operations. Where field shop operations are involved for
fabrication of fittings, river crossings, road crossings, and pumping and
compressor stations the requirements of the "Fire prevention and protection",

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"Protection of personnel" and the "Health protection and ventilation" sections of

this SPI shall be observed.

5.1.3 Electric shock. When arc welding is performed in wet conditions, or

under conditions of high humidity, special protection against electric shock
shall be supplied. Welding machines shall be grounded either by an external
ground or internal ground; supervision shall verify that grounds are effective.
Welding machines should be kept dry and free from water accumulation.

5.1.4 Pressure testing. In pressure testing of pipelines, the workers and the
public shall be protected against injury by the blowing out of closures or other
pressure restraining devices. Also, protection shall be provided against
expulsion of loose dirt that may have become trapped in the pipe.

5.1.5 Construction standards. The welded construction of transmission

pipelines shall be conducted in accordance with the Standard for Welding Pipe
Lines and Related Facilities, API Std. 1104--1968.

5.1.6 Flammable substance lines. The connection, by welding, of branches to

pipelines carrying flammable substances shall be performed in accordance
with Welding or Hot Tapping on Equipment Containing Flammables, API Std.
PSD No. 2201--1963.

5.1.7 X-ray inspection. The use of X-rays and radioactive isotopes for the
inspection of welded pipeline joints shall be carried out in conformance with the
American National Standard Safety Standard for Non-Medical X-ray and
Sealed Gamma-Ray Sources, ANSI Z54.1--1963.

5.2 Mechanical piping systems

5.2.1 General. The requirements of the "Fire prevention and protection",

"Protection of personnel" and the "Health protection and ventilation" sections of

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this SPI shall be observed.

5.2.2 X-ray inspection. The use of X-rays and radioactive isotopes for the
inspection of welded piping joints shall be in conformance with the American
National Standard Safety Standard for Non-Medical X-ray and Sealed Gamma-
Ray Sources, ANSI Z54.1--1963.

6. TRAINING

6.1 Types of training. Supervisors will determine whether training required for
specific jobs will be conducted in a classroom or on-the-job. The degree of training
provided shall be determined by the complexity of the welding, brazing, or cutting
requirements of the individual job and the associated hazards.

6.1.1 Initial Training. Prior to job assignment, this employer shall provide
training to ensure that the hazards associated with welding, brazing, and
cutting operations are understood by employees and that the knowledge and
skills required for the safe application, usage, of work place equipment, are
acquired by employees. The training shall include the following:

6.1.1.1 Each authorized employee shall receive training in the

recognition of applicable hazards involved with particular job. The
methods and means necessary for safe work.

6.1.1.2 Each affected employee shall be instructed in the purpose and

use of the confined space entry procedure (where needed).

6.1.1.3 All other employees whose work operations are or may be in an

area where welding, brazing, or cutting is to be performed, shall be
instructed about the procedure, and about the prohibitions relating to
working in that area.

6.1.2 Refresher Training. Scheduled refresher training will be conducted on an

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basis.

6.1.2.1 Retraining shall be provided for all authorized and affected

employees whenever there is a change in their job assignments, a
change in welding equipment, equipment or processes that present a
new hazard, when their work takes them into hazardous areas, or when
there is a change in the confined space entry procedures (when used).

6.1.2.2 Additional retraining shall also be conducted whenever a

periodic inspection reveals, or whenever this employer has reason to
believe, that there are deviations from or inadequacies in the employee's
knowledge of known hazards, or use of equipment or procedures.

6.1.2.3 The retraining shall reestablish employee proficiency and

introduce new equipment, or revised control methods and procedures,
as necessary.

6.1.3 Certification. This (Employer Name) shall certify that employee training
has been accomplished and is being kept up to date. The certification shall
contain a synopsis of the training conducted, each employee's name, and
dates of training.

7. SELECTION AND USE OF WORK PRACTICES

Supervisors shall develop and ensure use of standardized safety-related work

practices to prevent injuries resulting from hot-work accidents. The specific safety-
related work practices shall be consistent with the nature and extent of the associated
hot-work hazards.

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(EMPLOYER NAME) WELDING & CUTTING

8. Code Of Safe Practices

Welding And Burning Operations

1. Special precautions must be taken to ensure proper ventilation when burning

or welding.

2. When burning or welding on coated surfaces, special precautions are to be

taken. The coating must be removed four (4) inches en every direction around
the weld area.

3. Before starting to burn or weld, you must inspect your work area to ensure that
sparks or molten metal will not contact flammable or combustible materials. If
you cannot provide the necessary safeguards, check with your supervisor
before starting work.

4. When burning or welding, you must wear personal protective equipment.

5. Suitable fire extinguishing equipment must be available in your immediate

work area.

6. Employees are responsible for inspection of equipment before use. If

equipment is not in safe working condition, report to your supervisor.

7. Welding leads and burning hoses must be kept away from walkways,
stairways, and ladders. They must be protected from vehicular and equipment
traffic areas.

8. Never weld or burn on barrels, tanks, piping, or other systems that may have
contained either combustible or unknown products, without first obtaining
clearance from your supervisor.

9. Hoses shall be disconnected from the manifold and stored properly after each shift.
Do not store in confining areas (unvented gang box) where gases may accumulate.

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10. Flash back arresters shall be installed on all torches (if not incorporated into
the torch).

Welding

1. When exposed to flying objects such as chipping slag, or other weld-cleaning

activity, employees must wear approved eye protection.

2. When arc-welding near other workers, all workers must be protected from the
arc rays by non-combustible screens which reduce the transmission of
ultraviolet rays. Additional eye protection may be required by both the welder
and nearby worker.

3. The frames of all welding machines shall be grounded.

4. Special precautions shall be taken during Tig and Mig welding operations to
ensure that inert gases do not collect in adjacent low-lying areas or confined
spaces. Do not enter a confined space without training and authorization.

Burning and Cutting

1. Inspect equipment prior to use and repair or replace if necessary.

2. Do not use matches or lighters to ignite torches. Spark igniters must be used.

3. Turn off all valves and gauges when not in use, and disconnect hoses at the
end of each shift.

4. Air arcing may require hearing protection. Check with your supervisor before
proceeding.

5. Do not use oxygen to blow off clothes or clean welds; serious skin burns or
death may result.

6. Employees must wear appropriate gloves and proper eye protection.

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7. When a wrench is required to operate the acetylene cylinder valve, the wrench
shall be kept in position on the valve while the cylinder is in use.

Storage and Handling of Cylinders

1. Protective caps or collars shall be secured on all cylinders in your work area
when not in use.

2. During storage, use, or transport, cylinders shall be properly secured in an

upright position.

3. Flammable and non-flammable cylinders in storage shall be separated from

each other by 20 feet or by a 5-foot barrier that has a 1 hour fire rating.

4. Cylinders shall not be taken into confined spaces.

5. Employees must not use oily rags or other oily substances to lubricate caps,
valves, or gauges.

Ventilation and Protection

1. Welding, burning, and heating performed in confined spaces may require

general mechanical or local exhaust ventilation to reduce he concentrations of
smoke and fumes to acceptable PELs levels. Consult your supervisor before
starting these operations.

2. If adequate ventilation cannot be provided, employees will be provided with and

required to use respirator protection appropriate for the type of work and exposure.

3. Employees must wear approved respiratory protection when welding, cutting,

or heating metals having toxic significance, such as zinc, lead, beryllium,
cadmium, or chromium bearing or coated metals. Check with your supervisor
for training and authorization.

4. Oxygen must never be used for ventilation.

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(EMPLOYER NAME) WELDING & CUTTING

9. SPECIFIC SAFETY TRAINING AND INSTRUCTION

TOPIC: WELDING

Welding equipment shall be inspected regularly and maintained in good working

condition. Report any defective equipment to your supervisor. Do not use damaged or
malfunctioning equipment.

1. Prior to starting any welding operation, the appropriate permits and fire watch
shall be obtained.

2. Clear area near below welding operations so that you do not drop hot slag on
hoses, cables or other employees. If items or employees near or below welding
operations cannot be removed appropriate measures shall be taken for
protection. Where normal fire prevention precautions are not sufficient, a fire
watch shall be present during the welding operation.

3. No welding or heating shall be done where the application of flammable paints,

or the presence of other flammable compounds or heavy dust concentrations
create a hazard. Do not refuel equipment around welding procedures.

4. Keep suitable fire extinguishers readily available when welding.

5. The appropriate Personal Protective Equipment shall be used. Welding hoods

shall be used for eye protection and to prevent flash burns.

6. Employees working in close proximity to any welding operations shall wear

approved eye protection.

7. Make sure that all parts subject to electrical current are fully insulated against
maximum voltage encountered to ground. A ground return cable shall have a
safe current carrying capacity equal to or exceeding the specified maximum
output capacity of the welding unit that it services.

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(EMPLOYER NAME) WELDING & CUTTING

8. Frames of all arc welding machines shall be grounded either through a third
wire in the cable containing he circuit conductor or through a separate wire
which is grounded at the source of the current.

9. Welding cables shall be of the completely insulated, flexible type, capable of

handling the maximum current requirements of the work in progress.

10. Place cables, leads, and connections so there are no fire or tripping hazards.
Do not attach lead to safety cables or guardrail.

11. When the stinger is left unattended, remove the rod and place the stinger so it
will not make electrical contact with employees or conducting objects. Discard
electrode stubs in cans or pouches.

12. Drums, containers, or hollow structures which have contained toxic or

flammable substances, shall either be filled with water or thoroughly cleaned,
ventilated, and tested to ensure they are not combustible.

13. Be sure proper ventilation and/or suitable respiratory protection is provided

when required.

14. Oxygen shall not be used for ventilation purposes.

15. Do not weld in confined spaces without authorization and hazard recognition
and preparation.

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

17. The cylinder valve shall always be opened slowly to prevent damage to the

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(EMPLOYER NAME) WELDING & CUTTING

regulator. For quick closing, valves on fuel gas cylinders shall not be opened
more than 1 1/2 turns. When a special wrench is required, it shall 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. In the case of manifolded
or coupled cylinders, at least one such wrench shall always be available for
immediate use. Nothing shall 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.

18. Fuel gas shall not be used from cylinders through torches or other devices
which are equipped with shutoff valves without reducing the pressure through a
suitable regulator attached to the cylinder valve or manifold.

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

20. If, when the valve on a fuel gas cylinder is opened, there is found to be a leak
around the valve stem, the valve shall be closed and the gland nut tightened. If
this action does not stop the leak, the use of the cylinder shall be discontinued,
and it shall be properly tagged and removed from the work area. In the event
that fuel gas should leak from the cylinder valve, rather than from the valve
stem, and the gas cannot be shut off, the cylinder shall 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.

21. If a leak should develop at a fuse plug or other safety device, the cylinder shall
be removed from the work area

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(EMPLOYER NAME) WELDING & CUTTING

SPECIFIC SAFETY TRAINING AND INSTRUCTION

WELDING
DATE: PROJECT:

SUPERVISOR:

ATTENDEES:

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(EMPLOYER NAME) WELDING & CUTTING

9. SPECIFIC SAFETY TRAINING AND INSTRUCTION

TOPIC: OXYGEN AND ACETYLENE

Equipment shall be inspected at the beginning of each working shift. Damaged or

faulty equipment shall be taken from service.

1. Gas cylinders shall be stored and used with the valve end up. Cylinders containing
oxygen, acetylene or fuel gases shall not be taken into confined spaces.

2. Compressed gas cylinders in portable service shall be securely fastened to a

suitable handcart, rack, or other steadying device. Unless cylinders are firmly
secured on carriers intended for this purpose, regulators shall be removed and
valve protective caps replaced.

3. When transported by a motor vehicle, cylinders shall be secured in an upright

position with the caps on.

4. Gas cylinders raised or lowered by crane or hoist must be secured on suitable

cradles, sling boards, pallets, or skip boxes. They shall never be lifted by
magnets, choker slings, or valve protective caps.

5. Cylinders must not be placed where they might form a part of any electrical circuit.

6. Cylinders shall be moved by tilting and rolling them on their bottom edges. They shall
not be intentionally dropped, struck, or permitted to strike each other violently.

7. Oxygen cylinders in storage shall be separated from fuel-gas cylinders or combustible

materials, (minimum distance of 20 feet or by a non-combustible barrier at least five
feet high giving a fire- resistance rating of at least one-half hour).

8. Cylinders shall 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 shall be provided.

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(EMPLOYER NAME) WELDING & CUTTING

9. Oxygen shall never be used from a cylinder or cylinder manifold unless a

pressure-reducing device is used.

10. Cylinders shall never be used as rollers or supports, whether full or empty.

11. Compressed oxygen shall not be used for ventilation testing, or similar purposes
different from its intended function in welding and burning.

12. Hose couplings shall be of the type that cannot be unlocked or disconnected by
means of a straight pull without rotating.

13. Hoses and other equipment shall be kept clear of passageways, ladders, stairs,
and vehicle/equipment traffic.

14. Only approved friction lighters or other approved devices shall be used to light
torches.

15. A dry chemical or carbon dioxide fire extinguisher, rated a least 10B:C, shall be
kept near operations where d gases are being used.

SAMPLE SAFETY TRAINING AND INSTRUCTION PROGRAM | WELDING & CUTTING 43

(EMPLOYER NAME) WELDING & CUTTING

SPECIFIC SAFETY TRAINING AND INSTRUCTION

OXYGEN AND ACETYLENE
DATE: PROJECT:

SUPERVISOR:

ATTENDEES:

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(EMPLOYER NAME) WELDING & CUTTING

10. Written Assessment

WELDING AND BURNING OPERATIONS

True or False

1) Before a regulator to a cylinder valve is connected, the valve must be opened

slightly and closed immediately. This is called “cracking.”

True False

2) After the cylinder valve is cracked, it must be opened slowly to prevent damage to
the regulator.

True False

3) It is common practice to use compressed gas cylinders for rollers or supports.

True False

4) Hose connections must be kept free of grease and oil.

True False

5) Cylinders may be hoisted by synthetic slings only.

True False

Multiple Choice

6) Arc welding cables should be:

a) completely insulated
b) flexible
c) capable of handling the maximum current requirements
d) all of the above

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(EMPLOYER NAME) WELDING & CUTTING

7) A damaged welding cable may be used:

a) only in dry conditions

b) for a short duration
c) only after being repaired
d) only if the employee is wearing appropriate PPE

8) Before heat is applied to a drum, container, or hollow structure:

a) Verify that a vent or opening is provided for the release of any built up pressure
b) Wet down the outside with water
c) Filled with water or thoroughly cleaned of substance
d) Both a and c

9) Training for employees shall be conducted:

a) Prior to job assignment

b) Only for Journeymen
c) Only for confined spaces
d) When the Supervisor deems it necessary

10) It is permissible to use oxygen to blow off clothes or other surfaces if:

a) You are wearing safety glasses.

b) You do not blow debris in the direction of other employees.
c) You are outside.
d) None of the above. Never use oxygen in this manner.

Fill in the Blanks

11) S D S

12) The atmosphere must be tested before entering and working

in a .

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(EMPLOYER NAME) WELDING & CUTTING

13) When welding is conducted near combustible material, a shall

be posted.

14) Cylinders, gauges, and hoses shall be regularly checked

for before use.

15) Cylinders shall be stored with the on.

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 (EMPLOYER NAME) WELDING & CUTTING

PROJECT: DATE:

11. WELDING – CUTTING – BRAZING

COMMENTS
Fire Prevention/Protection
Plan

CUTTING - BURNING
Fire Extinguishers
Clyinders
Gauges
Hoses
Cylinder Storage
Cylinder Transportation
Signage

√ YES Χ NO N/A

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 (EMPLOYER NAME) WELDING & CUTTING

12. JOB HAZARD ANALYSIS

Project: Date: New:

(employer name) JHA No. Pag of Revised:

e
Controlling Superintendent: Analysis By:
PRE-JOB HAZARD Contractor
ANALYSIS

Location: Foreman: Approved By:

Activity Potential Hazards Recommended Action, Procedure, and/or Equipment

Use of torch and compressed
gas cylinders
Burns, fire, explosion Employees shall be trained in the safe use of oxygen/acetylene cutting
procedures.
Hot Permit shall be obtained when burning in a hazardous area.
Before cutting, the area shall be inspected for potential fire hazards.
Burning goggles shall be worn. .04 or greater lenses are required.
Fire extinguishers shall be available with each torch when burning.
When stored, gages shall be removed from cylinders.
Hoses shall be in good repair and shall be stored properly.
Cylinders shall be stored and secured in an upright position with caps on. When
stored, oxygen/acetylene cylinders shall be stored a minimum of 20 feet apart, or
separated by 5 foot high, 1 hour fire-wall.
Gauges shall be removed before transported in cart.
Caution shall be taken when burning at elevated areas to prevent sparks or slag
from falling on workers or flammable materials below.
Gloves shall be worn when burning or cutting.
Backflow check valves shall be installed on both acetylene and oxygen lines.
Hoses shall be elevated when needed to prevent slips, trips, and damage.

Project Safety Representative:

 (EMPLOYER NAME) WELDING & CUTTING

JOB HAZARD ANALYSIS

Project: Date: New:

(employer name) JHA No. Pag of Revised:

e
Controlling Superintendent: Analysis By:
PRE-JOB HAZARD Contractor
ANALYSIS

Location: Foreman: Approved By:

Activity Potential Hazards Recommended Action, Procedure, and/or Equipment

Welding Burns, fire, explosion, electrocution Employees shall be trained in the safe use of welding equipment.
Hot Permit shall be obtained when burning in a hazardous area.
Before welding, the area shall be inspected for potential fire hazards.
Appropriate PPE shall be worn.
Fire extinguishers shall be readily available.
Equipment shall be inspected before each shift.
Welding lead shall be in good repair and shall be stored properly.
All parts subject to electrical current shall be fully insulated against maximum voltage
encountered to ground.
When stinger is left unattended, remove the rod.
Caution shall be taken when welding at elevated areas to prevent sparks or slag
from falling on workers or flammable materials below.
Gloves shall be worn when welding.
Proper ventilation and/or respiratory protection shall be used where required.
Welding lead shall be elevated when needed to prevent slips, trips, and damage.

Project Safety Representative:

(EMPLOYER NAME) WELDING & CUTTING

EMPLOYEE ACKNOWLEDGEMENT

By signing below, I acknowledge that I understand and agree to comply with

(EMPLOYER NAME) “Welding-Cutting-Brazing Safety Program” and Company
Safety Policies and Procedures. I have reviewed a copy of the Program and have
received a verbal orientation identifying the safety requirements associated with the
scope of work contained in this Program.

This statement is to remain in the files of (EMPLOYER NAME).

SIGNATURE DATE

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