HSE - Safety Goodwe: Hot Work Safety

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Chapter : Hot Work

WELDING SAFELY

There are several potential hazards when undertaking welding and cutting operations, by your actions you can prevent these hazards, protect yourself and protect others.

The general hazards and their solutions are as follows:-

1. LIGHT RAYS

(Infrared, Visible Light and Ultra Violet radiation). Hot Metal and Sparks cause eye damage and can burn the skin. Therefore, wear correct eye and body protection.

EYE PROTECTION : For most welding and cutting operations filter lenses are required but for all operations where sparks and hot metal splash is possible, eye protection MUST be worn.

CLOTHING : Flame resistance materials are required for body, hand and foot protection, leather being the favorite for heavy works. Clothing should not retain sparks and synthetic fabrics should not be used. These melt when contacted by sparks. DO NOT WEAR A HIGH VISIBILITY VEST.

2. FUMES AND GASES

Welding and cutting of all metals produces fumes which can harm the respiratory system whilst fumes from galvanized, lead or toxic coated materials can also affect the rest of the body.

PROTECTION : Wear correctly filtered respirators for low volume works, use and exhaust ventilation system for large concentrations of welders or where working in ‘confined spaces’ (additional precautions WILL be necessary - see your supervisor) – know your method statement.

3. COMPRESSED GASES

Compressed gases can cause fires or explosions due to their being either highly flammable or under pressure.

PRECAUTIONS:

Only have the required amount of cylinders at work position (1 days supply). Store spares correctly in a storage area.
Use a bottle trolley to secure cylinders upright.
Flash back arrestors must be fitted at cylinder gauge ends and non-return valves at the inlets to the blowpipe.
Close valves before moving cylinders and after use.
Do not allow cylinders to become heated. Keep oil away from oxygen cylinders, valves etc. If you suspect a leak, move the cylinder into the open air and notify suppliers.
Always ensure that you work within the control of the hot work permit system. Do not weld material degreased with solvents unless it is dry.
Always have the right fire extinguisher at hand.

4. ELECTRICITY

When electric arc welding the greatest danger is from electric shock.

PRECAUTIONS:

Never touch live metal parts with bare skin or wet clothing.
Ensure cables electrode holders and cable connections are in good condition and insulation is complete.
Ensure welding machine is correctly earthed.
Do not weld whist standing in water or change electrodes whilst on a wet or earthed surface.
Do not connect earth lead to electrical circuits or pipes containing flammable materials.
Arc Eye – erect barriers to reduce the risk to other personnel who may be working or passing through the area adjacent to your work area.

5. FIRE PRECAUTIONS

Welding and cutting operations cause many fires on construction sites.

PRECAUTIONS

Ensure you have a Hot Work Permit from organization
Ensure area is free of flammable materials before starting work and check area after completion for likely smoldering materials

Hierarchy of Control For Welding work

Elimination: Eliminate the hazard by avoiding welding work or using alternative processes.
Substitution: Substitute the hazardous process or material with a safer alternative.
Engineering controls: Implement engineering controls to reduce exposure to hazards, such as:

- Ventilation systems to remove welding fumes.
- Screens or shields to protect against sparks and UV radiation.
- Automated welding processes to reduce worker exposure.

Administrative controls: Implement administrative controls to reduce exposure to hazards, such as:

- Scheduling welding work during off-peak hours to minimize exposure to others.
- Providing training and supervision to ensure safe work practices.
- Implementing safe work procedures and checklists.

Personal protective equipment (PPE): Use PPE as a last resort to protect against hazards, such as:

- Welding helmets and face shields to protect against UV radiation and sparks.
- Respiratory protection to reduce inhalation of welding fumes.
- Protective clothing and gloves to prevent skin exposure.

Additional Considerations

Welding fume management: Implement measures to manage welding fumes, such as using fume extractors or providing respiratory protection.
Electrical safety: Ensure electrical safety by using proper equipment, grounding, and lockout/tagout procedures.
Fire safety: Implement measures to prevent fires, such as using fire-resistant materials, keeping flammable materials away, and having fire extinguishers nearby..

ARC WELDING Protective Measures

Wear proper protective clothing. Eye, face and hand protective equipment must be in use during all welding. Other protection, such as a welders hood, jacket and apron may be necessary.
Ensure that appropriate hot work permits have been issued and a copy has been issued to the supervisor in charge.
A gas test must be carried out prior to welding and the area must be clear of flammable material, liquid, or gas.
Install welding screens to prevent other persons getting “FLASH” when possible. Each welder must be provided with helper to assist in barricade / guard and watch area for possible arise of any harmful condition.
If welding above ground level, contain hot slag with suitable sheeting and ensure that a water hose and/or Fire Extinguishers are within the work area.
Ensure ground return clamps are in good condition and located as close as possible to the work position.
In hydrocarbon and chemical industries ensure –through coordination with operating party - that all drains, vents, harmful fumes or material within the affected area were safely isolated/covered.
In confined spaces ensure there is adequate and safe lighting ventilation, and use a suitable respiratory protection if necessary.
Ensure that welding generators are grounded when in use.

Oxygen and Acetylene Cutting/ Welding

All employees engaged in oxygen/acetylene welding, or torch cutting must wear appropriate protective clothing including welder‟s hood, gloves,. welder‟s clothing, etc. The welder‟s assistant must wear a minimum of goggles for eye protection, and gloves.
Oxygen and Acetylene cylinders in use must be secured to a welding cart, or other suitable structure.
All oxygen /acetylene equipment must be inspected prior to use including regulators, hoses, flash back arrestors, torches, etc.
Hot work permits must be obtained prior to welding and/or torch cutting where any flammable liquid and/or gas exist.
Other combustible material such as paper, plastic, trash, etc , must be moved out of the area before welding or cutting.
Cylinder caps must be replaced on oxygen and acetylene cylinders prior to moving to a new location.
Take precautions to prevent oil and grease from getting inside oxygen regulators or on oxygen valve threads.
Use forced air ventilation when welding or cutting in any confined space. Confined space to be issued for such activities.

HSE - Safety Goodwe