TITLE:

ES&H Manual

 

DOCUMENT ID:

6122 Appendix T1

Hot Work Station Set-Up and

Safe Operating Procedures

(includes Oxygen/Fuel Safety)

 

 

1.0          Purpose

 

There are a number of inherent hazards associated with hot work operations.  Appropriate work station set-up is one method to avoid hazards.  This appendix outlines Jefferson Lab’s minimum requirements for station set-up and equipment maintenance.

 

2.0          Scope

 

Hot work environments increase the risk of electrocution because clothing and equipment become soaked with perspiration.  ES&H Manual Chapter 6670 Heat and Cold Stress Mitigation Program provides mitigation techniques required by Jefferson Lab for this condition.

 

Requirements for all compressed gases used and/or stored at Jefferson Lab are defined in ES&H Manual Chapter 6150 Compressed, Liquefied, and Solidified Gas Program.  Additional requirements for hot work are listed below.

 

The process steps for this procedure are performed in coordination with ES&H Manual Chapter 6122 Hot Work (i.e. Welding, Cutting, Brazing, and Grinding) Safety Program.

 

3.0          Responsibilities

NOTE:           Management authority may be delegated at the discretion of the responsible manager.

 

3.1            Qualified Hot Work Operator

·       Prior to commencement of work:

o   Ensure station set-up complies with all requirements listed below.

o   Fix non-compliances.

·       Have supervisor’s approval prior to use of any welding station or equipment.

·       Ensure appropriate work control documents (e.g. Hot Work Permits, Operational Safety Procedures, Laser Operational Safety Procedures, and/or other Temporary Work Permits) are appropriately reviewed, approved, and signed.

 

4.0          Minimum Requirements

 

Step 1:          Station Requirements

·       Hot Work Area:

o   Non-flammable flooring material.

o   Non-reflective, heat resistant, shielding.

o   Adequate ventilation (see ES&H Manual Chapter 6122 Appendix T5 Ventilation/Respirator Requirements.

·       All welding machines are isolated-output type – with no direct galvanic connection between the AC power ground and the output terminals of the machine. 

·       Hot work bench(es) and table(s) have fireproof tops and are grounded.  (If ground is in question contact the Electrical Safety Engineer.)

·       Electrical outlets are of adequate voltage.  (If voltage is in question contact the Electrical Safety Engineer.)

·       Nonflammable protective covering – available.

·       All welding equipment (e.g. torches, regulators, electrode holders, and welding machines) have:

o   Current inspection (See ES&H Manual Chapter 6122 Appendix T3 Inspection of Hot Work Equipment and

o   Appropriate labels.  (See ES&H Manual Chapter 6122 Appendix T4 Work Area Posting Requirements.

 

Step 2:          Work Station Equipment 

 

NOTE:  Inspect any personal protective equipment (PPE) prior to use. 

In particular DO NOT use gloves that are contaminated by grease/oil.

 

·       Cylinder Set-up (NOTE: If oil or grease is detected do not use.)

o   Transport cylinder per ES&H Manual 6150 Compressed, Liquefied, and Solidified Gas Program.

o   Group and secure your cylinders as far away from the work as possible.  If they are within the “spark-zone” cover with nonflammable protective covering.

o   Remove dirt from cylinder valve threads with a clean cloth. 

o   Crack each cylinder valve to dislodge any dirt.  (When cracking cylinder stand to one side.)

 

·       Regulators 

o   Attach and securely tighten the appropriate regulators approved for the gas and pressure of the cylinder.

o   Release the tension of the adjusting screws.

o   Install flashback arrestors following manufacturer’s instructions.

 

·       Opening Cylinders

o   Slowly open the oxygen cylinder completely to seal the valve packing.

o   Slowly open the fuel cylinder.  (Note:  Do not open acetylene cylinder valves more than ľ turns so cylinder may be turned off quickly.)

 

·       Welding Hoses

o   Inspect hoses ensure they are clean and in good repair.

§  Do not use if cut, worn, or otherwise damaged.

o   Ensure hose placement is clear of walkways; falling metal, slag, or sparks.  Cover if necessary to ensure their protection.

o   Oxygen hose:

§  Connect the oxygen hose to the oxygen regulator and tighten.

§  Allow 3 to 5 PSIG of gas to escape for 5 to 10 seconds to clear the line.

§  Shut off oxygen flow.

o   Fuel hose:

§  Connect the fuel hose to the fuel regulator and tighten.

§  Allow 3 to 5 PSIG of gas to escape for 5 to 10 seconds to clear the line.

§  Shut off fuel flow.

 

·       Welding Torch Handle and Tip (NOTE: If oil or grease is detected do not use.)

o   Remove dust or dirt from torch handle with a clean cloth.

o   Connect the oxygen hose to the torch handle valve marked “oxy” and tighten securely.

o   Connect the fuel hose to the torch handle valve marked “fuel” and tighten securely.

 

·       Welding/Cutting Tip (NOTE: If oil or grease is detected do not use.)

o   Ensure welding/cutting tip is the appropriate size for the job.

o   Inspect cone end, coupling nut, and torch head – repair or replace if damaged.

§  Remove dirt and dust with a clean rag.

§  Ensure that there are two “O” rings on the cone end.

o   Connect welding or cutting tip to the welding torch handle using hand pressure only.

 

·       Leak Check

o   Check for leaks using the industry standard “soap and water” leak test. 

 

If a leak is found on the cylinder valve:

Step 1:          Move the cylinder outdoors (per ES&H Manual Chapter 6150 Compressed, Liquefied, and Solidified Gas Program)

Step 2:          Disconnect the regulator and other equipment,

Step 3:          Notify the Fire Protection Engineer.

 

Step 3:          Review Work Control Documents

·       Ensure work control documents (e.g. Hot Work Permits, Operational Safety Procedures, Laser Operational Safety Procedures, and/or other Temporary Work Permits) are appropriately reviewed, approved, and signed.

·       Discuss all roles and responsibilities with Fire Watch.  Ensure these are understood and agreed upon per ES&H Manual Chapter 6900 Appendix T1 Fire Protection: Hot Work Permit

 

Step 4:          Don Appropriate Personal Protective Equipment (PPE)

·       In accordance with ES&H Manual Chapter 6122 Appendix T2 Hot Work Personal Protective Equipment.

 

Step 5:          If performing oxygen/fuel torch work: go to Alternate Step 5.0: Oxygen/Fuel Torch Work)

 

OR

 

Commence Work

 

Alternate Step 5: Oxygen/Fuel Torch Work

 

Light the Torch and Adjust the Flame

·       Open oxygen valve on the torch handle and adjust the oxygen regulator to the desire delivery range.

·       Close the torch handle oxygen valve.

·       Open the fuel valve on the torch handle and adjust the fuel regulator to the required delivery range.

·       Close the torch handle fuel valve.

·       Hold the torch in one hand and flint striker in the other.  (A flint striker is the only authorized method for lighting a torch.)

·       Open the fuel valve approximately one half turn and ignite the gas.  Keep opening the fuel valve until the flame stops smoking, and then slightly reduce the fuel supply to bring the flame back to the tip.

·       Open the torch handle oxygen valve until desired flame level is reached.

 

Commence Work

 

Finish Torch Work Operations

·       Shut off the torch oxygen valve.

·       Shut off the torch fuel valve.

·       Close both cylinder valves.

·       Open the torch oxygen valve (5-10 seconds)

·       Close the torch oxygen valve.

·       Release the adjusting screw of the oxygen regulator by turning the screw to the left (counterclockwise).

·       Open the torch fuel valve (5-10 seconds)

·       Close the torch fuel valve.

·       Release the adjusting screw of the fuel regulator by turning the screw to the left (counterclockwise).

 

5.0          References

 

                          Victor Welding, Cutting & Heating Guide, Denton Texas, 1977 and 1991

 

6.0          Revision Summary

 

Revision 1 – 04/14/11 – Updated to reflect current laboratory operations.

 

 

 

ISSUING AUTHORITY

TECHNICAL

POINT-OF-CONTACT

APPROVAL DATE

EXPIRATION DATE

REV.

 

 

ESH&Q Division

Mike Martin

04/14/11

04/14/16

1

 

This document is controlled as an on-line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 8/14/2012.