Download TITLE: Quality Objectives

Appendix A
Hot Work Permit
Appendix A
Hot Work Permit
Appendix B
Arc Welding and Cutting Checklist
1.
Topic Area
Voltage
Polarity
Wet
conditions
Arc Welding
Machines
Requirements
Alternating current machines:
 Manual arc welding and cutting – 80 volts (V)
 Automatic arc welding and cutting – 100 V
Direct current machines:
 Manual & automatic welding & cutting - 100V
When special welding and cutting processes require valves or open circuit
voltages higher than listed above, means must be provided to prevent the
operation from making accidental contact with the high voltage.
All D.C. machines must be connected with the same polarity. All singlephase A.C. machines must be connected to the same phase of the supply
circuit with the same instantaneous polarity
Reliable automatic controls for reducing the no load voltage are required
to reduce the shock hazard. Insulating mats or nonconductive pads must
be used if welding in wet conditions
All welding equipment must be inspected annually. The inspection must
be performed by the manufacturer or other qualified individual and must
include an evaluation of internal grounding, internal insulation, switch
operation, excessive dust buildup, warning labels, safety devices, etc.
Welding machines must be enclosed except for wheels, levers, knobs or
handles.
Input power terminals, tap change devices and live metal parts connected
to the input circuits must be completely enclosed and accessible only by
means of tools.
Terminals for welding leads must be protected from accidental contact by
personnel or nearby objects.
Welding Cable: Welding Equipment, cables and rod holders must be
inspected for any damage prior to use. Only cable free from repair or
splices may be used. If such damage is found, the welder is to be locked
and tagged out until repaired.
A disconnecting switch or controller must be provided at or near each
welding machine, which is not equipped with such a switch or controller
mounted as an integral part of the machine.
For individual welding machines, the rate current carrying capacity of the
supply conductors must be not less than the rated primary current of the
welding machine.
For groups of welding machines, the rated current carrying capacity of
conductors may be less than the sum of the rated primary currents. The
conductor rating must be determined according to the machine loading
Machine Hookup: Before starting operations, all connections to the
machine must be checked to make certain they are mechanically strong
and properly made. The work lead must be firmly attached to the work;
magnetic work clamps must be freed of adherent metal particles.
Done
Appendix B
Arc Welding and Cutting Checklist
Topic Area
Grounding
and
Electrical
Safety
Electrode
Holders
General
PPE
Other local
requirements
Completed by:
Date:
Requirements
Coiled welding cables must be spread out to avoid serious overheating.
Welding leads and cables must be checked for faults.
The welding machine frame ground must be checked before use. Special
attention must be given to safety ground connections of portable
machines.
All ground connections must be carefully checked to determine that a
good physical connection has been made. If the ground connection is not
made directly to the item to be welded, a visual observation should be
made to assure that a suitable ground path exists between the weld and
the ground before attempting to weld. Failure to do so could result in
serious electrical shock.
When welding in a position that results in kneeling, sitting, leaning or
laying on conductive surfaces a non-flammable, non-conductive pad to
insulate oneself from current is required.
Machines that have become wet must be thoroughly dried and tested
before being used.
Only manual electrode holders, which are specifically designed for arc
welding and cutting, may be used. The electrode holder must be kept in
proper condition with all insulating components intact.
When electrode holders are to be left unattended, the electrodes must be
removed and the holders must be so placed or protected that they cannot
make electrical contact with employees or conducting objects. Electrodes
or welding leads must never be draped over wire rope guardrails or plumb
cables, or otherwise come into contact with them.
Welding lead in need of repair must not be used. When a cable becomes
worn to the extent of exposing bare conductors, the portion exposed shall
be protected by means of rubber and friction tape or other equivalent
insulation
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 machine must be turned off.
All welding hoods must be of the type that fastens directly to the hardhat.
Welding hoods must be used during all welding operations including
bridging and decking. In some cases, an approved face shield/cutting
goggle combination can be used to supply adequate protection from
welding rays.
All personal protective equipment (PPE) must be inspected prior to use
and must be properly worn.
Done
Appendix C
Oxygen Fuel Gas Welding and
Cutting Equipment Checklist
Topic Area
Maximum
Pressure
Markings
Storage
Transport
and Handing
Topic Area
Requirements
Under no condition must the acetylene be utilized at a pressure equal to or
greater than 15psi
Compressed gas cylinders will be legibly marked to clearly identify the gas
content.
Oxygen cylinders in storage will be separated from fuel-gas cylinders or
combustible materials (especially oil or grease), by at least 20 feet or by a
fire wall at least 5 feet high having a fire-resistance rating of at least onehalf hour.
Cylinders will be stored away from radiators and other sources of heat.
Cylinders will be kept far enough away from the actual welding or cutting
operation so that sparks, hot slag or flame will not reach them, or fireresistant shields will be provided
Cylinders will not be placed where they might come in contact with an
electrical circuit.
Cylinders will not be placed where they might come in contact with an
electrical circuit.
Cylinders will be spotted in well-protected, well-ventilated dry location at
least 20 feet from any highly combustible material or electrical
transmission service areas.
Cylinders will be stored in an assigned place away from elevators, stairs,
manlifts or gangways
Assigned storage spaces will be located where cylinders will not be
knocked over or damaged by passing or falling objects.
All cylinders will be secured from falling during storage, transportation and
use.
Empty cylinders will be marked empty and stored with its valve closed.
Protective valve caps will be in place when the cylinder is designed to
accept when cylinders are in use. Acetylene cylinders will be stored valve
up.
Oxygen cylinders will not be stored near highly combustible material (i.e.,
propane, acetylene). Oxygen cylinders or apparatus will not be handled
with oily hands or gloves. A jet of oxygen will never be permitted to strike
an oily surface, greasy clothes or enter a fuel oil or other storage tank
Cylinders, cylinder valves, couplings, regulators, hoses and apparatus will
be kept free from oily or greasy substances
When transporting cylinders the valve will be closed and the valve
protective cap in place. Do not attempt to lift the cylinder by the valve
protective cap
The cylinders will not be dropped or struck or permitted to strike each
other violently.
After the welding operation is complete or during all breaks from the
operation, the cylinder valves will be shut off, the pressures released and
the regulator adjustment backed off.
Cylinders will never be used as rollers or supports.
Requirements
Done
Done
Appendix C
Oxygen Fuel Gas Welding and
Cutting Equipment Checklist
Safety devices or check valves on cylinders will not be tampered with.
A hammer or wrench will not be used to open cylinder valves. If valves
cannot be opened by hand, a tag will be placed on the cylinder and the
supervisor notified.
Cylinders will be placed with the valve up whenever they are in use and
held to a wall or other support device by means of chains. A best practice
is chains at two levels of the cylinder (high and low).
Before connecting a regulator to a cylinder valve, the valve will be opened
slightly and closed immediately. The valve will be opened while standing
to one side of the outlet. Never perform this procedure while any
employee is standing in front of the opening. Never crack the valve on a
fuel-gas cylinder near other work or any other possible ignition sources.
Before a regulator is removed from a cylinder, the cylinder valve will be
closed and the gas released from the regulator
Nothing will be placed on top of an Acetylene cylinder when in use that
may interfere with the quick closing of the valve.
If cylinders are found to have leaky valves of fittings that cannot be
stopped by closing the valve, the cylinder will be tagged, then taken
outdoors away from any source of ignition and slowly emptied.
The
warning tag will include “DO NOT USE” and a brief explanation of the
reason not to use it. The supplier will be notified immediately for removal.
Acetylene valves will be opened only three-fourths to one turn. At no time
is the valve to be opened more than one and one-half turn.
Where a special wrench is required it will be left in position on the stem of
the valve while the cylinder is in use.
All hose lines will be equipped with check valves.
Other local
requirements
Completed by:
Date:
Appendix D
Burning, Cutting & Welding
Authorization Certification
is authorized to operate burning, cutting or welding equipment. This employee
has been trained, according to Ingersoll Rand standards.
The training included:
1. Instruction in the inspection of cutting and welding equipment and procedures for
reporting defects and safety hazards.
2. Instruction in the proper use of personal protective equipment used in cutting and
welding operations.
3. Instruction in the hazards involved. Basic training included ventilation, fire, burns
and electrical shock.
4. Instruction in fire control measures.
5. Detailed instruction in safe operating procedures.
6. Instruction in what areas require or do not require a Hot Work Permit.
7. Review local regulations and the procedures outlined in the burning, cutting and
welding plan.
8. Fire Watch Training Which Included:


I
Instruction in fire control measures.
Instruction in sounding alarm and evacuation procedures.
certify that I have been trained in all the requirements listed above.
AUTHORIZATION: This employee has successfully completed necessary training to
safely weld at this facility.
Approved By:
Title:
Date: