Safety instructions for oxygen cutting

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OCCUPATIONAL SAFETY AND HEALTH
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Safety instructions for oxygen cutting

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. Persons at least 18 years of age who have passed a medical examination, appropriate training and instruction, tested knowledge of labor protection requirements and have practical skills in servicing equipment are allowed to perform oxygen cutting work (gas cutters).

1.2. Repeated briefing and testing of knowledge on labor protection and industrial sanitation should be carried out at least once a quarter with a mark in a special journal and in the welder's personal card. The employee must be able to provide first aid in case of acute poisoning, burns of the skin and mucous membranes, electric shock.

1.3. Employees must undergo periodic medical examinations in the prescribed manner.

1.4. Employees transferred from one workshop to another may be allowed to work after receiving introductory instructions on labor protection and testing their knowledge of these instructions.

1.5. Gas cutting produces dangerous and harmful factors that have an adverse effect on workers.

Harmful production factors during gas cutting include:

solid and gaseous toxic substances in the composition of the welding aerosol;
intense thermal (infrared) radiation of the parts to be welded and the weld pool;
sparks, splashes, emissions of molten metal and slag;
high frequency noise;
static load, etc.

1.6. When performing oxygen cutting work, it is necessary to monitor the serviceability of equipment, hoses, gearboxes and cylinders.

1.7. Combustible gas and oxygen cylinders must not be stored together.

1.8. When performing oxyfuel cutting work, gas cutters must be provided with personal protective equipment (PPE) and protective clothing.

1.9. Protective equipment, issued on an individual basis, must be at the gas cutter or at his workplace during work. Each workplace must have instructions for handling protective equipment, taking into account the specific conditions of their use.

1.10. Personal respiratory protection equipment (RPP) is used when ventilation means do not ensure the required cleanliness of the air in the work area.

1.11. The use of RPE should be combined with other personal protective equipment (shields, helmets, goggles, insulating clothing, etc.) in ways convenient for the worker.

1.12. When oxy-fuel cutting, to protect your eyes from radiation, sparks and splashes of molten metal and dust, you should use safety glasses of the ZP and ZN type.

1.13. During oxygen cutting, gas cutters are provided with goggles of a closed type with glasses of the TS-2 brand, having a density of light filters GS-3 for cutters with an acetylene flow rate of up to 750 l / h, GS-7 - up to 2500 l / h and GS-12 - over 2500 l /h.

It is recommended that auxiliary workers working directly with the cutter use safety glasses with SS-14 glasses with P-1800 filters.

1.14. Overalls should be comfortable, not restrict the worker’s movement, not cause discomfort, protect from sparks and splashes of molten metal of the welded product, moisture, industrial pollution, mechanical damage, meet sanitary and hygienic requirements and working conditions.

1.15. To protect hands when cutting, gas cutters are provided with mittens, mittens with gauntlets or gloves made of spark-resistant material with low electrical conductivity.

1.16. When powering gas cutting equipment from single cylinders, a safety device should be installed between the cylinder reducers and the cutter.

1.17. With centralized power supply of stationary workplaces (posts), the use of combustible gases from the gas pipeline is allowed only through a safety device to protect the gas pipeline from the penetration of backfire.

1.18. When operating cutters on liquid fuel, it is necessary to install a protective device that protects the oxygen hose from the penetration of the backlash of the flame.

1.19. It is forbidden to use liquefied gases for work carried out in the basement.

1.20. When cutting in hard-to-reach places and confined spaces, it is necessary to organize a control post to monitor workers.

1.21. When working in confined spaces, it is prohibited to: use equipment that runs on liquid fuel; leave cutters and sleeves unattended during breaks or after finishing work.

1.22. Gas-flame work should be carried out at a distance of at least 10 m from portable generators, 1,5 m from gas pipelines, 3 m from gas dispensing stations during manual work. The indicated distances apply to gas-flame work, when the flame and sparks are directed in the direction opposite to the gas power sources. If flames and sparks are directed towards gas power sources, measures should be taken to protect them from sparks or exposure to flame heat by installing metal screens.

1.23. When cutting with liquid fuel, the tank with kerosene should be located at a distance of no closer than 5 m from oxygen cylinders and from an open fire source and no closer than 3 m from the cutter’s workplace.

1.24. When cutting near current-carrying devices, the place of work should be protected with shields that exclude accidental contact with the current-carrying parts of the cylinder and sleeves. Hazard notices must be posted on fences.

1.25. Metal coming for cutting must be cleaned of paint (especially lead-based), oil, scale, and dirt to prevent metal splashing and air pollution from evaporation and gases.

1.26. When carrying out work on oxygen cutting, it is necessary to place first aid equipment in a specially designated place: sterile dressing material, hemostatic tourniquet, adhesive plaster, bandages, iodine tincture, ammonia, washing syringe, burn ointment.

1.27. Employees are responsible for violation of the requirements of this instruction in accordance with applicable law.

2. Labor protection requirements before starting work

2.1. Inspect, tidy up and put on overalls and safety shoes.

2.2. Check the serviceability and completeness of the PPE.

2.3. Inspect the workplace, remove from it everything that may interfere with work, clear the aisles and do not clutter them up.

2.4. Prepare a soapy solution to check the tightness of the equipment connections.

2.5. Check the serviceability of hoses, connection tools, pressure gauges, gearboxes, and the presence of suction in the equipment.

Replace the faulty equipment with a serviceable one, thoroughly clean the mouthpieces, check the fastening of the gas cylinders.

2.6. Check the condition of the water safety lock, if necessary, add water to the lock to the control level.

2.7. Check the tightness of all detachable and soldered connections of the equipment.

2.8. Inspect primary fire extinguishing equipment and make sure they are in good working order.

2.9. Check ventilation operation.

2.10. Check if the lighting is working.

3. Labor protection requirements during work

3.1. Oxygen cutting work should be performed only in special clothing and using PPE.

3.2. Before starting work, you need to check:

tightness and strength of connection of gas hoses to the cutter and gearboxes;
the tightness of all connections in the gate and the tightness of the connection of the sleeve to the gate;
correct supply of oxygen and combustible gas to the torch.

3.3. After removing the cap and plug from the cylinders, it is necessary to check the serviceability of the thread of the fitting and valve and make sure that there are no visible traces of oil and grease on the fitting of the oxygen cylinder.

3.4. Before connecting the reducer to the oxygen cylinder, you must:

inspect the inlet fitting and union nut of the reducer and make sure that the thread is in good condition, that there are no traces of oils and fats, and that the sealing gasket and filter are present and in good condition on the inlet fitting of the reducer;
purge the cylinder fitting by smoothly opening the valve to remove foreign particles; at the same time, it is necessary to stand away from the direction of the gas jet.

3.5. Attaching the oxygen reducer to the cylinder must be done with a special key. It is not allowed to tighten the union nut of the reducer with the cylinder valve open.

3.6. Opening the acetylene cylinder valve must be done with a special socket wrench made of non-sparking material. During operation, this key should be placed on the valve spindle. It is not allowed to use ordinary homemade keys for this purpose.

3.7. Cutters should be operated under the following safety precautions:

when igniting a flammable mixture on a cutter, first open the oxygen valve, then the flammable gas valve and ignite the combustible mixture; shut off the gases in the reverse order;
The cutting process should be stopped if it is impossible to adjust the flame composition of the combustible gas, when the torch or cutter heats up and after a backfire strike.

3.8. Before connecting the regulator to the cylinder valve, check:

the presence of seals or other marks (paint) on the safety valve, indicating that the factory (or after repair) adjustment is not violated;
serviceability of the pressure gauge and the period of its verification;
the state of the thread of the fittings;
lack of oil and fat on the surface of gaskets and connecting units of oxygen reducers;
the presence of gaskets on the inlet fitting of the reducer, and in acetylene - the presence of gaskets in the valve;
the presence of filters in the inlet fittings.

3.9. Sleeves should be used in accordance with their purpose. It is not allowed to use oxygen hoses to supply acetylene and vice versa.

3.10. When using manual equipment, it is prohibited to attach forks, tees, etc. to the hoses. to power multiple cutters.

3.11. The length of hoses for oxygen cutting, as a rule, should not exceed 30 m.

In installation conditions, the use of hoses up to 40 m long is allowed.

3.12. The fastening of the sleeves on the connecting nipples of the equipment must be reliable; for this purpose, special clamps should be used. It is allowed to tie the sleeves with soft annealed (knitting) wire at least in two places along the length of the nipple. Hose connections must be carefully checked for tightness before and during work.

3.13. Gas cutters are prohibited from repairing burners, cutters and other equipment at their workplace.

4. Labor protection requirements in emergency situations

4.1. Do not operate a cutter that does not have a vacuum. If there is no or insufficient suction, it is necessary to tighten the union nut, clean and blow out the injector nozzle, mouthpiece and mixing chamber, or unscrew the injector half a turn.

4.2. In the event of a flammable gas leak, work with fire must be stopped immediately. Resumption of work is possible only after eliminating the leak, checking the equipment for gas tightness and ventilating the room.

4.3. When passing gas through the gland nuts of the valves, the rubber rings should be replaced and lubricated.

4.4. If gas leaks when the valves are closed by hand, the cutter should be sent in for repair (the seal of the hole in the cutter body is leaking).

4.5. In the absence of an injector seal or adhering spatter, popping occurs when adjusting the power and composition of the flame or when extinguishing it. It is necessary to clean the injector and remove burrs and adhering metal from the inner and outer surfaces of the mouthpiece with a fine emery cloth.

4.6. If a backfire occurs, you must immediately close the valves: first the flammable gas valve, then the oxygen valve on the torch, the cylinder valve and the safety valve.

4.7. After each kickback, cool the torch in clean water to ambient temperature, check the safety device, hoses, blow them out and, if necessary, replace them.

4.8. Cool the dry shutter body if it is hot.

4.9. After a reverse blow, it is necessary to tighten the mouthpiece and the union nut; clean the mouthpiece from soot and splashes.

4.10. In the event of an accident, you should immediately stop working, notify the work manager and seek medical help.

4.11. In the event of a fire (cylinder explosion, reverse impact, etc.), call the fire brigade, inform the work manager and take measures to eliminate the source of fire.

5. Labor protection requirements at the end of work

5.1. After stopping work, it is necessary to close the valves of all cylinders, release gases from all communications and release the pressure springs of all gearboxes; at the end of the working day, disconnect the cylinders from the communications leading inside the premises, and remove all equipment from the cylinders used in the open air.

5.2. Disconnect the sleeves and put them together with the cutters in the pantry.

5.3. When stopping work with liquid fuel, release the air from the fuel tank before the cutter flame is extinguished.

5.4. At the end of the work, the kerosene cutter should be laid or hung upside down so that liquid fuel does not enter the oxygen line.

5.5. Clean up the workplace.

5.6. Remove and put in order overalls and PPE.

5.7. Wash hands and face with soap and take a shower.

5.8. Report to the foreman about the completion of work and leave your workplace only with his permission.

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