Instructions for labor protection when handling oxygen and acetylene cylinders

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Instructions for labor protection when handling oxygen and acetylene cylinders

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. This instruction applies to workers (welders) performing work on servicing portable acetylene generators designed to produce acetylene gas from calcium carbide and water to power gas-flame metal processing equipment with acetylene.

1.2. Persons at least 18 years of age who have undergone a medical examination and technical training in this specialty, passed an exam and have a certificate for the right to work on servicing portable acetylene generators are allowed to work on servicing a portable generator.

1.3. Permission to work as a welder is issued by order of the enterprise after induction training and the issuance of a certificate of testing knowledge on labor protection.

1.4. All work after initial on-the-job instruction and knowledge testing for 2 to 5 shifts (depending on length of service, experience and nature of the work) is carried out under the supervision of a foreman or experienced worker, after which workers are given permission to work independently.

1.5. A welder who has received instruction and has demonstrated unsatisfactory knowledge is not allowed to work and must undergo repeated instruction.

1.6. At least once a quarter, the welder must undergo repeated instruction in safe techniques and work methods. At least once a year, a knowledge test is carried out by a specially created commission chaired by an employee appointed by order of the head of the enterprise. The results of the knowledge test are documented in a protocol, the number of which is affixed to the certificate and approved by the seal of the enterprise.

1.7. Welders should undergo a medical examination once every 2 years.

1.8. The welder must comply with the work and rest schedule established by the administration.

1.9. The production of acetylene in portable generators falls into the category of explosive and hazardous industries.

Failure to comply with labor protection and fire safety rules, as well as technical regulations, can lead to accidents. Therefore, welders are required to be especially careful and have a clear knowledge of safe work practices.

1.10. Welders may be exposed to the following hazardous and harmful production factors:

acetylene;
gaseous toxic impurities in acetylene: hydrogen sulfide and hydrogen phosphorous;
aerosols generated during welding or cutting.

1.11. In accordance with the Standard Industry Standards, the welder is provided with free work clothing, safety footwear and other personal protective equipment (PPE):

rubber and canvas gloves;
rubber aprons; respirators;
Closed-type safety glasses with lenses having appropriate light filter density or shields.

1.12. The welder, in addition to these instructions, should know:

emergency response plan at your workplace;
instruction manual for the acetylene generator;
instructions for emergency shutdown of the acetylene generator;
fire safety instructions at your workplace;
rules for the use of PPE (respirators, shields, goggles, etc.);
rules for first aid in case of accidents;
personal hygiene rules.

1.13. If a welder is injured, the shift supervisor or station manager should be reported immediately.

1.14. 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. Wear appropriate clothing and footwear.

2.2. Prepare a soapy solution to check for gas leaks.

2.3. Install the generator in a vertical position in a place where it cannot fall, outdoors or under a canopy.

2.4. Install a safety device (lock), safety valve, pressure gauge or medium pressure indicator on the generator.

2.5. Fill the generator with water to the control level (faucet) and into the valve, if it is of the water type.

2.6. Load calcium carbide with pieces of 25 - 80 mm in size into a dry loading basket in the amount recommended depending on the work being performed, but not more than the volume of a one-time load for this type of generator.

2.7. Check the presence of a gas welding tool (torch or cutter), oxygen hoses, acetylene hoses and an oxygen cylinder.

2.8. Check the tightness and strength of the connection of the gas hoses to the burner (cutter) and reducer.

2.9. Check for sufficient suction in the injection equipment.

2.10. Install the generator at a distance of at least 10 m from the place where gas-flame work is performed, as well as from any other source of fire and sparks.

2.11. Put the generator into operation after stabilizing the pressure, blow out the hoses and welding equipment with acetylene, open the oxygen supply and light the burner (cutter).

3. Labor protection requirements during work

3.1. Work only in overalls and PPE.

3.2. Monitor the pressure reading on the pressure gauge. If the pressure in the generator has risen above the maximum permissible, gas must be released through a safety valve; if the valve does not work, acetylene should be forced to be released into the atmosphere through it.

3.3. Take gas out evenly and avoid forcing productivity.

3.4. Unload the generator only after complete decomposition of calcium carbide.

To recharge the generator after complete decomposition of calcium carbide: discharge the remaining acetylene into the atmosphere, turn off the gas welding equipment, remove the safety valve, rinse the basket, drain the water and sludge from the generator, and condensate from the hose.

3.5. Do not allow vacuum in the generator, because In this case, air leakage and the formation of an explosive acetylene-air mixture are possible.

3.6. The use of a metal tool may result in the formation of a spark upon impact, so a non-sparking tool should be used.

3.7. During work it is prohibited:

shake and pump a working generator;
operate the generator without a safety device, safety valve and pressure gauge;
leave a loaded generator unattended;
work from one generator to two or more welders;
apply calcium carbide with a size of pieces less than 25 - 80 mm;
reuse water after working out the first load of calcium carbide;
drain carbide sludge in the wrong place (into the sewer or onto the site);
disassemble and reassemble the safety device without subsequently checking it for leaks, gas resistance and the ability to retard detonation combustion of an acetylene-oxygen mixture;
leave the generator with undecomposed calcium carbide.

4. Labor protection requirements during work

4.1. In case of danger or situations that could lead to accidents or incidents, the welder must:

turn off the gas welding equipment;
forcedly through the safety valve to release pressure to the atmosphere.

4.2. If it is impossible to extract gas (the pressure in the generator increases several times above the maximum), it is necessary to release the pressure to the atmosphere, allow the generator to cool completely, open the lid and remove the loading device with undecomposed calcium carbide.

4.3. When acetylene is withdrawn before the pressure is completely reduced, air or oxygen is sucked in, which can lead to a backfire.

After each kickback, the safety device is triggered, i.e. inhibition of detonation combustion of acetylene-oxygen mixture. In this case, it is necessary to disconnect the safety valve and replace it with another one.

4.4. The generator does not provide rated performance if siltation of calcium carbide occurs during operation. This can lead to an increase in temperature and pressure, the formation of polymerization products and an explosion of the generator. It is necessary to allow the generator to cool, if necessary, release the pressure to atmosphere, slowly open the lid and unload the basket.

5. Labor protection requirements at the end of work

5.1. At the end of the shift, completely refine the calcium carbide and unload the generator. Rinse the generator and loading basket with water, drain the water from the safety device (wet type).

5.2. Place the remaining calcium carbide in an airtight container and hand it over to the technician.

5.3. Blow out condensation from hoses.

5.4. Remove working tool.

5.5. Clean up the workplace.

5.6. Place a clean generator complete with tools and hoses in a warehouse.

5.7. Report to the shift foreman about the completion of work.

5.8. Remove and put in order overalls and PPE.

5.9. Wash face and hands with warm water and soap, take a shower.

5.10. Turn off the lights.

5.11. Leave your workplace only with the permission of the master.

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