Labor protection instructions for manual gas welding, soldering and surfacing

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OCCUPATIONAL SAFETY AND HEALTH
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Labor protection instructions for manual gas welding, soldering and surfacing

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. To perform work on gas welding, soldering, surfacing (hereinafter referred to as welding), persons are allowed at least 18 years old who have passed a medical examination, technical training in this specialty and instruction, who have passed the exam, who have practical skills in welding and a certificate for the right to carry out work for welding.

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 a welder's personal card. At least once a year, knowledge is tested by a specially created commission appointed by order of the head of the enterprise. The results of testing the knowledge of welders must be documented in a protocol, the number of which is affixed to the certificate and sealed with the seal of the organization.

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

1.4. Persons transferred from one workshop to another may be allowed to work after receiving an introductory briefing and testing knowledge on labor protection.

1.5. In the process of work, the employee may be exposed to the following hazardous and harmful production factors:

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 work on gas welding, it is necessary to monitor the serviceability of the equipment, sleeves, reducers and cylinders.

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

1.8. When performing gas welding work, employees must be provided with personal protective equipment (PPE) and overalls.

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

1.10. Personal respiratory protection equipment (PPE) is used when ventilation means do not provide the required air purity of the working area.

1.11. The use of PPE should be combined with other PPE (shields, helmets, goggles, insulating overalls, etc.) in a way convenient for the worker.

1.12. In gas welding, soldering and surfacing, to protect the eyes from radiation, sparks and splashes of molten metal and dust, goggles of the ZP and ZN type should be used.

1.13. Gas welders must be provided with goggles of a closed type with glasses of the TS-2 brand, having a density of light filters GS-3 for burners (cutters) with an acetylene flow rate of up to 750 l / h, GS-7 - up to 2 l / h and GS-500 - over 12 l/h. Auxiliary workers working directly with the welder are recommended to use protective goggles with glasses of the SS-2500 brand with P-14 light filters.

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

1.15. To protect hands, workers should be provided with mittens, mittens with leggings or gloves made of spark-resistant material with low electrical conductivity.

1.16. When supplying the equipment from single cylinders, a safety device should be installed between the cylinder reducers and the tool (torch).

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

1.19. In the production of welding, soldering, surfacing and cutting in hard-to-reach places and confined spaces, it is necessary to organize a control post to monitor the workers.

1.20. When working in confined spaces, it is prohibited:

use equipment that runs on liquid fuel;
leave the burners and sleeves unattended during a break or after the end of work;
weld vessels under pressure or containing explosive or toxic substances.

1.21. Performing manual 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 collapsing posts. The specified distances refer to cases where the flame and sparks are directed away from the gas supply sources. In the case of a flame and spark directed towards the power sources by gases, measures must be taken to protect them from sparks or exposure to flame heat by installing metal screens.

1.22. When soldering in confined spaces, solders containing cadmium must not be used.

1.23. When gas welding near current-carrying devices, the place of work must be fenced off with shields that exclude accidental contact with the current-carrying parts of the cylinder and sleeves. Hazard notices must be posted on fences.

1.24. Metal entering for welding must be free of paint (especially lead-based), oil, scale, and dirt to prevent metal spatter and air pollution by evaporation and gases.

When welding painted, primed metal, it must be cleaned along the seam line. The width of the strip to be cleaned from paint must be at least 100 mm (50 mm on each side).

The use of a gas flame for this purpose is prohibited.

1.25. Personnel should be able to provide first aid in case of acute poisoning, burns of the skin and mucous membranes, electric shock. When carrying out work on gas welding, in a specially designated place there should be means for providing first aid: sterile dressing material, hemostatic tourniquet, adhesive plaster, bandages, iodine tincture, ammonia, washing syringe, burn ointment.

1.26. 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 the hoses, connection tools, pressure gauges, reducers, 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.

2.10. Check if the lighting is working.

3. Labor protection requirements during work

3.1. Gas welding work should be performed only in overalls and using PPE.

3.2. Before starting work, you need to check:

tightness and strength of connection of gas hoses to the burner and reducers;
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 burner.

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 must, at all times, be on the valve spindle. It is not allowed to use ordinary homemade keys for this purpose.

3.7. The burners must be operated under the following safety precautions:

when igniting the combustible mixture on the burner, first open the oxygen valve, then the combustible gas valve and ignite the combustible mixture; shut off gases in the reverse order;
the welding process should be stopped if it is impossible to adjust the composition of the flame according to the combustible gas, when the burner heats up and after a reverse flame 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 must be used in accordance with their purpose. Do not use oxygen hoses to supply acetylene and vice versa.

3.10. When using manual equipment, it is forbidden to attach forks, tees, etc. to the sleeves. for feeding several burners.

3.11. The length of hoses for gas welding, soldering and surfacing, 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; special clamps must be used for this purpose. 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 welders are prohibited from repairing burners and cutters and other equipment at their workplace.

4. Labor protection requirements in emergency situations

4.1. It is forbidden to work with a burner that does not have a vacuum. If there is no or insufficient suction, it is necessary to tighten the union nut, clean and blow through the nozzle of the injector, mouthpiece and mixing chamber, or unscrew the injector by half a turn.

4.2. In the event of a combustible gas leak, work on fire must be stopped immediately. The resumption of work is possible only after the leakage has been eliminated and the gas-tightness and ventilation of the room has been checked.

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

4.4. If gas escapes when the valves are closed by hand, the burner must be returned for repair (leakage in the seal of the hole in the burner body).

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. In the event of a flashback of the flame, it is necessary to immediately close the valves: first the combustible gas, then the oxygen on the burner, the valve of the cylinder and the protective shutter.

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

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, immediately stop work, notify the administration and seek medical attention.

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 burners in the pantry.

5.3. Clean up the workplace.

5.4. Remove and put in order overalls and PPE.

5.5. Wash your face and hands with soap and take a shower.

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

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