LECTURE NOTES 3
Welding and Cutting Equipment
a. Apparatus such as torches, regulators, hoses and arc welding machines shall be in good
operating condition and repair. Only approved oxygen and acetylene cylinders shall be
used.
b. Oxygen and acetylene torches shall be equipped with flash-back arrestors.
c. All cylinders shall be equipped with a valve protection cap, a collar, or recess to protect
the valve. Valve caps should be in place except when cylinders are connected for use.
d. Cylinders should be stored in assigned places and shall be secured to prevent accidental
overturning.
e. Cylinders should not be kept in unventilated enclosures, such as lockers and cupboards.
f. Oxygen cylinders in storage shall be separated from fuel gas cylinders or combustible
materials a minimum distance of 20 ft (6.1 m) or by a noncombustible barrier at least 5 ft
(1.5 m) high.
g. Acetylene cylinders shall be stored valve end up with protective caps affixed and properly
secured. When a job using acetylene devices is completed or prior to transporting acetylene
cylinders, the valve on the acetylene cylinder shall be closed and pressure on the hoses bled
to zero.
h. When transporting cylinders by a crane or derrick, a cradle, bin, or other suitable platform
should be used. Slings alone shall not be used on a cylinder being transported or lifted.
Also, cylinders should not be dropped, struck, or permitted to strike each other.
i. On arc welding machines, the control apparatus shall be enclosed except for the operating
wheels, levers, or handles.
j. Input power terminals, top charge devices, and electrically energized metal parts shall be
completely enclosed and accessible only by means of tools.
k. Terminals from welding leads shall be protected from accidental contact by personnel or
metal objects.
l. The frame or case of an electrically driven arc welding machine shall be grounded.
m. Cables with splices within 10 ft (3.1 m) of the rod holder shall not be used. The welder
should not coil or loop welding electrode cables around parts of his body.
Contractor Safety and Training
When selecting contractors, operators should obtain and evaluate information regarding a
contractor’s safety policies and practices, and performance thereunder, and the contractor’s
procedures for selecting subcontractors. See API RP 2220. Contractors shall train their personnel
in the work practices necessary to perform their jobs in a safe manner. The training provided to
contract personnel should include applicable site specific safety procedures and rules pertaining to
the facility and the applicable provisions of emergency action plans. This section applies to
contractors performing operating duties, maintenance or repair, turnaround, major renovation, or
specialty work at the facility. Except for transportation safety orientation, emergency evacuation
training, and other applicable safety training, this paragraph does not apply to contractors
providing incidental services that do not influence operation of the facility, such as, janitorial work,
food and drink services, laundry, delivery, other supply services, etc. The operator should verify
contractor training utilizing a variety of methods, which may include audits of the contractor’s
safety training programs; worksite checks of individual contractor employees’ training; and
operator observation of contractor work performance. A major step in achieving acceptable
contractor performance is selecting a safe contractor. Therefore, it is appropriate for operators to
request that contractors submit specific performance information in their contract response
proposals. For example, such information might include:
a. Assurance of a contractor’s written safety policies and practices endorsed by the
contractor’s top management.
b. A statement of commitment by the contractor to comply with all applicable safety
regulations and provisions of this publication.
c. Recordable injury and illness experience for the previous 3 years.
d. Experience Modification Rates (EMR) for Worker’s Compensation Insurance for the
previous three years.
e. An outline of the contractor’s initial employee safety orientation.
f. Evidence of the existence of a disciplinary action procedure dealing with safety and
environmental related infractions.
g. A description of the contractor’s various safety programs, including: accident investigation
procedures; how safety inspections are performed; safety meetings; safety incentive
programs; substance abuse prevention programs.
h. Description of the safety and environmental training that each contractor employee has
received and the contractor’s programs for refresher training.
Safe Work Practices
Load lifting
The manufacturer’s rated load capacity shall not be exceeded on cranes or other load lifting devices.
This equipment should be operated and maintained in accordance with manufacturers’
recommendations. Tag lines should be used to guide and steady all loads being lifted.
Confined Space, Excavations, and Hazardous Environments
1. Where hydrogen sulfide, sulfur dioxide, carbon dioxide or other hazardous atmosphere is
known or suspected to exist, the operator shall ensure that personnel, contractor, and
service company supervisors are advised of the potential hazards. Safety guidelines and
recommendations for use in production operations where hydrogen sulfide or sulfur
dioxide gas may be encountered are contained in API RP 55. Also see ANSI 2117.1.
2. A confined space is an area which:
a. Has adequate size and configuration for people to enter.
b. Has limited means of entry or exit.
c. Is not designed for continuous employee occupancy.
3. Examples of confined spaces that can be found at onshore producing facilities are:
a. Well cellars
b. Electrical vaults
c. Fin fan coolers
d. Tanks
e. Vessels
f. Some diked areas
g. Valve pits
4. Confined space hazards should be identified for all facilities in the workplace and safe
work practices should be established for working in the confined spaces.
5. A confined space entry permit shall be used to enter any confined space that has
atmospheric, engulfment or configuration hazards. Attendant and emergency rescue
service shall be provided for all permit required confined spaces.
6. When preparing the confined space for entry, precautions must be in place to ensure the
space remains safe. This may include forced air ventilation, equipment isolation or other
measures. For equipment isolation, consideration should be given to blinding, double block
and bleed, or other equipment and energy isolation controls.
Trenching and Excavations
When operations require excavating and preparing trenches, persons should be knowledgeable
regarding the hazards and precautions necessary for preparing and working in trenches.
1. Underground Hazards
When preparing an excavation, consider the hazards of underground installations.
These include electrical equipment, oil and gas transmission, sewers, water lines,
telephone lines and other utilities.
2. Toxic Gas and Low Oxygen Hazards
Any trench 4 ft or greater in depth is usually considered a “confined space”. Entry into
these spaces is controlled by special safety procedures where oxygen deficient or toxic
gas hazards can reasonably be expected, such as near landfalls or near where hazardous
materials are used or stored. There is concern that heavy gases can collect inside a
trench.
3. Vehicle Traffic and Falling Loads
Vehicles on nearby roadways and construction equipment can present hazards at an
excavated site. Ensure that barricades and warnings are in place. Construction
equipment shall not lift material over people in the trench or excavation. The soil from
the trench is also a hazard to personnel inside the trench, for this reason it must be piled
at least 2 ft from the edge of the trench.
4. Stability of Nearby Structures
Before beginning an excavation it is important that consideration be given to nearby
buildings, light poles or other structures in the area. Additional support, installed by
professionals, may be needed.
5. Escape Means from Trenches
A stairway, ladder or ramp should be located in any trench that is at least 4 ft (1.2m)
deep. The escape means should be placed so that a person is never more than 25 ft away
from an escape means.
6. Inspections
A qualified person should inspect the trench at least daily and more frequently if needed,
such as after a rainstorm or other hazardous occurrence.
7. Prevention of Cave-Ins
Any trench 5 ft or deeper, that is not in entirely stable rock, must be sloped or shored
in accordance with recognized engineering practices.
LOCKOUT/TAGOUT
1. A lockout/tagout program shall be established to control hazardous energy as follows:
a. Locks and/or tags should be placed to plainly identify the equipment or circuits being
worked on. Systems locked or tagged should include the identity or job title of person
installing the lock or tag.
b. Personnel should be trained and disciplined in the use of this system to prevent
unexpected operation of any equipment that stores any type of energy that might inflict
injury to personnel.
c. The lock or tag should be removed by the person who installed it. In the event the
individual is not available, the lock or tag may be removed by the supervisor after ensuring
that no hazard will be created by energizing the locked or tagged equipment or circuit(s).
Note: See NFPA 70.
Well Pumping Units
1. Power to the pumping unit should be de-energized and locked or tagged out to eliminate
potential hazards during well servicing operations. In confined locations, overhead electric
power to the pumping unit control panel should be de-energized. Where necessary, power
service should be de-energized while moving the rig in or out and during rig-up and rig-
down operations. See Lockout/Tagout.
2. During well servicing operations, the pumping unit shall be secured to prevent unintended
movement. Use of the brake only or the brake and brake pawl are not acceptable means of
securing the pump unit.
3. Chain or wire rope sling of suitable strength should be used to handle the horsehead if
removal or installation operations are necessary. On installation, the horsehead should be
bolted or latched in accordance with the manufacturer’s specifications.
4. Upon completion of well servicing operations and before energizing the power source,
precautions shall be taken to ensure that all personnel and equipment are clear of the weight
and beam movement.
5. Brake systems on all pumping units in service should be maintained in safe working order.
6. After well servicing operations are completed all pumping unit guards and enclosure
guards (belt and motor sheaves) should be reinstalled prior to startup. Guards need not be
in place until all final adjustments (pump, spacing, etc.) are made, so long as the safety of
personnel is not compromised.
Hotwork, Welding, and Flame Cutting Operations
General
1. A written safe work permit (hot work permit) system covering welding and flame cutting
operations should be observed. See NFPA 51B. In general, safe works permit system
should consist of authorization to do the work along with the following:
a. Pre-Work Stage Communications meetings addressing the following:
1. Simultaneous operations.
2. Air/gas testing.
3. Equipment isolation.
4. Equipment preparation.
5. Identification of hazards.
6. Emergency procedures.
b. Work-in-Progress Stage:
1. Posting of permit.
2. Air/gas testing.
3. Personal protective equipment requirements.
4. Fire watch.
5. Special procedures/precautions.
c. Return to Service Stage:
1. Authorization and turnover signatures
2. The supervisor should hold a pre-job meeting with the crew and other involved persons to
review responsibilities for the operation to be performed.
3. Welding and flame cutting operations shall not be permitted close to flammable liquids,
accumulations of crude oil, escaping gas, or locations where sparks, flames, heat, or hot
slag could be sources of ignition.
4. Only qualified persons should perform welding or flame cutting operations on equipment
used to contain hydrocarbons or hazardous materials.
5. Appropriate personal protective equipment shall be utilized for hot work operations.
Welding and Flame Cutting Operations
1. If the object to be cut or welded cannot readily be moved, all movable fire hazards in the
vicinity shall be taken to a safe place.
2. If the object to be welded or cut cannot be moved, and if all the fire hazards cannot be
removed, guards shall be used to confine the heat, sparks, and slag and to protect the
immovable fire hazards.
3. A safe welding area may be designated. In this area, welding and flame cutting operations
can be conducted with minimal concern of providing an ignition source for flammable
hydrocarbons or combustible materials. A safety work permit is not normally required for
welding operations in an approved safe welding area.
4. Properly maintained fire extinguishing equipment shall be available for immediate use. A
minimum of at least one 30-lb dry chemical fire extinguisher shall be immediately available
during welding or cutting operations. This equipment is in addition to the general fire
protection equipment.
5. Fire watches with extinguishing equipment shall be required whenever welding or cutting
is performed in locations other than designated safe welding areas.
6. A fire watch shall be maintained for at least one-half hour after completion of welding or
cutting operations.
7. Before cutting or welding is permitted in areas outside a designated safe welding area, the
area shall be inspected by the individual responsible for authorizing cutting or welding
operations. This individual shall designate the precautions to be followed in granting
authorization to proceed.
8. Cutting or welding shall not be permitted in the following situations:
a. In areas not authorized by the supervisor.
b. In the presence of an explosive atmosphere.
c. In areas near storage of large quantities of exposed readily-ignitable materials.
d. Where ignition can be caused by heat conduction, such as on metal walls or pipes in
contact with combustibles on the other side.
e. On used containers such as drums unless properly cleaned.
Welding Fumes and Ventilation
1. Toxicity depends on the composition and concentration of the fumes. The composition and
quantity of fumes depends on the materials being welded, the composition of the welding
rods, any coatings or paints encountered in the welding operations, the process used, and
the circumstances of use. Toxic fumes can be generated from welding on metals coated
with or containing alloys of lead, zinc, cadmium, beryllium, and certain other metals. Some
paints and cleaning compounds may also produce toxic fumes when
heated. The potential health effects range in type and severity, depending on these factors;
and some effects can be extremely serious.
2. For more information on the toxicity and health hazards of welding fumes and the
appropriate protective measures, consult the following references: Industrial Ventilation,
A Manual of Recommended Practice, 22nd Edition; Threshold Limit Values and
Biological Indices for 1997-98; and API Publication 2201.
3. Mechanical ventilation at the minimum rate of 2,000 ft3/min (0.944 m3/s) per welder shall
be provided when welding:
a. In confined spaces or where the welding space contains partitions, balconies, or other
structural barriers to the extent that they significantly obstruct cross ventilation.
b. Where the nature of the welding, cutting, or brazing work is such that the release of toxic
fumes or gases is possible. This includes work on stainless steel, zinc, lead, and degreasing
or cleaning compounds containing hydrocarbons.
4. Adherence to confined space entry procedures shall be followed prior to any re-entries. For
example, releases from acetylene cutting equipment could change the atmosphere within
the confined space.
Work in Proximity to Exposed Energized Power Sources
1. Neither equipment nor machines on rigs (includes guylines) shall be operated closer power
lines than the recommended minimum clearances shown in Table 2, except when such lines
have been de-energized and visibly grounded or when barriers are present to prevent
physical contact with the lines.
2. An individual should be designated to observe equipment clearance as defined in Table 2.
The operator should notify the observer if he is having any difficulty in determining the
clearance. The observer should sound a warning at any time the clearance is not maintained.
3. When cage-type boom guards, insulating guylines insulating links, or proximity warning
devices on rigs or guylines are used, the recommendations of Table 2 are applicable.
4. Overhead wires should be considered energized (live) unless either the electrical system
owner reports them to be non-energized, or a qualified electrical person tests and finds
them to be non-energized.