WELDING PROCEDURE

PURPOSE
This Procedure provides safety and health instructions regarding gas and electric
welding, cutting, brazing, or similar flame or spark-producing operations to protect
personnel and property against heat, evolved gases and fumes, electrical shock, and
radiation. The following instructions and work practices have been established in
accordance with the Entity's Injury & Illness Prevention Program and requirements of
the following sections in 8 CCR: 4845-4853; 4649; 4650; 5189; 1536; and 1537.
SCOPE
This procedure shall apply to all employees responsible for planning, supervising, and
conducting welding and cutting operations.
RESPONSIBILITIES
A.

B.

C.

Management shall:
1.

Designate an individual, or individuals, responsible for authorizing welding

and cutting operations.

2.

Designate approved welding/cutting areas at their facility.

3.

Advise contractors about flammable materials or hazardous conditions of

which the contractors may not be aware, and select cutting/welding
contractors with appropriately trained personnel who understand the risks
involved.

Safety Coordinator shall:

1.

Provide guidance to employees and supervisors in the implementation of

this procedure.

2.

Ensure all work areas and equipment used for welding/cutting operations
are being inspected for compliance with the requirements of this procedure.

Welding Supervisors shall:

1.

Ensure that this procedure is adhered to during all welding and cutting
operations.

2.

Ensure that welding/cutting operations are performed in designated areas

by trained and authorized personnel.

D.

E.

3.

Approve hot work permits for welding and cutting operations in nondesignated areas.

4.

Maintain hot work permit records on site.

Welders shall:
1.

Perform welding and cutting operations in designated areas.

2.

Obtain an approved hot work permit prior to performing welding or cutting

operations in non-designated areas.

3.

Report any injury, including suspected flash burns, to their supervisor.

Fire Watchers shall:

1.

Be trained in the use of fire extinguishing equipment.

2.

Be familiar with alarm locations in the event of a fire.

3.

Watch for fires in all exposed areas, and extinguish them within the
capacity of equipment available.

4.

Maintain a fire watch for at least 1/2 hour after completion of welding or
cutting operations.

5.

Report any injury, including suspected flash burns, to their supervisor.

CONTRACTOR REQUIREMENTS
When a host employer arranges to have employees of a contractor perform welding or
cutting work, the contractor will be informed on the requirements of this Welding and
Cutting Procedure. Each contract employee is expected to follow this Welding and
Cutting Procedure when performing welding and cutting operations.
A.

The Host Employer shall:

1.

Inform the contractor of areas authorized for welding and cutting

operations.

2.

Inform contractors of specific areas and/or equipment where welding and

cutting are not authorized.

3.

Inform the contractor of any precautions or procedures the host has

implemented for employees in or near the contractors work areas.

B.

4.

Coordinate welding and cutting actions with the contractor when both the
host employees and contractor employees will be working on or near the
same equipment, machinery, or systems.

5.

Evaluate the compliance of contract personnel with this Welding and

Cutting Procedure.

6.

Debrief the contractor at the conclusion of welding and cutting operations

to determine any hazards confronted or created in the work area.

7.

Ensure proper risk transfer is in place.

The contractor shall:

1.

Obtain any available information regarding welding and cutting

procedures from the host employer.

2.

Coordinate welding and cutting actions with the host employer when both
host and contractor personnel will be working employees will be working
on or near the same equipment, machinery, or systems.

3.

Inform the host employer of any hazards confronted or created in the

welding and cutting work area.

DEFINITIONS
ADEQUATE VENTILATION

A ventilation flow, which allows fresh air to circulate to

replace contaminated air, which is simultaneously
removed.

COMBUSTIBLE
SUBSTANCE

Any substance which, after ignition, will continue to burn in

air.

FIRE WATCH

Person(s) assigned to work with welders to watch for fires

resulting from welding, cutting, and brazing operations.

HOT WORK PERMIT

An approval form required prior to performing welding or

cutting operations in areas not designated for welding.

IGNITABLE MATERIAL

Any material that is capable of burning.

LOCAL EXHAUST
VENTILATION

A ventilation system that captures and removes the

contaminants at the point they are being produced before
they escape into the worksite.

PROCEDURE REVIEW
The Welding and Cutting Procedure will be reviewed annually to ensure compliance
with regulatory mandates and improve, as necessary, the guidance included in the
procedure. Employee understanding of, and compliance with, this procedure will be
evaluated at least annually by management.
RECORD KEEPING
A.

Copies of open permits must be maintained at the job site and in the supervisors
office.

B.

Upon job completion, closed permits should be maintained for three (3) years.

WELDING AND CUTTING PROCEDURES

GENERAL INFORMATION
A.

Supervisors and workers performing welding, cutting, and/or brazing

operations shall be trained in hazard recognition, evaluation, and control;
fire protection; and safe work practices; and shall adhere to requirements in
this procedure.

B.

Welding/Cutting Areas: Whenever possible, welding and/or cutting

operations should be performed in areas that are isolated and designated
for such uses. Welding or cutting must not be performed in the following
areas:
1.

In the presence of explosive atmospheres;

2.

In areas near the storage of quantities of exposed, ignitable

materials;

3.

In sprinklered buildings while such protection is impaired; or,

4.

In areas not authorized by management or by a hot work permit.

C.

Whenever welding operations are interrupted for a substantial period of

time (e.g., lunch or overnight) or completed, "hot" metal areas must be
identified, and the equipment must be shut off with any valves closed.

D.

Equipment: Personnel are required to use approved welding, cutting, and

grinding equipment and follow the manufacturers instructions. Such
equipment shall be maintained in safe working order at all times.
Personnel shall report any equipment defect or safety hazard to a
supervisor, and the use of such equipment must be discontinued until it is
repaired by qualified personnel.

E.

Site Preparation: Prior to beginning welding or cutting operations,

workers must:
1.

Check the work area (35' radius) to ensure that no fire hazards
including oily or greasy materials are present;

2.

Remove all combustible materials within 35 not necessary for the

operation. Any combustible material that cannot be removed, such
as wood platforms, should be covered with a flame-resistant
material;
Check that all equipment is in good working condition;

3.

F.

G.

4.

Inform workers in the immediate area and display warning signs at

the worksite to alert others of the potential hazards;

5.

Install welding shields/curtains to protect other workers from the

sparks and intense light associated with welding/cutting operations;
and

6.

When performing welding, cutting, and/or brazing operations in

areas on or around Acutely Hazardous Materials which are included
in a Process Safety Management (PSM) Program, a hot work permit
is required.

Ventilation: Cutting or welding operations must be performed in areas with

adequate ventilation to keep fumes and gases within safe limits.
1.

Local exhaust ventilation must be used when potentially hazardous

materials are being worked on. (Examples of potentially hazardous
materials include, but are not limited to, chromium, fluorides, zinc,
beryllium, cadmium, lead, and mercury).

2.

Adequate exhaust ventilation must be used when using inert-gas

welding, plasma-arc cutting or carbon-arc cutting.

3.

The metal surface shall be free of all chlorinated solvents during any
welding or cutting operations.

Personal Protective Equipment: Approved personal protective equipment

(PPE) shall be worn by all employees performing or assisting in welding
and/or cutting operations.
1.

Examples of PPE include eye protection, helmets and hand shields,

flame resistant gloves, limb/body protection, and respiratory
protection.

2.

While performing overhead or vertical welding, personnel must wear

leather personal protective equipment (shoulder, head, and ear
covers).
All welders should wear flame-resistant aprons, coveralls, gauntlet
gloves and shirts with sleeves of sufficient length and construction to
protect the arms from heat, UV radiation, and sparks.

3.

4.

Wool and leather clothing are preferred because they are more
resistant to deterioration and flame than cotton or synthetics.
Synthetic fiber clothing should not be worn unless it is specifically
manufactured to be fire retardant.

5.

Clothing should be kept reasonably free of oil or grease.

6

6.

Front pockets and upturned sleeves or cuffs should be prohibited.

Sleeves and collars should be kept buttoned and high boots should
be worn under pant legs (or leggings worn) to prevent hot metal slag
or sparks from contacting the shin.

7.

Personnel must wear respiratory protection when ventilation is not

sufficient to prevent exposure above permissible limits. (When
performing cutting or welding operations involving coatings which
generate toxic substances upon heating, or working with materials
that contain beryllium, cadmium, lead, or mercury, personnel must
wear supplied-air respirators).

8.

Workers welding on metal alloys should wear work uniforms,

coveralls, or similar full-body coverings that are laundered each
day. Lockers or other closed areas should be provided to store
work and street clothing separately.

9.

Other personnel in welding/cutting areas not protected by

noncombustible or flameproof screens or shields must wear
appropriate goggles.

H.

Confined Space Operations: Proper precautions must be taken by

personnel who are required to perform welding or cutting operations in a
confined space area. Refer to the Confined Space Pre-Entry Procedure,
and contact the Entry Supervisor prior to performing welding or cutting
operations in a confined space.

I.

Prior to welding tanks, cylinders, or other containers, supervisory personnel

must complete a hot work permit and shall verify that such containers do
not contain, or have not contained, any flammable, toxic, or explosive
materials. If containers have contained flammable, toxic, or explosive
materials, they must be emptied, flushed, or otherwise purged and sampled
prior to welding.

J.

Fire Protection: Fire protection equipment must be maintained ready for

use at all times that welding or cutting operations are being performed.
1.

Utility trucks supporting welding/cutting operations must be

equipped with fire fighting and fire protection equipment, including a
fire extinguisher of at least 10 A:B:C rating.

2.

If welding is to be performed in areas where a fire hazard may

exist, fire watch practices must be established and implemented.
(See Appendix A Hot Work Permit.)

3.

When performing welding or cutting operations on coated surfaces

that are highly flammable (determined by a flammability test), the
coating must be stripped from the area to prevent ignition.

K.

All surfaces covered with toxic preservatives, including coatings which

generate toxic substances upon heating, must be stripped for a distance of
at least 4 inches from the area of heat application.

L.

Contractors performing welding and cutting operations must be made

aware of the risks involved in the operations, and shall obtain approval
from District prior to performing such operations.

FIRE SUPPRESSION & PROTECTION

A.

Suitable fire protection equipment must be maintained ready for use at all
times that welding or cutting operations are being performed. If welding is
to be performed in non-approved areas, supervisory personnel must
complete a hot work permit.

B.

A Fire watch and a hot work permit are required when welding or cutting is
performed where:
1.

Combustibles are closer than 35' to the point of operation, or where

there are appreciable combustibles easily ignited by sparks;

2.

Wall, floor, or other openings within 35' radius that expose

combustible materials; or

3.

Combustible materials are adjacent to the opposite side of metal

walls, partitions, ceilings, or roofs and are likely to be ignited by
conduction or radiation.

C.

If required, duties of the Fire Watch include:

1.

Using fire extinguishing equipment to extinguish fires within the

capacity of equipment available;

2.

Sounding an alarm in the event of a fire;

3.

Watching for fires in all exposed areas;

4.

Maintaining a fire watch for at least 1/2 hour (30 minutes) after
completion of welding or cutting operations; and

5.

Reporting any injury, including suspected flash burns, to their

supervisor.

HOT WORK PERMIT

Prior to performing welding/cutting operations in the following circumstances, a hot work
permit must be completed and approved by the appropriate supervisor.
A.

In locations that have not been designated as welding locations.

B.

In confined spaces.

C.

Welding or cutting tanks, cylinders, or other containers.

D.

In areas where a fire hazard may exist (example: weeds, wood products,
fabrics, etc).

E.

In areas included in the Process Safety Management Program (if

applicable).

F.

In areas where combustibles are closer than 35' to the point of operation.

G.

In areas where combustible materials are adjacent to the opposite side of

metal walls, partitions, ceilings, or roofs and areas likely to be ignited by
conduction or radiation.

Copies of open permits must be maintained at the job site and in the supervisors office.
Upon job completion, closed permits should be maintained for three (3) years.

OXY-FUEL WELDING & CUTTING

A.

Prior to beginning welding or cutting operations, workers must check that

the cylinders, regulators, backflow prevention device, flame arrestors,
hoses, clamps, and torches are in good working condition.

B.

Oil or grease must not come into contact with oxygen cylinders, valves,
regulators or other fittings. Do not handle oxygen cylinders or apparatus
with oily hands or gloves, or greasy materials. Do not let oxygen contact
oily or greasy surfaces or clothes, or enter a fuel oil or other storage tank.

C.

Fuel gas and oxidizers must pass through a pressure-reducing regulator

prior to being used. Pressure reducing regulators must only be used at or
below the rated pressures and must be specific to the type of gas being
used. Prior to connecting a pressure regulator, cylinder valves should be
"cracked" to clear the dust or dirt that might otherwise enter the regulator.
This procedure shall be performed away from other welding work or sparks.

D.

Prior to removing a regulator from a cylinder, personnel must close all

cylinder valves, and release the gas from the regulator.

E.

Personnel must follow the manufacturer's operating procedures for lighting

the torch. Generally accepted practices for start up and shut down follow:
1.

Start Up
(a)

Open the oxygen valve on the torch handle and adjust the
oxygen regulator to the desired delivery range.

(b)

Close the torch handle oxygen valve.

(c)

Open the fuel valve on the torch handle and adjust the fuel
regulator to the required delivery range.

(d)

Close the torch fuel control valve.

(e)

Hold the torch in one hand and the spark lighter in the other.
Open the torch fuel valve approximately one-half turn and
ignite the gas.

(f)

Point the torch away from people and combustible materials.

(g)

Keep opening the fuel valve until the flame stops smoking
and bring the flame back to the tip.
Open the torch oxygen valve until a bright neutral flame is
reached.

(h)

10

2.

Shut Down
When shutting down the system, first shut off the oxygen, then the
fuel gas. Drain the gas pressures from the system.

F.

Cylinders must 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 must be provided.

CARE OF COMPRESSED GAS CYLINDERS

A.

Compressed gas cylinders shall be legibly marked identifying the contents.

B.

Compressed gas cylinders shall be stored and transported in the following

manner:
1.

Valve end must be up.

2.

Outside storage areas must be protected from direct sunlight,

external heat sources, electric arcs, or high temperatures.

3.

Inside storage areas must be well-protected, well-ventilated, and in

a dry location at least 20 feet from highly combustible materials.

4.

Cylinders containing flammable gases will be stored at least 20 feet

from oxygen cylinders.

5.

Cylinders shall not be kept in unventilated enclosures such as

lockers and cupboards, or inside the cabs or passenger areas of
vehicles.

6.

Valve protection devices must be in place when cylinders are not in

use, and during storage and transport. Valve protection devices
must not be used for lifting cylinders.

7.

Cylinders must be prevented from tipping, falling, or rolling.

8.

All empty cylinders will be handled and stored as if they were still
pressurized.

C.

If cylinders are found to have leaky valves or fittings which cannot be

stopped by closing the valve, the cylinders shall be taken outdoors, away
from sources of ignition, and slowly emptied. Never put other workers at
risk. If the leak is large, do not attempt to move the cylinder, evacuate all
personnel from the area and notify your supervisor.

D.

Pressurized cylinders must not be taken into confined spaces.

11

ELECTRIC ARC WELDING AND CUTTING

A.

Prior to beginning welding or cutting operations, workers must:

1.

Check that the machine, all electrode holders and cable are capable
of carrying the maximum current, are properly insulated and
grounded, and have been maintained in good working condition.

2.

Check that any cable splices have been performed with insulating
quality equal to that of the cable, and that there are no splices within
10 feet of the electrode.

3.

The area must be free of chlorinated solvent vapors within 50 feet of

the exposed arc; surfaces prepared with chlorinated solvents shall
be thoroughly dry before welding is performed on them.

B.

When arc welding is performed in wet or high humidity conditions,

personnel must use additional protection against electric shock (e.g.,
rubber pads or boots).

C.

To protect workers or other personnel from the arc rays, noncombustible or

flameproof screens or shields shall be used, or personnel in the area shall
wear appropriate goggles.

D.

Manual electrode holders must be specific to welding and cutting, and

capable of handling the maximum current required for the operation. All
current carrying parts gripped by the user must be insulated against the
maximum voltage to ground.

E.

Arc welding and cutting cables must be insulated, flexible, capable of

handling the maximum current required by the operation, taking into
account the duty cycles, and must not have bare or worn conductors.
Cables must be free of repair or splice from 10' of the electrode holder
unless insulated connectors or splices with insulating quality equal to that
of the cable are provided. Exposed metal parts must be insulated.

F.

Ground return cables must have current carrying capacity equal to or

exceeding the total maximum output capacities of the welding or cutting
unit. Do not use electrical conduits or structures or pipelines containing
gas or flammable liquids as part of the grounding circuit system.

G.

Arc welding and cutting machine frames must be grounded, either through
a third wire in the cable containing the circuit conductor or through a
separate wire at the source of the current. Grounding circuit resistance
must be low enough to permit sufficient current to flow to cause the fuse or
circuit breaker to interrupt the current.
12

H.

When machines are not in use, the power supply switch shall be shut off
and the electrodes removed and the holders placed to prevent employee
injury.

INERT GAS METAL ARC WELDING

When performing inert-gas metal-arc welding, extreme caution shall be used; inert
gases can easily displace oxygen. The following safeguards must be followed.
A.

The area must be free of chlorinated solvent vapors within 50 feet of

exposed arc; surfaces prepared with chlorinated solvents shall be
thoroughly dry before welding is performed on them.

B.

Employees exposed to radiation must have their skin completely covered.

C.

If welding on stainless steel, personnel must be protected by local

exhaust ventilation or by wearing supplied-air respirators.

RESISTANCE WELDING
A.

B.

Prior to performing resistance welding operations, personnel must inspect

the machine to ensure:
1.

All machine guards are in position and in proper working condition;

and

2.

Emergency stop button(s) are in working condition.

Resistance welding equipment must be periodically inspected by qualified

personnel, and a certification record maintained. The record shall include
the date of the inspection, the signature of the person who performed the
inspection, and the serial number or other equipment identification.

13

HOT WORK PERMIT

Date

W.O.#

Work Location(s) & Description:

Employee(s) Performing Job:

Fire Guard Duty Schedule:

to

OPERATIONAL REQUIREMENTS (Check all areas that apply. This section must be
completed prior to approving this permit.)
YES
NO
1.
Fire Watch (during activity & 30 minutes after)

2.
Fire Extinguisher(s) (Type 10 ABC)

3.
Area clear of combustibles (35 ft radius)

4.
Area clear of Flammable Vapors

5.
General/Local Ventilation

6.
Respiratory Protection

Type:
7.
Confined Space Permit

8.
Process Safety Management Area

9.
Air Monitoring

10.
Hearing Protection

11.
Pressurized Cylinders

12.
Additional Comments/Instructions
Firewatch (name/emp#) ________________________Signature
Job Supervisors Approval
Date

Time

This form must be completed for all welding/cutting operations, which will be performed
in non-designated welding areas. Upon job completion, this form shall be maintained in
the field administrative office.