XXXXXXX Pty Ltd | Safe Work Procedure – Oxy-Acetylene | Revision: XX | DD/MM/YYYY

SAFE WORK PROCEDURE

For

OXY-ACETYLENE

Content: SWP and Training Plan for Oxy-Acetylene

Prepared by: XXXXXXX

Date of initial implementation, Version 1: DD/MM/YYYY

Current Revision No.: 1

Date current version implemented: DD/MM/YYYY

Date for next review: DD/MM/YYYY

PERSONAL PROTECTIVE EQUIPMENT TO BE UTILISED

  • No loose clothing or dangling jewellery, shirt tucked in.
  • Hair net or cap for long hair.
  • Safety brazing / welding goggles.
  • Fume extraction system if operating in an enclosed area.
  • Overalls. Long sleeved 100% wool or flame retardant cotton shirts and pants.
  • Leather apron.
  • Safety Boots.
  • Breathing apparatus / mask.
  • Hand protection.
  • Ear protection to prevent sparks from entering the ear.

LICENSE / PERMIT/TRAINING REQUIRED

  • Operators must have completed a training program recognised by XXXXXXXXX and be authorised to perform this procedure.
  • Hot work permit.

START UP PROCEDURE

Before starting check that:

  • You manually check cylinders, regulators, hoses and torches for damage.

DO NOT OPERATE UNSAFE MACHINERY.

If the Oxy-Acetylene equipment is not in a safe operational condition, advise your supervisor or maintenance staff immediately.

OPERATIONAL PROCEDURE

  • Good ventilation is essential wherever fumes are produced.
  • Never set the oxygen and acetylene regulator pressures higher than the job requires. Doing so is unnecessary, wasteful and dangerous.
  • Never use equipment near flammable materials.
  • Only use the gas and equipment for the designated purpose.
  • Never leave a lighted blowpipe ignited.
  • Keep hoses clear of walkways and out of the way of flames and sparks/molten metal.
  • Ignite gas with flint lighter. Do not use cigarette lighters or matches.
  • Do not cut or weld containers that have contained or do contain flammable materials, combustible liquids or gas or hazardous substances (Refer to MSDS).
  • Never use oxygen to blow out pipelines or to dust off work or clothing.
  • Be aware of the nearest fire fighting equipment and familiarise yourself with its use.
  • A watchperson should be left at hazardous locations for 30 minutes after welding and cutting operations have been completed.
  • Do not use this equipment with any gas other than that for which it was designed.
  • Know the whereabouts of the nearest first aid kit.
  • Be sure that the connections between the regulators, adaptors and cylinder valves are gas tight. Escaping acetylene can generally be detected by the odour. Test with an approved leak detection solution, NEVER with an open flame.
  • Use only proper wrenches to open valves. NEVER force connections that do not fit.
  • Never tamper with or try to repair cylinder safety devices.
  • Stand to one side away from the regulator face when opening cylinder valves. Open cylinder valves slowly. Using approved keys or hand wheels. Do not force. Oxygen cylinders should be opened fully but acetylene cylinder valves should only be turned 1½ times. Leave key wrenches attached to the cylinder so they can be closed quickly.
  • Never use acetylene at pressures in excess of 15 psi.
  • Before lighting the torch purge the lines to remove any mixed gases.
  • Do not relight a torch that has “blown out” without first closing both torch valves and then relighting properly.
  • Do not hang a torch by its hose on cylinder regulators or valves.
  • Do not store chlorinated hydrocarbons where ultraviolet light from welding can reach them.
  • Know the composition of the metals and welding rods you use, so you can evaluate the hazards.
  • Wear welding goggles with the appropriate shade number, depending on the intensity of the welding. Use the darkest shade number consistent with viewing ability.
  • Store welding rods away from oxidising sources in a well ventilated area.
  • Close cylinder valves when not in use.
  • Check for leaks on a regular basis.
  • Never smoke or carry out hot work in an oxygen rich atmosphere or with clothing saturated with oxygen.
  • Never use a blowpipe when working with any object suspended by fibre or nylon ropes.
  • Do not use wooden horses or boards to support welding or cutting work.
  • Cylinders standing in the open should be screened against the direct rays of the sun.
  • Never try to fill a cylinder or mix gasses in a cylinder.
  • Always remove regulators when moving cylinders.
  • Use an approved device to light a blowpipe.
  • Matches and cigarette lighters should be removed from the welding area or on person.
  • NEVER use water pipes or gas pipes as part of the welding circuit.
  • Oxygen vigorously supports combustion of many materials, which will not normally burn in air.
  • If the acetylene cylinder is found to be leaking through a fusible plug, do not attempt to stop the leak. The area around the cylinder should be cleared of all possible sources of ignition. The cylinder should be removed to an outside area. Notify the authorities.
  • If a flashback occurs immediately turn off the blowpipe oxygen valve, the fuel gas valve. Allow the blowpipe and tip or nozzle to cool. Purge gasses before relighting.
  • Ensure your own clothing is not oily or that you have sleeves rolled up or cuffs which will receive sparks or hot slag.
  • The oxy-fuel gas flame is rarely itself the cause of fire. But sparks, which fly from welding or cutting work, are little balls of glowing metal oxides. They can travel a surprising distance from their point of origin and may stay hot for some time after landing.
  • When necessary to cut and weld near wooden floors, walls etc. shield them with a fire resistant screen. If cutting over a wooden floor wet the floor down thoroughly before starting to cut.
  • Clear the area within a radius of 7.5 meters of all rubbish.

Cylinders/Regulators:

  • Never remove or deface markings on a regulator.
  • Never drop or let cylinders strike together. Secure at all times.
  • Never tamper with valves or safety devices.
  • Mark empty cylinders with chalk or “Empty” tag. Close valves and replace caps if applicable.
  • Always store and move in an UPRIGHT position.
  • “Crack” the cylinder before connecting to clear dust etc.
  • Remove leaking cylinders outdoors and notify suppliers.
  • Point valve away from persons when opening.
  • NEVER wipe oxygen valves with oil or grease as oxygen can react explosively with both.
  • Do not reticulate at pressures greater than 100 kPa (pure acetylene can ignite by decomposition above 200 kPa.
  • Open cylinder valves slowly.
  • Cylinders must be placed on a trolley or be positively secured. This area must be appropriately signed.
  • Never “crack” a full gas cylinder near other welding works, spark or open flame.

Hoses:

  • Don’t use hoses if the connections are leaking.
  • Inspect daily for defects; replace as required.
  • Protect hoses: make sure hoses are located where they will not get tangled or be tripped over. Protect the hose and cylinders from flying sparks, molten splashes, hot objects and open flames.
  • Use correct fittings and never interchange hoses.
  • Ensure flash back arresters are installed on equipment.
  • Do not allow the hose or valves to come in contact with oil or grease. These can affect the rubber and cause fires.
  • Damaged and frayed hoses are dangerous.
  • Do not kink hoses to stop gas flow.

Torches:

  • Use approved torches and compatible fittings only.
  • Check all fittings with Teepol (never soap) before use.
  • Light with approved device only, not matches or cigarette lighters.
  • Point tip away from persons and flammable material when lighting.

Clothing:

  • Synthetic fabrics should not be used because they are often flammable, and molten splashes could cause the fabric to melt. Clothing should not have any cuffs, pockets or other folds in which sparks could be trapped.
  • Clothing should be free from oil grease or flammable substances.

Nozzles:

  • Do not mistreat the nozzle. Do not use it as a hammer or as a lever to prise away cut portions of metal.
  • To clear the orifices, special nozzle cleaning reamers are available. It is most important that the small holes at the seating end of the nozzles are not enlarged in any way.
  • Do not use old pieces of wire, reamers or brooches to clean out pre–heat and cutting stream orifices.
  • Do not interfere in any way with the seating surfaces either on the nozzles or in the blowpipe head.
  • Ensure that the correct lighting up and closing down procedures are followed.

CLOSEDOWN PROCEDURE

  • Close acetylene torch valve first, then close oxygen torch valve.
  • Back out the Acetylene regulator T-handle until loose. Then open acetylene torch valve to release the pressure off regulator. Then close torch valve.
  • Back out the Oxygen regulator T-handle until loose. Then open oxygen torch valve to release the pressure off regulator. Then close torch valve.
  • Take tip out of torch body and replace in storage hanger.
  • Hang up spark lighter and pliers.
  • Replace any filler metal back to storage shelf.
  • Coil hose up and hang on hanger.
  • Turn stool upside down and place on welding station.

EMERGENCY PROCEDURE

  • Burns: Seek medical aid for all burns.
  • Eye: Seek medical aid for all eye injuries.
  • Inhalation of fumes gases or dusts: Asphyxiation:
  • Conscious persons should be assisted to an uncontaminated area and inhale fresh air. Quick removal from the contaminated area is most important.
  • Unconscious persons should be moved to an uncontaminated area, given mouth to mouth resuscitation and supplemental oxygen. Further treatment should be symptomatic and supportive. Seek medical aid urgently.
  • Contact XXXXXXXXXXXXX or your Supervisor immediately.

IF YOU HAVE NOT BEEN TRAINED IN THE TASK OR YOU ARE NOT SURE HOW TO PERFORM THE TASK OR OPERATE THE MACHINERY, DO NOT OPERATE THE MACHINERY AND ADVISE YOUR SUPERVISOR IMMEDIATELY.

OPERATOR’S STATEMENT

I have been trained in and I understand this procedure.

I will perform my tasks to the best of my ability and in accordance with this safe working procedure.

Date: ......

Operator’s Name: ......

Operator’s Signature: ......

Witness Name: ......

Witness Signature: ......

Page 1

OXY-ACETYLENETHEORY ASSESSMENT

Q1. Name at least five pieces of protective equipment to be utilised whilst working with Oxy-Acetylene.

......

Q2. Who is permitted to work on the Oxy-Acetylene equipment on this site?

......

Q3.May the Oxy-Acetylene equipment be used if it has been isolated by tags or lockouts?

Yes /  / No / 

Q4. What do you need to check each day before you start with Oxy-Acetylene equipment?

......

Q5. How must cylinders be moved and stored?

......

Q6.Where must the valves be pointing when being opened?

......

Q7. What are two substances that oxygen may react explosively with?

......

Q8. What must hoses be protected from during operations?

......

Q9. Is it safe to interchange the hoses with the fittings?

Yes /  / No / 

Q10.May hoses be crinked to stop the flow of gas?

Yes /  / No / 

Q11.Is it safe to light torches with cigarette lighters and matches?

Yes /  / No / 

Q12.How might you test for a gas leak?

......

Q13.Is good ventilation important when using Oxy-Acetylene equipment?

Yes /  / No / 

Q14.Where must you stand in relation to the cylinder valves when openingvalves?

......

Q15.Must the regulators be removed when moving cylinders?

Yes /  / No / 

Q16.What is the procedure if a flash back occurs?

......

Employee signature: ......

Questioned by: ......

Position/ Qualifications: ......

Date:......

OBSERVATION OF ASSESSMENT

I have observed the employee …………………………………….in a work situation and he/she has demonstrated competence in the practical aspects of the operation of an Electric Oxy-Acetylene equipment by following the Safe Work Procedure.

Signed: ......

Name: ......

Position: ......

Date: ......

Signed: ......

Name: ......

Position: ......

Date: ......

Signed: ......

Name: ......

Position: ......

Date: ......

SELF-ASSESSMENT – OXY-ACETYLENETRAINING

Employee:......

Trainer: ......

Date: ......

I have received training in the following and understand (please initial): / YES / NO
I must wear my eye and ear and foot and hand protection, protective clothing, have my hair tied back and my shirt tucked in at all times.
I must change this protective equipment when it wears out or is damaged.
I must carry out a pre-operational check including but not limited to:
Ensuring access to fire blankets and suitable extinguishers and first aid kits.
Manually checking all cylinders and regulators, hoses and torches.
The immediate area must be clear and kept clear during the operations; including:
No persons in close proximity.
I must ensure that I:
Never remove or deface markings on a regulator.
Ensure cylinders are secured at all times.
Never drop or let cylinders strike together.
Mark cylinders as “empty”.
Always store cylinders in an upright position.
Never wipe oxygen valves with oil or grease.
Open cylinder valves slowly.
Point valves away from persons when opening.
Not reticulate at pressures greater than 100 kPa (pure acetylene can ignite by decomposition above 200 kPa).
Never “crack” a full gas cylinder near other welding works, spark or open flame.
Not use hoses if the connections are leaking.
Inspect hoses and fittings before use and replace if defective.
Use the correct fittings and not interchange hoses.
Not allow hoses or fittings to come in contact with grease or oil.
Not kink hoses to stop the flow of gas.
Ensure flashback arrestors are installed before use.
Not use the nozzle as a hammer or lever.
Not enlarge the nozzle holes in any way.
Not alter the seating surfaces in the nozzle or blowpipe.
Never use equipment near flammable surfaces.
Only use the equipment for the designated purpose.
Follow the safe operating procedure at all times.
Never leave a lit blowtorch.
Never allow the hoses to become a trip hazard.
Never tamper with or repair safety devices.
Purge the lines to remove any mixed gasses before lighting the torch.
Wear welding goggles of the appropriate shade number.
Close cylinder valves when not in use.
Never smoke or carry out hot work in an oxygen rich atmosphere.
Check for gas leaks on a regular basis.
Not use wooden supports for welding work.
Never attempt to fill a gas cylinder or mix the gasses.
Never use water pipes or gas pipes as part of a welding circuit.
Be aware that oxygen vigorously supports combustion of many materials that do not normally burn in air.
Be aware that if a flashback occurs, immediately turn off the blowpipe oxygen valve and the fuel gas valve. Allow the blowpipe, tip and nozzle to cool. Purge the gasses before use.
Ensure my own clothing is not greasy or oily.
Clear the area of all rubbish.
  • I have had the operation of Oxy-Acetylene demonstrated to me.
  • I have had the opportunity to ask questions.
  • I am aware that I can request further training at any time.
  • I understand that by signing below; I agree to operate Oxy-Acetyleneequipment by following this Safe Work Procedure.

Signed: ......

Name: ......

Date: ......

ATTENDANCE REGISTER – OXY-ACETYLENETRAINING

Trainer:......

Date: ......

NAME

OXY-ACETYLENE THEORY ASSESSMENT - ANSWERS

Q1. Name at least five pieces of protective equipment to be utilised whilst working with Oxy-Acetylene.

A: Safety Eyewear(Brazing Goggles), Hearing Protection, Safety Boots, Hand Protection, Overalls, Leather apron, Ear protection.

Q2. Who is permitted to work on the Oxy-Acetylene equipment on this site?

A: Only people who have successfully completed a training program and are authorised to do so.

Q3.May the Oxy-Acetylene equipment be used if it has been isolated by tags or lockouts?

Yes /  / No / 

Q4. What do you need to check each day before you start with Oxy-Acetylene equipment?

A: Cylinders, regulators, hoses and torches.

Q5. How must cylinders be moved and stored?

A: In an upright position.

Q6.Where must the valves be pointing when being opened?

A: Away from yourself and anyone else.

Q7. What are two substances that oxygen may react explosively with?

A: Oil & grease.

Q8. What must hoses be protected from during operations?

A: Being tripped over, flying sparks, molten splashes, hot objects, and open flames.

Q9. Is it safe to interchange the hoses with the fittings?

Yes /  / No / 

Q10.May hoses be kinked to stop the flow of gas?

Yes /  / No / 

Q11.Is it safe to light torches with cigarette lighters and matches?

Yes /  / No / 

Q12.How might you test for a gas leak?

A: A non-fat soapy solution. Never an open flame.

Q13.Is good ventilation important when using Oxy-Acetylene equipment?

Yes /  / No / 

Q14.Where must you stand in relation to the cylinder valves when openingvalves?

A: To the side.

Q15.Must the regulators be removed when moving cylinders?

Yes /  / No / 

Q16.What is the procedure if a flash back occurs?

A: Immediately turn off the blowpipe oxygen valve and the fuel gas valve. Allow the blowpipe and tip or nozzle to cool. Purge gasses before relighting.

SAFE WORK PROCEDURE – OXY-ACETYLENE

STARTUP PROCEDURE
  • Manually check cylinders, regulators, hoses and torches for damage.
CLOSEDOWN PROCEDURE
  • Close acetylene torch valve first.
  • Back out the Acetylene regulator T-handle until loose. Then open acetylene torch valve to release the pressure off regulator. Then close torch valve.
  • Back out the Oxygen regulator T-handle until loose. Then open oxygen torch valve to release the pressure off regulator. Then close torch valve.
  • Take tip out of torch body and replace in storage hanger.
  • Hang up spark lighter and pliers.
  • Replace any filler metal back to storage shelf.
  • Coil hose up and hang on hanger.
  • Turn stool upside down and place on welding station.
EMERGENCY PROCEDURE