SAFETY MANAGEMENT SYSTEM PROCEDURE

08PR318C OXY ACETYLENE WELDING, CUTTING, USE

AND STORAGE

Brierty Ltd ABN 65 095 459 448

38 Mandarin Road Maddington WA 6109
PO Box 150 Maddington WA 6989
Telephone (08) 9459 2855
Facsimile (08) 9459 8202
headoffice@brierty.com.au
OXY ACETYLENE WELDING, CUTTING, USE AND
STORAGE
HEALTH AND SAFETY MANAGEMENT SYSTEM PROCEDURE

CONTENTS
1 Purpose ...................................................................................................................................................... 3
2 Responsibilities ........................................................................................................................................... 3
3 Definitions ................................................................................................................................................... 3
4 Procedure Details ....................................................................................................................................... 3
4.1 Quality Requirements ........................................................................................................................ 3
4.2 Precautions ........................................................................................................................................ 3
4.3 Required PPE .................................................................................................................................... 4
4.4 Operating Procedures ........................................................................................................................ 4
4.5 Fire Watch.......................................................................................................................................... 5
4.6 Handling ............................................................................................................................................. 5
4.7 Storage .............................................................................................................................................. 6

DOCUMENT CONTROL
Document ID Document Name Comment
08PR318C Oxy Acetylene Welding Cutting Use and Storage

Date Version Description Originator Reviewer Approver

27/03/12 1 Issued for use I Majeed

DEFINITIONS
Term Abbreviation Comment

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1 PURPOSE
The purpose of this document is to ensure a safe working procedure for the storage and use of Oxy
Acetylene for welding and cutting

2 RESPONSIBILITIES
Project Manager - It is the responsibility of the project manager to provide safe equipment and safe systems
of work.

Supervisor - The supervisors must ensure they have sufficiently explained and conducted where necessary
all relevant JHAs and SWPs and provide a suitable level of supervision depending on the maintenance
person’s experience.

Maintenance Person - It is the responsibility of the maintenance person to present fit for work and to
operate and maintain the equipmentin a manner that does not endanger themselves, fellow work mates or
equipment. The operator must read and understand all relevant operator manuals/ maintenance manuals,
SWP’s and JHA’s and follow these instructions and all other site requirements. Where hazards exist, they
must be listed with the controls on a JHA.

3 DEFINITIONS
Fire Watch: Person whose sole responsibility is to observe hotwork in progress in hazardous areas for signs
of fire resulting from the hot work task and act accordingly. This person is to be competent in the use of fire
protection facilities required and communication systems that might be in use in case of an emergency.

Hazardous Area: A place where the presence (actual or potential) of a flammable material is likely to exist
or an area where hot work may directly or indirectly cause damage to electrical wiring, high value materials
and fixed/mobile plant.

Shall: The word “shall” is to be understood as mandatory.

Should: The word “should” as recommended.

4 PROCEDURE DETAILS
4.1 QUALITY REQUIREMENTS
Prior to using oxy acetylene equipment, personnel shall demonstrate that they have a clear understanding of
this procedure and the manufacturer’s operation manual before being assessed.

4.2 PRECAUTIONS
NB:This procedure is to be used in conjunction with SWP - 08PR306C_Welding

NB: Only persons who have passed appropriate assessment as supervised by a competent person
should conduct Oxy Acetylene work.

 Prior to the use of oxy/acetylene equipment, the exact location of the nearest dry chemical powder
fire extinguisher shall be noted by the person(s) using that equipment.
 Cylinder cooling: prior to the use of oxy/acetylene equipment, the exact location of the nearest
hose water outlet and hose shall be noted by the person(s) using that equipment.
 Flashback arrestors shall be fitted to the oxy/acetylene units, at the operator’s side of each
regulator connection or gas discharge of a manifolded cylinder pack, and to the blowpipe.

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 In the event that a flashback occurs, the flashback arrestors must be replaced, unless it is fitted
with a re-setable type.
 Flashback arrestors must have an annual inspection by an authorized agent (BOC) or must be
replaced.
 Oil and grease shall not be allowed to come into contact with the oxygen cylinder valves,
regulators, gauges, blowpipes, hose or connections.
 A Hot Work Permit is required for all oxy/acetylene welding and cutting and must be displayed
prominently at the worksite for the duration of its validity. If within Boily Bay a permit is to be issued
at start of each shift and remains valid for the duration of the shift.
 Always use correct lifting techniques when lifting heavy objects.
 Safety screens shall be placed strategically to minimize sparks dispersing
 When working in a hazardous area it shall be mandatory to assign a person on firewatch.

4.3 REQUIRED PPE

Recommended PPE to include but not limited to:

 Site Specific PPE

 Eye protection – Facemask, goggles
 Non flammable outer clothing with long sleeves (Sleeves shall be buttoned and cuffs and top
pockets should be avoided)
 Safety footwear
 Spats or calf length leather boots fully laced
 Leather apron
 Hand shields or Helmet and grade of visor designed for the type of welding
 Gloves
 Hearing protection
 Safety screens

4.4 OPERATING PROCEDURES

 Prior to using Oxy/acetylene equipment, JHA, Take 5 and Hot Work Permit should be done.
 Before using oxy/acetylene equipment, the person in charge of the set is responsible to ensure that
combustible material is either cleared from the work area or effectively protected.
 Materials to be cut or welded must be free of oil, grease and debris to safeguard against any
possible spontaneous combustion.
 Prior to using any Oxy /Acetylene equipment check that it is in good working condition and that all
inspection tags are current.
 Cylinders shall be secured in an upright position away from hot process piping, electrical circuits,
and arc welding equipment.
 Oxygen /Acetylene cylinders should generally be located and guarded in such a way that they
cannot be contacted by sparks or flame etc. from the cutting/welding site.
 Cylinders should be located such that they cannot be struck by falling objects.
 Cylinders shall be secured with chain or a suitable steel clamping device. Rope or fusible material
shall not be used.
 The correct standard key shall remain attached to all cylinders that are in use.

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 Standard keys shall be attached to the oxy/acetylene trolley/cradle by a suitable chain.

 Hose identification: The colour of hoses shall be outlined
 Acetylene - Red
 Oxygen - Black or Blue
 Gauges are to be set to 100 kPA for Acetylene and 200 kPA for Oxygen for general use. Some
changes may be necessary for particular circumstances.
 The lighting of blowpipes shall only be carried out using an approved type of flint gun. Matches,
naked flames, rope wicks or other smoldering matter shall not be used.
 When using oxy/acetylene equipment on a grid mesh or open floor, or in such a manner that
sparks, debris, etc. can fall upon lower workplace, appropriate guarding shall be used (eg.
Fiberglass/flameproof blankets, barricades, etc).
 There shall be no more than 1 (one) hose connection for each 5 metres of hose. Hose connectors
shall be an approved type, securely made and leak tight. Wire etc shall not be used to fasten hose
connections. Copper connections shall not be used.
 Adequate ventilation must be provided during oxy/acetylene cutting or welding by either forced
dilution or natural draught. Emitted vapour during oxy/acetylene cutting and welding within a 10
metre radius of an enclosed space must not affect the atmosphere of people working within that
enclosed space or build up to unacceptable levels within that enclosed space.
 When oxy/acetylene equipment is shutdown for extended periods of time or after use, it shall be left
such that regulators and hoses are de-pressurised and free of gases.

4.5 FIRE WATCH

 A fire watch shall be required for hot work performed in a location where more than a minor fire
might develop, or when any of the following conditions exist:
o Presence of Combustibles: If combustible materials such as those used in construction of a
building are closer than 10 metres to the location of the arc or flame.
o Opening: Any wall or floor openings which expose combustible materials within 10 metres of
the location of the work. This includes concealed spaces such as in double walls or floors.
o Metal walls: If combustible materials are adjacent to the opposite side of metal walls,
partitions etc and could possibly be ignited by conduction or radiation.
o Segmented Containers: Where direct penetration of sparks, conduction or radiation could
cause combustion in an adjacent compartment.’
 Personnel on fire watch shall:
o Have fire extinguishing equipment and any necessary PPE and communication equipment
readily available and shall be trained in its use.
o Shall be familiar with procedural requirements outlined in AS1674.1 and for sounding an
alarm in the event of fire.
o Watch for fires in all exposed areas and extinguish them if possible with the equipment
available or otherwise sound the alrm immediately.
o Maintain a fire watch for at least a half hour after completion of cutting or welding operations
to detect and extinguish smouldering fires.

4.6 HANDLING
 Whenever cylinders are to be handled by a crane or other lifting device, they shall be carried in a
plant standard cylinder cradle.
 Whenever cylinders are to be moved by a hand trolley, they shall be transported in the vertical
position and secured by a chain or steel clamping device.

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HEALTH AND SAFETY MANAGEMENT SYSTEM PROCEDURE

 Valves shall always be closed before cylinders are moved or transported.

 Cylinders shall not be transported unsecured in the rear of a vehicle.
 Cylinders shall not be dragged from one position to another, but may be rolled on its base end on
concrete floors for short distances.
 Whenever cylinders are transported in a plant standard cylinder cradle or approved trolley, by
crane, cherry picker or other lifting device, the cradle shall be tied back to the crane, cherry picker
or lifting device by means of a “tail rope”.

4.7 STORAGE
NB: Please refer to SWP for Storage and Handling of Gas Cylinders in addition to below

 Cylinders should be located such that they cannot be struck by falling objects.
 Where more than 20 `G’ size cylinders are stored together, they must be stored in accordance with
the Dangerous Goods Regulations 1992.
 Oxygen and Fuel gas cylinders in storage shall be separated by at minimum 6.1 metres or by a 1.5
metre high fire wall with a 1 hour fire resistance rating.
 Keep fuel gases away from sources of ignition.
 Cylinders shall not be placed where they may become exposed to an electrical arc, sparks, slag,
flame or other heat sources.
 Store cylinders in a well ventilated location.
 Full and empty cylinders shall be kept apart in storage to avoid confusion.
 Portable gas cylinders shall be stored in an upright position and be secured in an approved cart or
bottle rack.
 Acetylene cylinders (full and empty) shall be stored in accordance with AS 4332.
 Each cylinder shall be individually chained.
 Take care gas cylinders, equipment and hoses are not damaged by bumping, abrasion, contact
with sharp metal edges or hot metal particles or exposure to flame or metal heat.
 When gas welding or cutting is suspended for a substantial period of time, the blowpipe and
cylinder valves shall be closed, the regulator adjusting screws released and hoses withdrawn from
confined spaces.
 When the gauges have been removed from oxygen and gas cylinders stored in carts or racks, they
are considered to be in storage and therefore shall be separated.

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