Welding and Cutting

1. Welding and Cutting Hershey Entertainment and Resorts Company Revised 2006 Ref 29 CFR 1910.251-255

2. Introduction • Instructor Introduction • Class Introduction

3. Purpose • This program is designed to communicate our welding and cutting policies and procedures to employees • This program promotes safe practices and a safe workplace

4. Welding and Cutting Equipment

5. Operating Procedures • Electrical Equipment • Employees should: • Not arc weld while standing on damp surfaces or in damp clothing • Properly ground, install and operate equipment • Not use defective equipment • Use well-insulated electrode holders and cables • Insulate themselves from both the work and the metal electrode and holder

6. Operating Procedures • Electrical Equipment • Employees should: • Not wrap a welding cable around your body • Wear dry gloves and rubber-soled shoes • Not use damaged or bare cables and connectors • Not touch a victim who has had an electrical shock

7. Operating Procedures • Personal Protective Equipment • Employees should: • Be provided and use proper PPE • Have first aid equipment available at all times • Be provided air line respirators for confined space jobs or otherwise hazardous atmospheric conditions

8. Operating Procedures • Compressed Gas Cylinders • Employees should: • Keep valve protection cap in place at all times when cylinder is not in use • Use care in handling and storage of cylinders • Secure cylinders on a cradle, slingboard or pallet when hoisting • Secure cylinders in an upright position at all times • Use carriers or carts when in use • Isolate cylinders from welding or cutting

9. Operating Procedures • Compressed Gas Cylinders • Employees should: • Maintain a distance of at least 20 feet or provide a non-combustible barrier at least five feet high • Take care of designated, well-ventilated storage areas • Check that valves are closed before removing regulators • Keep apparatus free of oily or greasy substances

10. Operating Procedures • Compressed Gas Cylinders • Employees should: • Keep empty compressed gas cylinders appropriately marked and their valves closed • Store full and empty cylinders apart • Group cylinders by type of gas • Use old stock before newer stock

11. Operating Procedures • Compressed Gas Cylinders • Employees should not: • Use valve protection caps for lifting cylinders • Use damaged or defective cylinders • Use a wrench or hammer to open cylinder valves • Attempt to repair a cylinder valve • Not mix gases • Use a magnet or choker sling when hoisting • Use a bar to pry cylinders from frozen ground • Take oxygen, acetylene, or other fuel gas or manifolds with these gases into confined spaces • Store cylinders near elevators, stairs or gangways

12. Operating Procedures • Fire Prevention • If the object to be welded or cut cannot readily be moved, all movable fire hazards in the vicinity shall be removed • If objects cannot be moved, guards shall be put up to protect from fires • If the object cannot be moved and guards may not be put up, then welding may not take place

13. Operating Procedures • Fire Prevention • If there are openings or cracks in the floor that cannot be closed, care should be taken to ensure that sparks do not fall through these cracks • Fire extinguishing equipment should be provided at all times • The welding area should be inspected before operations commence

14. Operating Procedures • Fire Prevention • All outside contractors should be advised of our policies on welding operations • Welding should not be permitted: • In areas not authorized • In sprinklered buildings while protection is impaired • In the presence of explosive atmospheres

15. Operating Procedures • Fire Watchers • Fire watchers shall be required • In places where other than a minor fire may develop • They shall have fire extinguishing equipment readily available for use • They shall be trained on specific fire hazards • They must remain at the site for at least 30 minutes after completion of welding operations to detect and extinguish possibly smoldering fires

16. Operating Procedures • Firefighting Equipment and Use

17. Operating Procedures • Gas Welding and Cutting • Before a regulator to a cylinder valve is connected, employees should “crack” the valve to clear it of dust and dirt • Employees should open cylinder valves slowly to prevent damage to the regulator • Employees should not place anything on top of a fuel gas cylinder, when in use, which may damage the safety device or interfere with quick closing

18. Operating Procedures • Gas Welding and Cutting • Employees should not use fuel gas directly from cylinders through torches or other devices equipped with shutoff valves without reducing the pressure through a suitable regulator • The cylinder valve should always be closed before the regulator is removed • If the gas leaks around the valve stem, employees should close the valve and tighten the gland nut

19. Operating Procedures • Gas Welding and Cutting • If the gas leaks from the cylinder valve and the gas cannot be shut off, the cylinder should be properly tagged and removed from the work area • Oxygen should not be used for personal cooling, cleaning off surfaces, ventilation or blowing dust from clothing

20. Operating Procedures • Gas Welding and Cutting • Acetylene or oxygen pipelines should not be welded or cut until the line has been purged • Only pressure-reducing regulators for gas ad pressures for which they are intended • Regulator parts or regulators should not be repaired unless by a skilled mechanic

21. Operating Procedures • Safe Practices in Using Torches • Clogged tips should be cleaned only with suitable cleaning wires, drills or other devices designed for such purpose • Inspections should be conducted at the beginning and end of each shift for leaking shutoff valves, hose couplings, and tip connections • Only friction lighters or other approved devices may be lit

22. Operating Procedures • Safe Practices in Using Regulators and Gauges • Oxygen and fuel gas pressure regulators should be in proper working order • Oxygen cylinders and fittings should be kept away from oil or grease

23. Operating Procedures • Arc Welding and Cutting • Special protection against electric shock shall be in place when working in wet or humid conditions • Hot electrodes should not be dipped in water • Holders, cables and other apparatus should be used which is specifically designed for the purpose of welding

24. Operating Procedures • Arc Welding and Cutting • Electrodes should be removed from holders when unattended • Non-combustible screens should be used to protect other employees • All connections should be checked before operation to ensure proper set up • Grounding of the welding machine frame shall be checked

25. Operating Procedures • Arc Welding and Cutting • There shall be no leaks of cooling water, shielding gas or engine fuel • Wet machines must be thoroughly dried before use • Cables with damaged insulation or exposed bare conductors shall be replaced

26. Operating Procedures • Ventilation • Oxygen shall never be used for ventilation • General ventilation should not be relied on as the only means of protection when air contaminants are toxic • Where ventilation is not sufficient to provide clean, breathable air, respirators will be used

27. Operating Procedures • Confined Spaces • Atmospheric testing should be performed for oxygen deficiency, toxic and flammable or combustible gases before entry • Gas cylinders and welding machines shall be left on the outside of the confined spaces • Means shall be provided for the swift removal of employees from confined spaces if necessary

28. Operating Procedures • Confined Spaces • All electrodes shall be removed from the holders carefully so that accidental connection may not be achieved when arc welding activities are suspended for a period of time • The torch valves shall be closest and the fuel-gas and oxygen supply to the torch will be positively shut off to eliminate gas escaping • Warning signs should be erected on hot metal

29. Operating Procedures • Flammable, Toxic or Hazardous Materials • Testing for flammability of unknown coatings should be done • When coating is found to be flammable, it will be stripped from the area to prevent fire

30. Operating Procedures • Slip, Trip and Fall Protection • Any employee working on platforms, scaffolds or runways should be protected against falling • Welding cable and other equipment should be placed out of passageways • Welding and cutting areas should be clear to prevent slips, trips and falls

31. Operating Procedures • Housekeeping Measures

32. Operating Procedures • Inspections • Only trained and/or authorized personnel should be using equipment • Operators should follow operating instructions • Pressure-reducing regulator should be used only for gas and pressure for which they were intended • Grounding should be checked periodically

33. Operating Procedures • Inspection • Only approved apparatus and equipment should be used • Adequate ventilation should be established • Environmental monitoring tests should be completed when working in confined spaces • PPE provided and used • Open circuit voltage of arc welding and cutting machines should be as low as possible

34. Operating Procedures • Inspection • Red = acetylene • Green = oxygen • Black = inert gas, air hose • Empty compressed gas cylinders should be marked and their valves closed • Cylinders should be checked for obvious signs of defects, rusting or leakage

35. Operating Procedures • Liquefied gas should be stored and shipped valve-end up with valve covers in place • The valve should be closed and gas released from the regulator before a regulator is removed • Oily and greasy substances should be kept clear of cylinders

36. Operating Procedures • Inspection • Cylinders should be kept away from elevators, stairs or gangways • Cylinders should not be dropped or struck • If necessary, welding areas must be marked to indicate hazardous air emissions • Exhaust systems should be in place to keep fumes at a minimum

37. Operating Procedures • Inspection • Aisles should be marked, widths maintained, in good condition, properly illuminated and free of obstructions • Fire alarm systems should be in place and testing frequently to maintain good working order • Portable fire extinguishing equipment should be mounted and readily available at all times

38. Operating Procedures • Inspection • Air and/or oxygen should never be mixed with flammable gases, except at a burner or standard torch • Signs should be placed so that everyone is aware to not activate any incendiary devices in the area • A five foot barrier should separate the oxygen and acetylene

39. Operating Procedures • Inspection • Cylinders should be kept away from heat sources • Combustible scrap and waste should be removed from the welding area • PPE should be in good, working order otherwise the purpose is defeated

40. Operating Procedures • Testing Methods

41. Operating Procedures • Alarm Systems

42. Operating Procedures • Maintenance • All deficiencies with equipment should be repaired before continued use • Modifications or additions to equipment should not be made without the manufacturer’s written approval • The safety factor of the equipment should not ever be reduced • Periodic maintenance should be done by factory-trained experts or dealers

43. Operating Procedures • Signs and Labels • Hot metal must be labeled after welding • Warnings should be placed on or near cylinders which are leaking • Station outlets shall be marked to indicate the name of the gas • Acetylene generators shall be plainly marked with the maximum rate or acetylene in cubic feet per hour

44. Operating Procedures • Signs and Labels • Operating instructions shall be posted conspicuously near the generator • Lenses shall be marked so that the source and shade may quickly be determined • Precautionary labels should be hung • Compressed gas cylinders should be legibly marked • Gauges on oxygen regulators shall be marked “Use No Oil” • The total hourly output of a generator shall not exceed the rate for which it is approved

45. Company Specific Hazards