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DOCUMENT ID: |
6122 Hot
Work (i.e. Welding, Cutting, Brazing, and Grinding) Safety Program |
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NOTE: Jefferson Lab has determined that hot work (e.g. welding, brazing, or spark producing grinding or cutting) is considered to be an unmitigated Risk Code >2 and requires an approved work control document (Operational Safety Procedure (OSP), and/or Hot Work Permit) prior to the commencement of operations. |
1.0
Purpose
Hot work (e.g. welding, brazing, or spark producing grinding or cutting) is a common part of Jefferson Lab’s fabrication and construction activities. Because of the high temperatures involved and the potential for fire and serious personal injury, care is taken to ensure that work is performed safely. This hot work safety program has been developed to document Jefferson Lab’s minimum safety requirements for this type of work.
This program satisfies applicable federal, state, and local requirements as outlined in ES&H Manual Chapter 2410 Appendix T1 Hazard Issues List.
A copy of the “American National Standards Institute (ANSI) document Z49.1, Safety in Welding, Cutting, and Allied Processes” is available through the Environmental, Safety, Health, and Quality (ESH&Q) Department, contact the Technical Point-of-Contact for this document.
2.0
Scope
This chapter and its associated appendices apply to all hot work performed at Jefferson Lab. The two areas where hot work is permitted onsite are outlined below.
2.1
Permanent (i.e.
a weld shop) – established by an Operational Safety Procedure (OSP). See ES&H Manual Chapter 3310 Operational Safety Procedure (OSP) Program
for more information.
The following special welding operations require the following considerations over and above that of the permanent welding area: · Electron Beam Welding (used in the Test Lab to fabricate super conducting RF cavities) – Requires a separate relevant OSP. · Laser Beam Welding – Requires a separate relevant Laser Operational Safety Procedure (LOSP). · Thoriated Tungsten Electrodes – When sharpening or grinding Thoriated Tungsten Electrodes use appropriate enclosed grinder to capture grinding dust. Contact the Radiation Control Department when disposal of the dust is required. |
2.2
Temporary – requires
a Hot Work Permit outlining the specific safeguards to be used. See ES&H Manual Chapter
6900 Appendix T1 Fire Protection: Hot
Work Permit - Instructions for more information.
Table
1: Required Hot Work Safety Training by Job Classification
Training Course |
Qualified Hot Work Operator |
Qualified Welder |
Fire Watch |
Fire Safety Training SAF108 |
X |
X |
X |
Welder
Safety SAF150 |
|
X |
|
Operate
or Repair Pressure or Vacuum Systems SAF130A |
|
X |
|
Visual Acuity For Welders MED14 |
|
X* |
|
Shielded
Metal Arc Welding (SMAW) SAF150SM |
|
X** |
|
for Gas
Tungsten Arc Welding (GTAW) SAF150GT |
|
X** |
|
Oxy Fuel
Welding/Brazing (OXY/FUEL) SAF150OX |
|
X** |
|
Flux
Core Arc Welding (FCAW) SAF150FC |
|
X** |
|
Gas Metal Arc Welding (GMAW) SAF150GM |
|
X** |
|
Automatic Gas Tungsten Arc Welding
(GTAW-A) SAF150GTA |
|
X** |
|
* Per ES&H
Manual Chapter 6800 Appendix T1
Medical Monitoring ** As Appropriate. Contact the QA/CI Senior Technical Specialist for
Certification Qualification requirements |
3.0
Responsibilities
and Qualifications
NOTE: Management authority may be delegated to a task qualified Jefferson Lab employee at the discretion of the responsible manager.
3.1 Qualified Hot Work Operator:
·
Complete and
maintain appropriate training, certification, and medical monitoring including SAF 108 Fire Safety Training.
·
Have supervisor
approval prior to commencement of hot work.
·
Follow all
guidance in this chapter and any authorizing Work Control Document (including Hot Work Permit) as applicable.
·
Inspect PPE before and after use. Dispose
of damaged items appropriately.
·
Wear appropriate PPE while working.
·
Frequently change or alternate
gloves and other protective clothing to avoid perspiration accumulation.
· Prior to commencement of work, ensure equipment complies with inspection requirements. See ES&H Manual Chapter 6122 Appendix T3 Inspection of Welding and Cutting Equipment.
· Request an equipment/area hazard evaluation from Industrial Hygiene if you have concerns regarding area hazards or postings.
3.1.1
Qualified Welder also:
·
Certified in
accordance with ASME code and AWS code. Contact the QA/CI Senior Technical
Specialist (x5859) for certification qualification requirements.
3.2 Fire Watch:
·
Abide by the
responsibilities outlined within ES&H Manual Chapter
6900 Appendix T1 Fire Protection: Hot
Work Permit – Instructions.
·
Complete
and maintain SAF 108 Fire Safety Training.
3.3 Supervisor/Technical Representative (TR – formerly SOTR)/Sponsor
·
Ensure that the
Qualified Hot Work Operator assigned to hot work activities is
appropriately trained and qualified to perform the work. See the updated list
of certifications for welding operations.
·
Establish
appropriately configured hot work area(s). Include requirements outlined within
this chapter and appropriate work control documents (e.g.: OSP or Hot Work
Permit)
·
Ensure only
approved equipment and PPE is available and used in hot work areas.
·
Ensure warnings are posted in areas under your
authority in accordance with requirements.
·
Ensure cleaning and maintenance of ventilation systems is
scheduled in accordance with hazard evaluation requirements.
3.3.1
TRs Also:
·
Advised
subcontractors of Jefferson Lab’s requirements regarding hot work operations.
3.4
Equipment
Owner
· Ensure equipment is inspected biannually (at a minimum) and maintained in accordance with the Operator’s Manual and Jefferson Lab requirements.
· Perform area hazard evaluation.
3.6 QA/CI Senior Technical Specialist
· Inspect welding operations at Jefferson Lab.
·
Certify and document all
Jefferson Lab Qualified Welders in accordance with ASME code and AWS code.
·
Verify that biannual
welding equipment inspections are performed.
4.0
Expectations
4.1
Hot
Work Station Set-up
There are a number of inherent hazards associated with hot work operations. Appropriate work station set-up is one method to avoid hazards. ES&H Manual Chapter 6122 Appendix T1 Hot Work Station Set-Up and Safe Operating Procedures (includes Oxygen/Fuel Safety) outlines Jefferson Lab’s minimum requirements for station set-up and equipment maintenance.
4.2 Personal Protective Equipment
Jefferson Lab recognizes that hot work exposes workers to certain recognized hazard issues, some of which can be mitigated through the use of appropriate personal protective equipment (PPE). ES&H Manual Chapter 6122 Appendix T2 Hot Work Personal Protective Equipment (PPE) provides information on how to: determine the appropriate PPE, and obtain it.
4.3
Equipment Inspections
Biannual inspections of welding and cutting equipment are required to ensure it is kept in good operating condition. ES&H Manual Chapter 6122 Appendix T3 Inspection of Welding and Cutting Equipment outlines the responsibilities and process steps established by Jefferson Lab to ensure compliance with this requirement.
4.4
Posting Requirements
Jefferson Lab recognizes that hot work is inherently
dangerous. It is therefore required that designated areas and associated
equipment be labeled to provide warning of potential hazards. ES&H Manual Chapter 6122
Appendix T4 Hot Work Area Posting Requirements
defines Jefferson Lab’s labeling and posting requirements; and how to update,
repair, and maintain these labels.
4.5
Ventilation/Respiratory Requirements
Respiratory hazards are often associated with hot work operations (in particular welding). In order to control exposure to harmful gases/fumes, local or general exhaust ventilation is required during welding operations. ES&H Manual Chapter 6122 Appendix T5 Hot Work Ventilation/Respiratory Requirements provides Jefferson Lab’s minimal ventilation requirements.
4.6
Communicating Quality Standard Requirements
Quality standards for welding and
brazing work at Jefferson Lab are provided in the “Welding and Brazing Program Supplement.” This document provides the minimum
requirements for the following activities in relation to welds and brazes:
·
Design
·
Inspection
and examination
·
Procedure
specification and qualification
·
Material
control
·
Performance
qualification
5.0
Revision
History
Revision 1.2 – 04/01/21 – Periodic Review; Updated ‘ESH&Q’ to ‘ES&H’; updated contact information; corrected hyperlinks; other minor edits, changed annual to biannual per email from SME, No approval required.
Periodic
Review – 03/25/16 – No changes per
TPOC
Revision 1.1 – 05/20/14 – Added Required Safety Training Table.
Revision
1.0 – 04/11/11 – Updated to reflect current laboratory operations.
|
ISSUING
AUTHORITY |
TECHNICAL
POINT-OF-CONTACT |
APPROVAL
DATE |
REVIEW DATE |
REV. |
|
|
ES&H Division |
03/25/16 |
04/01/24 |
1.2 |
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