Safe Operating Procedure

GAS CUTTING & HEATING OPERATIONS

Personal Protective Equipment (PPE) Required
Safety helmet Safety Goggle Hand Gloves (Leather) Safety Shoe. Respiratory Protection Wear Aprons Risk Analysis :

Toppling of cylinders ,Fire & Explosion , Fumes, Burn injury.

Safety Instruction : 1.Shift cylinders by means of trolleys only/Cylinder carts equipped with a cylinder restraint, such as a chain or strap, should be used for all transporting of compressed gas cylinders. 2.Ensure that safety cap is in position. 3. Flash Back Arrestor must be used to prevent back flow. 4.Before connecting a regulator to a cylinder valve, the valve shall be opened slightly and closed immediately(Cracking)- to clear the valve of dust . The valve shall be opened while standing to one side of the outlet, never in front of it 5. A fuel-gas cylinder valve shall never be cracked near other welding work or near sparks, flame or other possible sources of ignition 6. Before a regulator is removed from a cylinder valve, the cylinder valve shall always be closed and the gas released from the regulator. 7. check all gas line connections for leakage by using soapy water 8. Hammer or wrench shall not be used to open cylinder valves 9. Never Interchange the hoses: Red for fuel-gas hose/ green or black for oxygen hose. oxygen inlet of the blowpipe shall be identified with the letter 0 or using a blue coloured identification Fuel gas inlet shall be marked with the following letters to indicate the particular gas for which the blowpipe has been designed: A: Acetylene, C: Coal Gas, H: Hydrogen, M: Methane , L: LPG blowpipe is designed for use with more than one fuel gas inlet shall be marked with a red colour 10.Hose shall not be crimped or kinked. Hose shall not be bent or otherwise deformed to control the pressure. 11.After connecting cutting apparatus each gas shall be allowed to flow through its respective hose separately for a few seconds so as to purge the hose. 12. Prior to start Ensure the Flammable materials are cleared & proper housekeeping operation carried out and after completion of the job ensure molten metals are not left in place. 13. Cover floor and wall openings of the work site to prevent hot sparks from entering walls or falling beneath floors or to a lower level. 14.Protect the heating burners from heat / provide heat retardant protection on the hose joint( minimum 500mm away from last burner). 15. Position the heating burner in such a way that it will not make the hose joint heated up while heating the job. 16.Open the Fuel gas slowly and ignite the gas with a spark lighter then open oxygen valve and adjust the flame. 17. On completion of work close Oxygen valve first then close the Fuel valve . 18. Display Empty or MT on used cylinders. 19. Display HOT surface dont Touch on the Job 20. Use heat retardant clothes(sleeves, aprons, Leather hand Gloves, safety shoes, safety helmet & goggles to protect from burn injury) to prevent Burn injury. 21. Ventilation of the work site, either through local or general exhaust ventilation, should be adequate for the work performed. 22.Fume extractor shall be used to avoid the inhalation of fumes . 23. Wear Fume mask to avoid the inhalation of fumes and to protect from dust. 24. Fire extinguisher shall be placed near HOT work area. 25. Do Not leave the work place while heating operation is in progress.

Training Provided : SOP training given by Lead Engineer.

Persons Authorized to Operate This Machine :

SOP NUMBER AREA Prepared by Lead Engineer : SOP- Fab/HC/1 : Fabrication Shop

Trained Gas cutters /Welders for Pre Heating activity.

First Issue Date Reviewed by EHS Officer : 04.05.2012 Revision No.: 0 Approved by Fabrication shop Manager