White Nile (5B) Petroleum Operating Company Ltd

Gas Cutting & Welding

Procedure

WNPOC/LII/HSE/017
 Main Contents

Page No

Document – New /Amendment Request (DNAR) i

Document Change History (DCH) ii
Distribution iii

1.0 Purpose 1
2.0 Scope 1
3.0 References 1
4.0 Abbreviations 1
5.0 Responsibilities 2
6.0 General HSE Considerations 3
6.1 Preparatory Work 3
6.2 Work sites 3
6.3 Understanding Hazards and Consequences 3
6.4 Fire Watchers 4
6.5 Ventilation 4
6.6 Waste Disposal 5
7.0 Specialised Personal Protective Equipment 6
7.1 Heads and Eyes 6
7.2 Hands 6
7.3 Body 6
7.4 Nose 6
7.5 Feet 7
8.0 Specialised HSE Considerations 8
8.1 Cutting and Welding using Gas 8
8.1.1 Gas Cylinders 8
8.1.2 Cylinder Valves and Regulators 9
8.1.3 Hoses and Connectors 9
8.1.4 Gas Torches and Blowpipes 10
8.2 Arc Welding 12
8.2.1 Selection of Arc Welding set 12
8.2.2 Installation of the Arc Welding set 12
8.2.3 Safe Operation of the Welding set 13
8.2.4 Safety Precautions for Engine Powered Welding sets 13
 White Nile (5B) Petroleum PAGE NUMBER:
Operating Company Ltd. i
Document – New / DOCUMENT NUMBER:
Amendment Request (DNAR) WNPOC/LII/HSE/017

DNAR No. WNPOC/DNAR/HSE/LII/0017 DNAR Date 31.03.06

Status of Document:

New Revised Cancellation

Reasons of Changes:

New procedure establishment

Details of Changes

PART WAS

Page No Para/Clause Description

None

CHANGE TO

Page No Para/Clause Description

New document

Initial Date
QA Check

Prepared by Reviewed by Approved by

Section Head, HSE HSE Manager V.PRESIDENT

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Document – Change history DOCUMENT NUMBER:
(DCH) WNPOC/LII/HSE/017

Details refer to Document New /

Effective /
Revision Status of Change Amendment Request (DNAR)
Revision
No (New / Revised / Cancellation) Prepared Reviewed Approved by
Date
by by
0 New procedure establishment 31/03/06 Section HSE V. President
Head, Mgr.
HSE

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DOCUMENT NUMBER:
Distribution
WNPOC/LII/HSE/017

Copy No Position Title

1 Chairman, PETRONAS Sudan Operation

2 President, WNPOC
3 Vice President, WNPOC

4 GM, Exploration & Development

5 GM, Finance & Planning
6 GM, Human Resource & Admin
7 GM, Production
8 Sr. Manager, Exploration
9 Sr. Manager, Operations
10 Sr. Manager, Surface Development
11 Manager, HSE

12 Manager, Corporate Affair & Community Development

13 Manager, Security
14 Superintendent, Base Camp
15 Company Man, Drilling Rig
16 Company Man, Service Rig

17 HSE Supervisor, Block 5A

18 HSE Supervisor, Block 5B

19 HSE Supervisor, Block 8

20 HSE Department

21 Exploration Department
22 Drilling Department

23 Finance & Account Department

24 Human Resource & Admin Department

25 Contract, Procurement & Logistic Department

26

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DOCUMENT NUMBER:
Preliminary
WNPOC/LII/HSE/017

1.0 Purpose

This procedure shall highlight the HSE precautions that need to be adhered to whenever
gas cutting and welding works are carried out at WNPOC worksites and facilities during
construction, operation and maintenance activities.

2.0 Scope

This procedure covers the HSE precautions that need to be followed when:
• Cutting, welding and gouging of material using oxygen and fuel gas gaseous mixture.
• Electric arc welding including gas shielded metal-arc welding

3.0 References

• U.S. OSHA Standards 29 CFR 1910 & 1915

• U.K. HSE executive leaflet INDG 297 – Safety in Gas Cutting, Welding & Similar
Processes
• ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes
• RMA IP-7, Specifications For Rubber Welding Hose, Rubber Manufacturers Association
• CGA E-1, Standard Connections for Regulator Outlets, Torches, and Fitted Hose for
Welding and Cutting Equipment, Compressed Gas Association
• PETRONAS PTS 60.041
• Permit To Work procedure –WNPOC/HSE/LII/019

4.0 Abbreviations

PPE Personal Protective Equipment

HSE Health, Safety & Environment
WNPOC White Nile (5B) Petroleum Operating Co. Ltd
MIG Metal- Inert Gas
TIG Tungsten – Inert Gas
PTW Permit To Work

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Responsibilities
WNPOC/LII/HSE/017

5.0 Responsibilities

Position Responsibilities
• All welding and cutting equipments are kept in good working
condition
• All faulty or worn out equipments are replaced or repaired.
• All equipments are operated in accordance with the
manufacturers’ instructions.
• Work site supervisors and welders are competent to use the
equipment.
• Work site supervisors and welders are trained in emergency
Contract Holder
procedures.
• Welders understand hazards associated with welding and
cutting.
• Special areas are designated for welding and cutting where
possible.
• Safe work instructions are established
• PTW has been applied for and approved

• Ensuring welding and cutting activities are carried out in

accordance with approved procedures.
• Ensuring that welding and cutting equipments are operated
safely.
• Identifying the hazards present at the work site.
• Ensuring adequate controls and recovery measures are in
Worksite place to manage the hazards.
Supervisor • Obtaining required work permits before welding and cutting
commence and ensuring that PTW requirements are met
during the job.
• Ensuring that appropriate PPE are selected and used.
• Ensuring that firewatchers, fire protection and fire
extinguishers are available at the work site.

• Complying with all permit to work requirements

• Understanding the hazards and controls for welding and
cutting.
Welders • Handling their equipment safely.
• Preventing the activities from being a hazard to other people

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General HSE DOCUMENT NUMBER:
Considerations WNPOC/LII/HSE/013

6.0 General HSE Considerations

6.1 Preparatory Work

All gas cutting and welding work are categorised as “Hot Work”. A PTW for “Hot
Work shall be applied for and approved by the Person In Charge at the work site
prior to the commencement of work. The PTW requirements for Hot Work are
referred to in the WNPOC PTW procedure – WNPOC/HSE/LII/II/019.
For welding or cutting inside new vessels, old vessels and equipment, additional
Confined Space Entry PTW shall be obtained and shall be used together with the Hot
Work PTW.
All personnel involved in Hot Work shall undergo a briefing on Gas Cutting &
Welding Safety before they commence their work. Welders and burners shall be
skilled tradesmen. Apprentices and helpers shall work under the supervision of a
qualified person.

6.2 Work sites

• Welding and cutting equipment shall be placed so that it does not create a
hazard in passageways, on ladders or on stairways.
• Warning signs for eye protection shall be placed at designated welding and
cutting areas. Protection from heat, welding arcs and welding spatter shall be
provided around designated welding and cutting areas. This is typically in the
form of fire resistant screens, which provide protection, while allowing air
circulation.
• Walls adjacent to designated areas shall be painted to reduce the reflection of
ultraviolet light.
• Welding and cutting shall be carried out in designated areas designed to
minimise the risk of fires.
• Where the work cannot be moved, work areas shall be made safe by moving
combustible materials to a safe location.
• Welding and cutting shall not be carried out unless the surrounding atmosphere
is free from flammable gas.
• Fire resistant sheeting or damp sand shall be used to cover combustible floors.
Additional protection shall be provided to prevent electric shocks if floors are
wet. Openings in floors and walls shall be covered to prevent the possibility of
sparks igniting fires in adjacent areas.
• Additional precautions shall be taken when working in areas classified as
Confined Spaces – ref WNPOC/HSE/LII/011.

6.3 Understanding the Hazards and Consequences

Various hazards are associated with welding and cutting, but as in other operations
they can be controlled by appropriate preventive measures. Unless these measures
are taken, the hazardous situations can easily give rise to personal injury and/or
material damage. All personnel involved in such work, shall therefore, be aware of
these risks whilst ding their work.
Some typical hazards are:
• The brilliant light of an arc
• The heat of an arc, molten metal, sparks, hot objects, etc.
• Toxic fumes released during the welding/cutting process
• Fuel gases that are stored in gas cylinders
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• High amperage electrical energy that is stored in the cables and welding
generators/rectifiers

The consequences that can result from the release of these hazards are;
• Fire resulting in burns, equipment damage
• Explosions resulting in damaged equipment and fatalities
• Exposure to toxic fumes resulting in breathing difficulties, long term lung
damage and possible fatalities
• Heat burns
• Eye damage due to exposure of radiating light of welding arc leading to
headaches and long term blindness
• Electrical shocks leading to partial/permanent disabilities or fatalities

6.4 Fire Watchers

• A firewatcher is required for all welding and cutting jobs carried out at worksite.
• Firewatchers shall be competent in the use of fire extinguishers and emergency
response and shall not be assigned to other duties while they are on fire watch
duty.
• The firewatcher shall remain in the immediate area at all times work is in
progress.
• The firewatcher shall have two dry powder or carbon dioxide fire extinguishers
available at the worksite.
• The firewatcher shall:

o Be at the work site throughout the welding and cutting.

o Ensure that sparks do not fall into unprotected areas such as drains
containing hydrocarbons or flammable material.
o Ensure a source of running water is available for immediate use throughout
the job.
o Ensure nearby materials do not catch fire.
o Ensure that drainage from the area is not restricted and there is no
possibility of hydrocarbon accumulation.
o Warn the welder of any hazard developing in the work area.
o Isolate welding equipment in the event of an emergency.
o Initiate emergency response in the event of emergencies.
o Continue to monitor the work area for 30 minutes after completion of work to
ensure that fires do not start.

6.5 Ventilation

• Adequate ventilation must be provided for all welding and cutting activities to
limit exposure to the hazardous dust and vapours produced.
• Natural ventilation is acceptable for welding, cutting and related processes
provided precautions are taken to keep the operator away from the welding
fumes.
• Where the natural ventilation is insufficient mechanical ventilation comprising
local exhaust or forced ventilation shall be provided

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6.6 Waste Disposal

On completion of gas cutting or welding work, the waste generated shall be

disposed off as per the site Hazardous Waste Management procedure requirements
ref: WNPOC/HSE/LII/007.
Waste such as spent electrodes, welding slag, dust and contaminated welding gloves
shall be treated as hazardous waste.
Other waste generated can be treated as domestic waste and managed as per the
Site Domestic Waste and Sewage Management procedure ref: WNPOC/HSE/LII/008.

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Specialised PPE
WNPOC/LII/HSE/013

7.0 Specialised Personal Protective equipment

7.1 Heads and eyes

• Safety Helmets and shields that protect the operator’s face and head from heat,
light and weld spatter shall be used. It is preferred that the welding shields fixed
to the safety helmets are used for welding work
• The shields that are used shall:
Be thermally insulating, electrically insulating and non-combustible
Be able to absorb visible and non-visible light.
Be fitted with suitable filter lenses and cover plates to protect the filter
lens
Be fitted with a window that allows easy replacement of the plates
Have outer cover plates that are impact resistant and made of clear glass
or self-extinguishing plastic
• Materials in contact with the body must be non-irritating and be capable of being
disinfected.
• During arc welding or cutting, goggles or safety spectacles with side-shields
must be worn under the helmet or hand shield
• Goggles lenses may be clear or coloured, depending on the amount of exposure
to adjacent welding or cutting radiation. Ventilation slots on cup type goggles
must have baffles to prevent light from entering.
• Caps shall be worn under helmets to prevent head burns.

7.2 Hands

• The welders and helpers shall wear flame retardant and heat resistant welding
gloves.

7.3 Body

• Suitable protective clothing shall be worn during all welding and cutting activities
to provide protection from sparks, weld spatter and radiation
• The clothing shall be of fire resistant material
• Aprons shall be used to protect the front of the body when there is a potential of
extensive weld spatter generated during welding
• Additional leg protection shall be used when there is high potential for the legs to
be affected by weld spatter and heat
• For overhead welding work capes with sleeves or shoulder covers shall be used

7.4 Nose

• Where the ventilation is insufficient to prevent the welders and helpers breathing
toxic fumes generated, approved respirators as specified in the PTW shall be
used.
• When welding or cutting metals with hazardous coatings such as galvanized
metal the operator should use a supplied-air type respirator or a respirator
specially designed to filter the specific metal fume.
• Respirators shall be used when working with welding rods coated with flux.
• Respirators shall also be used when welding materials containing fluorine
compounds, zinc, lead, beryllium, cadmium, and mercury.

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Specialised PPE
WNPOC/LII/HSE/013

• Respirators shall also be used when cleaning and degreasing metals to be

welded with hazardous compounds. Refer to Chemical safety Data sheets when
these compounds are used with regards to the precautions to be taken

7.5 Feet

• All welders and helpers shall wear high cut safety boots that protect the ankles
and shins from welding splatter
.

PPE

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– Gas Cutting & Welding WNPOC/LII/HSE/013

8.0 Special HSE Considerations

8.1 Cutting & Welding using Gas

8.1.1 Gas Cylinders

Gas used for cutting and gas welding comprises a mixture of Oxygen and
Acetylene or Propane. The gases are contained in cylinders and special
precautions have to be taken to ensure that the gases do not leak and lead
to hazardous conditions that result in catastrophic consequences.
The following precautions shall be adhered to when dealing with gas
cylinders:
• Cylinders should be stored in areas specially defined for the purpose,
outdoors, away from all sources of heat and away from elevators,
gangways and other traffic hazards. Oily rags, waste and other refuse
should not be allowed to accumulate on or near stored cylinders.
Cylinders should be protected against extremes of weather and direct
radiation from the sun or hot equipment.
• Fuel gas cylinders should be placed with valve end up whenever they are
in use.
• A cradle, boat or similar platform closed on all sides, should be used
when cylinders are transported by crane or derrick. Slings or electric
magnets should never be used for this purpose.
• When cylinders are moved by hand, they may be tilted and rolled on their
bottom edges. Dragging and sliding should be avoided. When cylinders
are transported by vehicle they should be secured in position. Cylinders
should not be dropped nor should they be permitted to strike violently
against anything.
• Valve-protection caps should not be used for lifting cylinders from one
vertical position to another. Bars should not be used under valves or
valve protection caps to prise cylinders loose when they have become
frozen to the ground or otherwise fixed. The use of warm water is
recommended for this purpose.
• Cylinders shall be secured with a suitable steadying device to prevent
their being knocked over.
• Cylinders in use shall be kept far enough away from the welding or
cutting operation to prevent their coming into contact with sparks, hot
slag, hot metal or flame.
• Cylinders shall not be placed where they might become part of an electric
circuit. Contact with radiators, piping systems, layout tables rails or
trolley wires shall be avoided. Never strike an arc against a cylinder.
• Cylinders should not be placed under structures where valves could be
damaged by falling objects.
• Oxygen and fuel cylinders shall be colour coded to prevent incorrect
identification.
• Empty cylinders should be marked and segregated from full cylinders for
return to the supplier.
• Valves on empty cylinders should be closed and fitted with valve
protection caps.
• Cylinder valves should be closed, and the valve protection cap should be
in place, hand- tight, when cylinders are not in use.

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• If a valve leak develops, the cylinder should be removed from service,

suitably tagged, placed outdoors, with an appropriate warning sign, away
from any source of ignition, and the supplier notified.
• Cylinders should only be re-filled by authorised persons or suppliers

8.1.2 Cylinder Valves and Regulators

• Before a gas cylinder is put into service, the valve shall be opened slightly
then closed immediately. This action is known as "cracking" the valve,
and is intended to clear the valve of dust or dirt that might otherwise
enter the regulator. Valves on gas cylinders shall not be cracked near
welding work, sparks, flames or other sources of ignition. The operator
shall stand on the far side of the cylinder from the outlet when cracking
the valve.
• After the cylinder valve has been "cracked" the regulator shall be
connected to the cylinder and tightened with the correct size open-end
spanner. Adaptors are required to attach some acetylene regulators to
the valves. Soapy water shall be used to check for leaks at the
connections between the regulators, adaptors, and cylinder valves. Care
should be taken to avoid getting oil or grease on the fittings when
connecting an oxygen regulator.
• All gas cylinder valves shall be opened gradually to prevent a sudden
surge of high pressure until the required pressure has been attained.
• Only gas supplier recommended pressure-reducing regulators shall be
used on the gas cylinders. Regulators shall be returned to the supplier for
repair, calibration or adjustment. To ensure their accuracy, gauges
attached to the regulators should be tested periodically. Oil shall never be
used to test the accuracy of gauges used oil oxygen cylinders. Faulty
seats in the unions on regulators may result in gas leaks. Damaged
unions shall be removed and replaced to prevent any gas leaks.
• If the low-pressure gauge on the regulator shows a continuous and
steady increase in pressure when the torch valves are closed, the cylinder
valve shall be closed immediately and the regulator repaired.

8.1.3 Hoses and Connectors

• Only welding hoses that meet Rubber Manufacturers Association and

Compressed Gas Association standards in the size and grade suitable for
both the conditions and gases shall used. Grades R & RM are designated
for acetylene use only. Grade T may be used with all fuel gases.
• Hoses are manufactured in distinctive colours for ready identification. Red
is the generally recognized colour for fuel-gas hoses, and green for
oxygen hoses. Hose connections on the regulator shall be similarly
marked for identification.
• Hoses shall be protected from kinking or tangling and from being stepped
on, run over by trucks, or otherwise damaged by taping the hoses
together and providing protective covering if they have be laid across
pathways.
• Hoses shall be protected from flying sparks, hot slag, and falling objects.
• Contact of the hoses with oil or grease shall be avoided to reduce
deterioration of the rubber.

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• Spare hoses shall be stored in a cool place, and away from direct sunlight
to reduce the deterioration of the rubber through ageing.
• Before a new hose is put into service, the fine talc dust on the inside
should be blown out to prevent any clogging of the torch valves.
• Damaged or worn out shall not be used. They shall be replaced wholly or
the damaged portion cut and removed.
• Hoses with more than one splice per 50-foot (15 m) section shall not be
used. For joining cut hoses select fittings with adequate inside diameter
to avoid flow restrictions.
• A "flashback arrester" shall be installed between the cylinders and hoses
immediately after the pressure regulators to prevent any reverse flow of
oxygen into the fuel gas hose (or fuel into the oxygen hose), producing
an explosive mixture in the hose.
• Hoses shall be connected by means of approved fittings and securely
fastened with clamps in such a manner as to withstand a pressure of
twice the maximum delivery pressure downstream of the regulator
without leakage.
• Hose connections shall be as per Compressed Gas Association standard
CGA E-1 - Standard Connections for Regulator Outlets, Torches and Fitted
Hose for Welding and Cutting Equipment.
• All connections shall be leak tested using soapy water or other safe
means.

8.1.4 Gas Torches and Blowpipes

• The fuel gas valves should always be closed before the oxygen valve on
the torch is to be opened for adjustment of pressure.
• When a cutting torch is used, both the oxygen valve and the cutting valve
on the torch must be open while oxygen pressure in being regulated.
There upon the oxygen valve on the torch should be closed. Oxygen
pressures should not exceed those recommended by the manufacturer of
the equipment.
• Only a friction lighter, stationary pilot flame, or other similar source of
ignition should be used to light the torch. No attempt should be made to
light or relight a torch from hot metal. Using matches to light the torch
brings fingers too close to the tip.
• The flame is extinguished by closing the oxygen valve and then the fuel-
gas valve.
• Momentary retrogression or burning back of the flame into the torch tip
may result in backfire or pre-ignition which causes the flame to go out
with a loud snap or pop. No adjustment of the torch valves is required.
This backfiring is usually the result of improper handling of the torch such
as touching the tip against the material being welded, overheating the
tip, operating the torch at other than recommended gas pressures, or a
loose tip.
• Correct delivery pressures of oxygen and the fuel gas shall be maintained
to prevent flashbacks at the torch ends.
• A torch shall not be relit after a flashback until it has been thoroughly
examined for damage.

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– Arc Welding WNPOC/LII/HSE/013

8.2 Arc Welding

The potential hazards that can be present during arc welding activities include toxic
fumes, dusts, burns, fires, explosions, electric shock, radiation, noise, and heat
stress. Any of these hazards can result in injury or death. These risks shall be
eliminated or minimised by following the HSE precautions listed.

8.2.1 Selection of the Arc Welding set

• Arc welders are typically ACDC, 240/415-volt transformer types or DC

rectifiers using electricity as the energy source. Portable welders are of
the diesel/gasoline engine powered type.
• Arc Welding sets shall comply with National Electric Manufacturers
Association (NEMA) standards or the safety standards for arc welders as
determined by the Underwriters Laboratories (UL).

8.2.2 Installation of the Arc Welding set

• Before the installation of electric arc welding sets, the electrical system
shall be checked to determine if it is adequate to handle the increased
load required by the welding set. The Competent Electrical Person shall
be consulted for this.
• The frame or case of the welding set shall be properly grounded.
• A safety-type disconnecting switch or controller shall be located near the
machine (See Figure 1).
• The welding set or sets used shall be protected by a properly sized fuse
or circuit breaker on an independent circuit.

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8.2.3 Safe operation of the Welding set

• No welding, cutting, or hot work shall be attempted on used drums,

barrels, tanks, or other containers since they may contain remnants of
toxic, flammable or explosive materials.
• If possible, work to be welded shall be placed on a firebrick surface at a
comfortable height.
• Welding shall never be done directly on a concrete floor. Heat from the
arc can cause steam to build-up in the floor that could cause an
explosion.
• The welding cables should be positioned so that sparks and molten metal
will not fall on them. They should also be kept free of grease and oil and
located where they will not be driven over.
• Welding cables shall be inspected before use to ensure the insulation is
good. Cables with damaged insulation shall not be used.
• For welding to be done on steel or other conductive material an insulating
mat shall be used under the operator. If the welding area is wet or damp
or the operator is actively perspiring then he/she shall wear rubber gloves
under the welding gloves.
• It is easier and safer to establish an arc on a clean surface than a dirty or
rusty one. Therefore, metal shall always be thoroughly cleaned by wire
brushing or other method prior to welding.
• When chipping slag or wire brushing the finished bead the operator shall
always be sure to protect his eyes and body from flying slag and chips.
• Unused electrodes and electrode stubs shall not be left on the floor as
they create a slipping hazard.
• Hot metal shall be handled with metal tongs or pliers. When quenching
hot metal in water it shall be done carefully to prevent painful burns from
the escaping steam. Any metal left to cool should be carefully marked
"HOT" with soapstone.
• When welding is finished for the day or suspended for any length of time
electrodes shall be removed from the holder. The holder shall be placed
where no accidental contact could occur, and the welding set shall be
disconnected from the power source.

8.2.4 Safety Precautions for Engine Powered Welding sets

• The welding set shall always be operated in an open well-ventilated area

or the engine exhaust shall be vented directly outdoors.
• The engine shall not be filled with fuel while running or in the presence of
an open flame.
• Spilled fuel shall be wiped up immediately and the fumes shall be allowed
to disperse before starting the engine.
• The radiator pressure cap from liquid cooled engines shall not be removed
while they are hot to prevent scalding.
• The engine shall be stopped before performing any maintenance or
troubleshooting. The ignition system shall be disabled to prevent
accidental start of the engine.
• All guards and shields shall be kept in place.
• Hands, hair, and clothing shall be kept away from moving parts.

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