HSE-RA-066 Using of Cutting Torch - Rev 0

DOC No DS/CA006P02/00022
PAGE No 1 of 16
AL SHAFAR GENERAL CONTRACTING LLC. REV 0
DATE 05/01/2017
SAFETY, HEALTH AND ENVIRONMENTAL PROCEDURE
Project Name: Festival Living Stream-02 HSE-RA 066
Job Description: Using a Cutting Torch – Acetylene / Oxygen, LPG etc.
Index:
Form 1 Task Analysis Initiation
Form 2 Risk Assessment Process As per Risk Assessment Procedure.
Form 3 Written Safe Work Procedure Result
Compiled by the following team:
NAME DESIGNATION SIGNATURE
Project Manager
Construction Manager
Site Engineer
Safety Officer
Risk Assessment Review 1 Review 2 Review 3 Review 4
Review Date: Date : Date : Date:
Name and Signature

of person reviewing :
AUTHORISATION
Prepared by: Approved by
Signature Date Signature Date
HSE Manager Project Manager
HSE QUALITY SYSTEM DOCUMENTATION

PAGE No 2 of 16
DATE 05/01/2017
TASK ANALYSIS - FORM 1

Impact
SEQUENCE OF TASK STEPS POTENTIAL INJURIES OR HAZARDS RECOMMENDED CONTROLS
H, S, E
1. Pre-use inspection and use of all equipment. Failure of equipment will cause injuries to  Faulty equipment to be repaired/maintained or
persons and / or property damage. replaced.
 Guards to be on all Machinery and appropriate PPE to
be worn.
Fuel/oil leaks could cause environmental H, S, E  Engine ran machinery to have fire extinguishers
concerns. available locally.
 Drip trays/heavy gauge plastic to be used in case of
leaks and spill kit to be within the project for accidental
spills.
2. Wear appropriate Personal Protective Failure to use Personal Protective
Equipment. Equipment will cause injuries to
Gloves. employees.
Safety boots.  Enforce the use of Personal Protective Equipment AT
H,S
Overalls. ALL times
Hard hat.
Hearing protection.
Eye protection
3. Use competent employees only Failure will result in injuries to persons and  Enforce the use of competent persons only
H, S
/ or property damage
4.  Competent supervisor should be appointed for every
activity to monitor the workers.
 Work task instruction should be provided for every
H, S activity.
Competent supervision Failure will cause injuries to employees

and or property damage
5. Setting oxy / acc. Cutting. Incorrect set up and the use of inferior H, S, E  Apply safe working procedure to gas cutting equipment
PAGE No 3 of 16
DATE 05/01/2017
equipments and Compressed gas and follow the manufacturer’s recommendation.

explosions could cause fire resulting  Use the appropriate PPE to ensure safe working
injuries or death and property. procedure with compressed gas.
 Ensure the provision of fire fighting equipment as per
Fumes could cause damage to the the civil defence recommendation.
environment.  Use fire blanket and remove the combustible materials
in the area.
 Provide adequate mechanical fume extraction or force
ventilation wherever work is carried out.
6. Test for gas leaks. Gas leaks can cause fires, explosions and  Enforce tests for gas leaks using soap test method.
burns to employees H, S, E
Environmental damage.
7 Means of ventilation Failure to provide adequate ventilation  Ensure general dilution ventilation in which fresh air is
results in respiratory discomfort leads to introduced into the workplace by mechanical means
death of person and is mixed thoroughly with the contaminants in the air
before removing the contaminants out of the workplace.
 Local exhaust ventilation in which air contaminants are
captured and removed by forced air current through
hood and duct near the point of emission and
discharged to the atmosphere outside the workplace.
8 Setting up of the gas cutting equipments. Incorrect setting will cause fire and  Ensure correct setting of the pressure gauges.
explosions leads to injuries /death and  Ensure flash back arresters and non return valves are
property damage used.
 Always leave a spindle key chained to the cutting set for
turn off the gas in emergency
H,S  Ensure that only triple flint lighters are used to ignite
flame.
 Ensure the use of correct nozzles.
 Remove all combustible materials from the vicinity.
 Ensure the provision of fire fighting equipment as per
the civil defence recommendation.
PAGE No 4 of 16
DATE 05/01/2017

PAGE No 5 of 16
DATE 05/01/2017
TASK ANALYSIS - FORM 1 (continued)

SEQUENCE OF TASK STEPS POTENTIAL INJURIES OR HAZARDS RECOMMENDED CONTROLS
9. Gas cutting works in confined space Suffocation caused of improper ventilation  Provide proper ventilation and smoke extraction.
 Inspect the confine space by using of gas detector if the
presence of gas is high
Exposure of fumes and gases  Never start welding works if there is high percentage of
H,S,E
gasses in the air.
 Provide multiple access and egress to the confined
space.
 Ensure sufficient lightings.
10. Gas cutting works in elevated area Persons falling from heights resulting  Provide safe working platform or good standard
injuries or death. scaffolding.
H,S  Scaffold erected by competent scaffolding erectors.
Falling of materials / property damage.  Use full body harness while working at heights.
 Materials to be protected from falling.
11. Upon completion of the activity Open valves can cause gas leaks resulting  Ensure the valves are closed and protected from any
H,S
in fires or explosions kind of leaks
12. Storage and handling of gas cylinders Fall over and damage to bottles can cause  Storage and movement of the cylinders should allow
serious injuries/death, fire and explosions. only in a steel framed chained trolley.
 Store the cylinders in upright position,
Fumes could cause damage to the  Protect the cylinders under shade from direct exposure
environment. to sunlight.
 Provide sufficient means of ventilation.

PAGE No 6 of 16
DATE 05/01/2017
RISK ASSESSMENT – FORM 2

Risk Rating Calculation
Risk Rating = A + B + C + D.
A + B + C + D
Injury Severity Potential Damage / Loss Frequency or Likelihood Environmental Impact
0 No injury 0 No damage 0 Never happened before 0 No effect
1 Minor – (FAC) 1 Minor < 500 AED, No delay 1 Happened somewhere 1 Minor Effect - Short term < less 1 month
2 Major – (MTC) 2 Major > 500 AED, No delay 2 Happens occasionally 2 Major Effect - Long term > Greater 1 month
3 LTI 3 Major > 10 000 AED, one day delay 3 Happened before
4 Disabling Injuries 4 Serious > 100, 000 AED, >1 day delay 4 Happens regularly
Risk Rating Matrix
5 Fatality 5 Severe > 1, 000, 000 AED, Weeks delay. 5 Daily occurrence
Result Classification:
Risk Rating
Critical = 17►15 High = 14►11 Medium = 10►7 Low = 6►0 16
Immediate action. Action in 24 hours. Action in a week. ASAP. 14

12
10
Risk Reduction Hierarchy: 8
6
1. Engineering to reduce risk. 4
2. Replacement with lower risk. 2

0
3. Isolation of risk – Barricading or Guarding. 1
5
2 4
4. Reduction of exposure to risk. 3
4 3
5 Probability
5. PPE and Training Potential Impact 6
7 2 (C)
(A / B / D) 8
9 1
RISK ASSESSMENT – FORM 2 (continued)

PAGE No 7 of 16
DATE 05/01/2017
Impact HOW IS HAZARD TO BE BY Result

No HAZARD IDENTIFIED RISK ASSOCIATED WITH HAZARD H, S, E RR BY WHOM RR
DEALT WITH WHEN
1  Faulty equipments and Bruises, cuts. Pre use inspection of the tools Supervisor Before &
tools Faulty tools and equipments during
should be replaced. the use
 Mechanical guards not Entanglement, Skeletal Damage. of
in place Guards in place and equipment equipme
H,S,E 13 regularly maintained. nt 6
 Unwanted Fuel/Oil and Contamination of the soil, atmospheric Care to be taken refuelling and
gas Spillages pollution, risk of fire. drip trays/heavy gauge plastic to
be in place as required.
Provision of sufficient ventilation.
2 Injury to project employees Potential Death, Major/Minor Skeletal Following PPE to be worn Supervisor Before &
damage, cuts and bruises to all parts of appropriately to the task – during
the body, asthma. Gloves. work
Safety boots.
H,S 10 5
Overalls.
Hard hat.
Hearing protection.
Eye protection
3 Un trained employees Poor quality of work, chance for accident Provided trained/competent PE/FM Always
H,S 7 5
/incident or property lost/damage worker and supervision
4 Lack of Supervision Poor quality of work, chance for accident Ensure the availability of PE/FM Always
/incident or property lost/damage competent supervisor at work
place.
H,S 10 4
Work task instruction should be
provided to the workers prior to
the commencement of activity
5 Incorrect setting oxy / acc. Potential Death, Major/Minor Skeletal H, S, E Hot work permit must be issued Supervisor / Before 4
gas damage, cuts and bruises to all parts of prior to start the job and Operator the

PAGE No 8 of 16
DATE 05/01/2017

DEALT WITH WHEN
the body, burn, respiratory disorders. inspection of workplace upon operation
issuing to be ensure
Compressed gas cylinder must
be kept in the trolley with chain
for safe transporting
Cylinders must have the cup and
flash back arrestors is provided
that connected on both end of
hose pipe, attached to the torch
Environmental concern Fire explosions Ensure that the cylinders are
12 stored properly when not in use,
oxygen and acetylene must be
separated
Isolate the area of work as well
as the cylinders and placed
signage
Ensure the provision of fire
fighting equipment
Enforce the use of competent
and experienced operatives
Use the appropriate PPE
Conduct toolbox talk to all the
operatives involve in the activity.
Do not keep the cylinders inside
the building after the activity,
return back to the store
6 Incorrect gauge settings Flash backs, fires, explosions and / or Ensure correct settings of Operator At all
injuries to persons H, S 10 pressure gauges times 3
7 Insufficient ventilation Respiratory discomfort H, S,E Ensure general dilution FM/ Always 4

PAGE No 9 of 16
DATE 05/01/2017

DEALT WITH WHEN
ventilation in which fresh air is Supervisor
Potential death Introduced into the workplace by
mechanical means and is mixed
thoroughly with the contaminants
in the air before removing the
contaminants out of the
8 workplace.
Local exhaust ventilation in which
air contaminants are captured
and removed by forced air
current through hood and duct
near the point of emission and
discharged to the atmosphere
outside the workplace
8 Incorrect setting up of gas Flash backs, fires, explosions and burns Ensure correct setting of the Supervisor Before
cutting equipments. Potential death. pressure gauges. /Operator the
Ensure flash back arresters and operation
non return valves are used.
Always leave a spindle key
chained to the cutting set for turn
off the gas in emergency
Ensure that only triple flint
H, S 3
8 lighters are used to ignite flame.
Ensure the use of correct
nozzles.
Remove all combustible
materials from the vicinity.
Ensure the provision of fire
fighting equipment as per the civil
defence recommendation.

PAGE No 10 of 16
DATE 05/01/2017

DEALT WITH WHEN
9 Gas cutting activity in the Chronic occupational damage to 8 Provide proper ventilation and PE/ FM/ Always
confined space personnel’s respiratory systems. smoke extraction. Supervisor
Inspect the confine space by
Potential death using of gas detector if the
presence of gas is high
H,S,E Never start welding works if there 4
is high percentage of gasses in
the air.
Provide multiple access and
egress to the confined space.
Ensure sufficient lightings.
10 Compressed gas usage on Potential Death, Major/Minor Skeletal Provide standard scaffolding. FM/ Always
elevated areas - Unsafe damage, cuts and bruises to all parts of Scaffolding platform must be Supervisor
scaffolding or working the body, burn, asthma. protected from falling of Operative
platforms materials.
Collapses the scaffolds/platforms and Proper access / egress to the
H,S 8 5
chance for accident / incident or property scaffold to be ensure
damage. Scaffolding must erect by
competent scaffolding erectors.
Enforce the usage of full body
harness while on top of scaffold.
11 Unprotected valves Gas spillage Ensure the valves are closed and Supervisor / After the
Fire and explosions protected from any kind of leaks Operator operation
H,S,E 8 4
Environmental damage
12 Storage and handling of Fall over and blast to cylinders, fire etc. Storage and movement of the Supervisor/ Always
cylinders and equipments cylinders should allow only in a Operator
H, S, E 12 4
steel framed chained trolley.
Store the cylinders in upright

PAGE No 11 of 16
DATE 05/01/2017

DEALT WITH WHEN
position,
Protect the cylinders under shade
from direct exposure to sunlight.
Provide designated storage area.
Provide sufficient means of
ventilation.
* RR = Risk Rating

PAGE No 12 of 16
DATE 05/01/2017
WRITTEN SAFE WORK PROCEDURE

1. OBJECTIVE
1. To prevent injuries to employees and / or property damage incidents.
2. PROCEDURE
1. Do pre-use inspection of all equipment to be used and replace or repair faulty items.
2. Use trained competent employees only.
3. Use appropriate Personal Protective Equipment i.e.:
3.1. Hardhat.
3.2. Safety boots.
3.3. Overalls.
3.4. Eye protection.
SAFETY
 Daily visual inspections must be carried out

 The appointed person must be monthly inspections
 Acetylene is not to come in contact with chlorine, line, fluorine or ammonia as combustion can occur
 All equipment, gauges, torches and flashback arrestors must be approved
 Never use oil or sealing tape on any regulation, oxygen, acetylene or fittings
Prior to work commencement
 Check safety caps on cylinders

 Check colours of cylinders (maroon for acetylene / black for oxygen)
 Check hoses for condition and wear. No joints are allowed unless full lengths are joined with proper quick release
connectors and clamps to allow for extreme heights

PAGE No 13 of 16
DATE 05/01/2017
 Check regulators and torch for condition and leaks (by using soapy water)
 Ensure that nozzle lock-nut and seal (ferrule) is in good condition and tight
 Clean nozzle with nozzle cleaners
 Set pressure on regulators to the required pressure for correct plate thickness to be cut
 Open oxygen and acetylene cylinders by means of a proper spindle key
 Ensure that the cylinder discharge hoses do not point towards each other or towards any combustible material when
opening the valve to clear it or clear the port of the cylinders
 Never coil hoses around cylinders. Make sure to unroll entire length of hose before operating
Hazards
1. Fire caused by heat, sparks, molten metal or direct contact with the flame
2. Explosion when cutting up or repairing tanks or drums which contain or may have contained flammable materials;
3. Fire/explosion caused by gas leaks, backfires and flashbacks
4. Fumes created during flame cutting
5. Fire/burns resulting from misuse of oxygen
6. Burns from contact with the flame or hot metal
7. Crushing or impact injuries when handling and transporting cylinders.
Harm
Potential Death, Minor/major cuts and contusion, loss of limbs, fractures, damage to respiratory system, electric shock.

PAGE No 14 of 16
DATE 05/01/2017
Persons in danger
1. Welder and Labour.

2. Other workers/visitors in vicinity
Control measures
No lone working
STANDARD GAS OPERATED EQUIPMENT
 Regulator: Regulator, quick release coupling flashback arrestor with terminal valve and standard hose
 Torch: Cutting / welding torch to be fitted with quick release coupling and flashback arrestor
 All mobile gas operated units must have a fire extinguisher (2,5 kg Dry Powder) and lifting hook
 Each set of gas cylinders must have a spindle key chained to the trolley

STANDARD OXYGEN AND ACETYLENE HOSES
 Hoses must not exceed 9m in length and must be of equal length. Hoses to be strapped with a suitable quick release hose
clamp. (Never use hose clamps, wire or cable ties)

PAGE No 15 of 16
DATE 05/01/2017
 Silver soldering of fittings:

Only silver solder with less than 21% copper is permitted. The gap to be filled must not exceed 0.3 mm
 Note: No aluminium or galvanised materials to be used. Only approved brass connectors.

 Never tamper with a cylinder and/or its fittings
 Replace damaged hoses immediately. Never tape or cut out leaks in pipes
 No oxygen: Acetylene cylinders to be transported with gauges fitted, except when mounted on trolley and secured
 No oxygen: Acetylene cylinders are to be transported without the appropriate safety guard protecting the brass valve
 Cylinders must be adequately secured before transportation by road.
 No cylinders are to be rolled, lying on the ground, as this will damage the porous material sheeting containing the dissolved
acetylene.
 No cylinders to be exposed to undue shock and direct heat
 Cylinders must not be lifted by the gauges or valves, nor should it be hoisted or handled by either slings or ropes. A
suitable lifting cradle must be used
 Cylinders must not be bumped against sharp edges
 Cylinders must not extend over the side of a vehicle when transported
 Only Competent Operators, apprentices and boilermaker semi-skilled are allowed to use gas-operated equipment
 Persons who are allowed to use a cutting torch by free hand only are:
Semi-skilled labourers with valid competency certificates
Steel fixers and MEP AC technicians with valid competency certificated
Plumbing helpers with valid competency certificates

PAGE No 16 of 16
DATE 05/01/2017
OPERATING PROCEDURE
 Open acetylene valve on torch by turning one fill turn

 Use only triple flint lighter to ignite flame, never matches or gas lighters
 Open oxygen valve and adjust to required flame
 Do not set flame to carbonise black or oxidised whitish
 Ensure that all safety protective equipment is available before cutting. Approved eye protection is most important
 To cut, bring flame close to the material, approximately 4mm, preheat for few seconds (not necessary to let material melt
before applying pressure) and then press the pressure lever and cut
 NOTE: Cast iron, copper, bronze, stainless steel, manganese and several other materials cannot be cut with an oxygen-
acetylene flame. Never try to cut into concrete with a torch
 After completing the job, the acetylene valve must be shut off first to extinguish the flame, and then close the oxygen valve
 The cylinders must always be closed with the spindle key after completing any job and / or for storage purposes
 At the end of each shift, or when the torch is not in use for a long period of time, disconnect the hoses from the torch ad
regulators, and joint the ends of the oxygen and acetylene hoses to prevent entry of dust and dirt

HSE-RA-066 Using of Cutting Torch - Rev 0

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DOC No DS/CA006P02/00022

Name and Signature

HSE QUALITY SYSTEM DOCUMENTATION

TASK ANALYSIS - FORM 1

Competent supervision Failure will cause injuries to employees

equipments and Compressed gas and follow the manufacturer’s recommendation.

HSE QUALITY SYSTEM DOCUMENTATION

TASK ANALYSIS - FORM 1 (continued)

HSE QUALITY SYSTEM DOCUMENTATION

RISK ASSESSMENT – FORM 2

Immediate action. Action in 24 hours. Action in a week. ASAP. 14

2. Replacement with lower risk. 2

RISK ASSESSMENT – FORM 2 (continued)

Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

Impact HOW IS HAZARD TO BE BY Result

HSE QUALITY SYSTEM DOCUMENTATION

WRITTEN SAFE WORK PROCEDURE

 Daily visual inspections must be carried out

Prior to work commencement

 Check safety caps on cylinders

HSE QUALITY SYSTEM DOCUMENTATION

HSE QUALITY SYSTEM DOCUMENTATION

1. Welder and Labour.

STANDARD GAS OPERATED EQUIPMENT

STANDARD OXYGEN AND ACETYLENE HOSES

HSE QUALITY SYSTEM DOCUMENTATION

 Silver soldering of fittings:

 Note: No aluminium or galvanised materials to be used. Only approved brass connectors.

HSE QUALITY SYSTEM DOCUMENTATION

 Open acetylene valve on torch by turning one fill turn

HSE QUALITY SYSTEM DOCUMENTATION

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