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Chennai Metro Rail Project, No.

53, Habibullah Road, T-Nagar, Chennai - 600 017 TamilNadu, INDIA


Project Name

Design and Construction of Underground Stations at Gemini, Teynampet, Chamiers Road and Saidapet and Associated Tunnels Contract UAA03
Safe operation procedure for Gas Cutting & Welding PREPARED/ DESCRIPTION CHECKED DESIGNED APPROVED



Safe operation procedure For Gas Cutting & Welding

Amit Ninawe

Manas R. Mohanty

Mahesh Chaturvedi

Prepared by

Checked by

Approved by

Amit Ninawe HSE Manager

Manas R. Mohanty Chief HSE Manager

Mahesh Chaturvedi Project Manager


1.1 General
To encourage and educate personnel on the GIL-MMS JV sites to regard Safety First as its prime objective and to be aware of their commitment, responsibility and statutory obligation. This procedure will provide information and guidance while performing gas cutting and welding

work at site. To identity tendency of unsafe activities and condition and provide safe work environment.


Gas Cutting & Welding Procedure

1.2.1 Sub-contractors shall ensure that all gas welding, cutting and gouging is carried out so that the risks are kept at a minimum and that appropriate risk assessments are carried out before welding or cutting takes place. 1.2.2 All persons carrying out welding or cutting shall be properly trained and qualified for the task. 1.2.3 All equipment must be in good condition, properly installed and routinely inspected by a competent person, and records must be kept available for inspection by GIL-MMS JV safety department. 1.2.4 The atmosphere in the vicinity of work must be known to be safe to breathe and free from flammable gases. 1.2.5 Adequate ventilation and fume extraction must be provided and used as required by the risk assessment and especially in enclosed areas, shafts, tunnels or pits. 1.2.6 4.5 kg. dry chemical powder fire extinguishers shall be kept with every gas bottle set and close to the work piece if the gas bottle set is more than 10 metres from the work piece. 1.2.7 Use firewatchers if there is a possibility of ignition unobserved by the operator (e.g. on the other side of bulkheads etc). 1.2.8 Ensure screwed fittings and hoses are correct and keep screwed and sealed surfaces free of contaminants, such as oil and grease. 1.2.9 Surfaces to be heated by the process must be cleaned of contaminants that may be degraded by heat or give off noxious fumes (e.g. paints, plastics, zinc coating). 1.2.10 Naked flames or high temperature surfaces must not be allowed in the vicinity of volatile solvents. 1.2.11 Welding or cutting shall not take place where welding splatter can fall on other persons or on to flammable materials. 1.2.12 All moveable flammable materials must be removed from the vicinity of work and fireproof covers placed over all flammable materials that cannot be removed. 1.2.13 No gas or weld / flame cutting of vessels, drums or tanks that have contained flammable or toxic substances to be allowed on the project. 1.2.14 Remove all blowpipes / torches and gas cylinders from enclosed areas when not in use.


Permit to Work 1.3.1 All sub-contractors must ensure Hot Work Permit before the start of activity, there will be circumstances when Hot Work Permits to Work will need to be issued, such as:0.1.1 Working in tunnels;

Working inside any building or structure; Welding over areas where others are working; Working in areas with increased fire risks or hazardous environments; or, Where the risk assessment requires:
1.4 Personal Protective Equipment (PPE) 1.4.1 Welders and their helpers shall wear the appropriate personal protective equipment which can include the following; Face and eye protection with correct grade of shield; Gauntlet gloves; Safety footwear Welders apron or fire retardant overalls; Cylinder handling 1.5.1 Gas cylinders must be handled with care and shall not be subject to shocks or falls. When gas cylinders are transported in a vehicle around site they shall properly secured. If cylinders are to be lifted by crane they shall be secured in a special carrier designed for the purpose. Acetylene cylinders must always be transported and used in the vertical position. Valve protection caps shall be fitted to all cylinders not in use. 1.5.2 All cylinders shall be used and moved in purpose built trolleys which hold the cylinders in an upright position and are properly secured. 1.5.3 Cylinders in use shall be protected from direct sunlight to prevent overheating. 1.5.4 All cylinder valves should be closed when the flame is extinguished. 1.5.5 No defective or damaged cylinders shall be used. 1.5.6 Cylinders containing oxygen or acetylene shall not be taken into a confined space. 1.5.7 Cylinders, whether full or empty shall not be used as rollers or supports.


1.5.8 All cylinders shall be colour coded as per international standards. e.g. Black for Oxygen, Maroon for Acetylene, Red for LPG. 1.5.9 1.6 Cylinders shall not be lifted by their valves.

Regulators / Gauges 1.6.1 Regulators / Gauges must always be fitted to the cylinders to reduce the gas pressure from that in the cylinder to the working pressure of the blowpipe. Only regulators

designed for the gas being used and rated for the current full cylinder pressure should be fitted to the cylinders. 1.6.2 Regulators / Gauges with broken parts or leaks shall not be used. Weekly checks of regulators should be carried out and recorded with the records being made available on request. 1.6.3 Each Regulator shall be fitted with an Outlet Pressure gauge and a Cylinder Contents gauge 1.6.4 1.6.5 1.7 Checks for gas leaks should carried out using soapy water. Suitable fire extinguisher should be available to every welding set.

Flash back arrestors and Non return valves 1.7.1 Flash back arrestors (flame arrestors) shall be fitted to both the fuel gas and oxygen cylinders. 1.7.2 Non return valves shall be fitted to both the fuel gas and oxygen supply on the blowpipe / torch.


Hoses 1.8.1 Hoses shall be kept for one type of gas only, and colour coded for identification, red for acetylene or other fuel gases (except LPG), orange for LPG and blue for oxygen. 1.8.2 Hoses should be inspected daily to see that they are free from cuts, cracks or burnt or worn patches. Damaged hoses must not be used and shall be removed from site. 1.8.3 Hoses shall be effectively crimped or spring clipped to the equipment and protected at all times from sharp edges etc. Jubilee clips shall not be used.


Storage of Gas Cylinders

1.9.1 Proper purpose built storage facilities shall be provided for all unused or used gas cylinders on site. Cylinders shall be shielded from direct sunlight or any other heat source. 1.9.2 Storage must be 10 metres from any site boundary, building, entrance to tunnel, pit, shaft or deep excavation. 1.9.3 All cylinders shall be stored in an upright position and shall be secured against falling. 1.9.4 Oxygen cylinders shall be stored at least 6 metres from fuel gas cylinders and both shall be stored at least 20 metres from any fuel store. 1.9.5 Full cylinders shall be stored separately from empty cylinders.



1.10.1 The Circuit In electric arc welding the voltage use should be as low as is consistent with efficient welding. Two cable should be used in electric arc welding. One called as welding lead takes the current from the generator/machine to the electrode holder where as the other one which is called as return earth cable carries the return current from the workpiece being welded back to the generator/machine.

1.10.2 Cables and cable coupling The insulation of the welding cable and return earth cable should be frequently examined for any defects. The part of the cable which is connected to the electrode holder should be flexible so as not to hamper the movement of the welder. Joints between the cable section should be made with properly constructed insulated cable coupling, adequately shrouded so that live metal is not exposed if the parts of the connector are separated. The return earth cable should be firmly connected to the metal on which welding is taking place by means of a well constructed clamp.

1.10.3 Electrode Holder An electrode holder is essentially a pair of spring loaded jaws fitted to the end of the welding lead. The holder should be fully insulated so that the live portions can not be touched accidentally. 1.10.4 Hazard associated with Arc welding. The principal hazards associated with arc welding are fire, burns, eye damage, respirator diseases, electric shock, ultraviolet radiation and ozone 1.10.41 Fire 1.10.42 Burns To protect skin from burn injury the hands, arms legs, and feet should be protected by gloves or gauntlets, spats and jackets made from chrome leather. The footwear should be made of leather. Flammable material should be kept out of any area where welding is taking place. Where such a course of action is not practicable, fire retardant cloth should be used to protect the surroundings from the flame and from spatter. At-least one fire extinguisher should always be immediately available in the area of any welding operation.

1.10.43 Eye damage

During welding operation the eye may be penetrated by sparks, spatter, slag, infra-red light, ultraviolet light, foreign bodies. During gas welding to protect eyes from infra red light, box goggles with a housing made to BS 1542 and filter made to BS EN 169 and 171. During arc welding the welder must use welding helmet or hand screen with housing complying with BS 1542 and fitted with appropriate filter to BS EN 169 &170.

1.10.44 Respiratory disease During welding the fumes generated mainly consists of iron oxide, carbon monoxide, nitrous, ozone. These fumes are mostly causing respiratory disease. The welding operation should be carried out in a well ventilated location. If a number of welding operation is carried out in a same location or the work being carried out in a confined space the most effective form of fume control equipment is suction type ventilation.

1.10.11 References
British Standards BS EN 169:2002. Specification for filters for personal eye protection equipment used in welding and similar operations. BS EN 470-1:1995. Protective clothing for use in welding and allied processes

BS EN 175:1997: Personal protection. Equipment for eye and face protection during welding and allied processes

BS EN 730-1:2002. Gas welding equipment Safety devices Part 1: Incorporating a flame (flashback) arrestor. BS EN 2503:1998. Gas welding equipment. Pressure regulators for gas cylinders used in welding, cutting and allied processes up to 300 bar. BS EN 585: Pressure regulator for gas cylinders.

Form No. 409802-008, Rev. A Monthly Safety Checklist of C2H2 & O2 Cylinders Contractor Location Weather Sunny Cloudy Rainy Typhoon No. 1 6 7 Items of Inspection All devices such as cylinders, valves, hoses, pressure gauges, flash-back arrestors and other devices are in good conditions Upright position of cylinders and provision of anti-sliding devices Fire extinguishers located at the workplaces Project Name Inspection Date (YY/MM/DD) Inspection Time (Yes) / Page:1/2 /

Status (No) (N/A)


8 9

Flash-back arrestors are in use Storage location of cylinders in cool and ventilated areaprovide shade or heat protections for mobile cylinders under sunshine Inspect cylinder supply values, pressure regulator, hose clamps prior and during operation Inspect for any leakage at cylinder valves and purge the hoses if change of gas cylinders




Use of soap water for checking any gas leakage


Wearing of PPE, including hardhat, protection glasses and gloves


Use of proper transportation devices for gas cylinders in the workplaces, and provide fire extinguishers and warning signs of "No Use of Fires" Use fireproof sheet to protect cables, pipes and flammable materials near work place Check for any inflammable materials prior to operation




Proper fire suppressing equipment available at the workplaces

Safety Checklist of C2H2 & O2 Cylinders No. 18 Items of Inspection Storage of C2H2 and O2 separately and posted with warning signs of "No Use of Fires" (Yes) Status (No) (N/A)

Page:2/2 Remarks

Today's Work Status

Instructions by Construction Manager

Remarks : 1. This safety checklist shall be performed prior to use of gas cylinders. 2. The status shall be recorded with: [ ]in "Yes" or "No" column. The required actions shall be indicated in rectification columns. 3. This checklist shall be signed by the DURL Senior / Site Engineer and filed by the safety personnel.


DURL/ Sub-Contractor Site Safety Officer: ____________________________________________ DURL Senior / Site Engineer: ______________________________________________________

HOT WORK PERMIT Permit No.: _____________________ Date and Time: ___________________

This permit is approved on the condition that the applicant has observed and taken all the necessary safety precautions as stated in the safe work practices and the checklist to prevent accident and that the safety precautions will be maintained throughout the permit period. Any change in condition will invalidate this permit. The copy of this permit shall be displayed at location of work. Location: ____________________________________________________________________ Description of work to be performed: ______________________________________________ Does other work in the area present a hazard to this job? ______________________________ SAFETY APPROVAL: Conditions of issue which must be observed at all time.



ADEQUATE PPE USED Item required and complied ()

LIFE LINE REQUIRED WITH HANDLER IF ANY Item required and not complied (X) Not required (NA)


PERMIT HOLDER (Contractor/sub-contractor supervisor/engineer who shall execute the job) I have read the SOP relating to this work to be performed, I fully understand the nature of the work. Company Name: ______________________________________________________________ Name: ________________________________ Signature: _____________________________ Approval by Construction Manager/ Station Manager The above work Approved / Not Approved ___________________ Name: _________________________________ Signature: ______________________________ Position: _______________________ Date & Time: ____________________ Position: ________________________ Date & Time: ____________________

On Completion of work ( Filled by supervisor in consultation with fire watcher 1hour after completion of work)
I have been checked the working area and adjacent area and found no hot metal or spark exist/ existed fire has been put off. Company Name: Name: Signature: Date & Time:

* * *

The permit must be obtained from the Safety Dept. before the commencement of work. This permit validity is for one shift only. This permit will be cancelled by GIL-MMS JV engineer or safety engineer if the above points are not complied.