Order of the Ministry of Labour and Social Protection of the Russian Federation No. 884n of 11 December 2020
Unofficial translation. Only the Russian original published in the official sources of the Russian Federation has legal force. This translation is provided for reference and does not replace the official document.
1. The Labour Protection Rules for the Performance of Electric Welding and Gas Welding Work (hereinafter referred to as the Rules) establish state regulatory labour protection requirements for the performance of electric welding and gas welding work. The Rules shall be binding on employers - legal entities and natural persons, regardless of their organisational and legal forms and forms of ownership - when performing electric welding and gas welding work.
2. The Rules apply to workers who perform electric welding and gas welding work and who use, in enclosed premises or in the open air, stationary, portable and mobile electric welding and gas welding installations intended for performing the technological processes of welding, surfacing, fusion cutting (severance and surface cutting) and welding with the application of pressure: 1) arc and plasma welding, surfacing, cutting; 2) atomic hydrogen welding; 3) electron beam welding; 4) laser welding and cutting (welding and cutting by light beam); 5) electroslag welding; 6) welding by contact heating; 7) resistance or diffusion welding, arc-contact welding; 8) gas welding and gas cutting of metals (hereinafter referred to as welding).
3. On the basis of the Rules and the requirements of the technical documentation of the manufacturing organisation for specific types of electric welding and gas welding equipment and tools, the employer develops labour protection instructions for occupations and (or) types of work performed, which are approved by a local regulation of the employer taking into account the opinion of the relevant trade union body or other representative body authorised by the workers (where one exists).
4. Where methods of work, materials, technological tooling, equipment and tools are applied for which safe application requirements are not provided for by the Rules, when performing electric welding and gas welding work the requirements of the relevant regulatory legal acts containing state regulatory labour protection requirements and the requirements of the technical documentation of the manufacturing organisation shall be followed.
5. The employer ensures that electric welding and gas welding equipment and tools are kept in good working order and that they are operated in accordance with the requirements of the Rules and the technical documentation of the manufacturing organisation.
6. When performing electric welding and gas welding work, workers may be exposed to harmful and (or) dangerous production factors, including: 1) electric shock; 2) increased gas content in the air of the working area, the presence of harmful aerosols in the air of the working area; 3) increased or decreased air temperature of the working area; 4) increased temperature of the material being processed, of products, of the outer surface of equipment and the inner surface of confined spaces, molten metal; 5) ultraviolet and infrared radiation; 6) increased brightness of light during the welding process; 7) increased levels of noise and vibration at workplaces; 8) location of the workplace at a height relative to the surface of the ground (floor), which may cause a worker to fall from height; 9) physical and neuropsychic overloads; 10) performance of work in hard-to-reach and confined spaces; 11) falling objects (equipment elements) and tools; 12) moving vehicles, lifting structures, and materials and tools being moved.
7. The employer, depending on the specific nature of its activities and proceeding from the assessment of the level of occupational risk, may: (a) establish additional safety requirements that do not contradict the Rules. The labour protection requirements shall be contained in the relevant labour protection instructions and shall be communicated to the worker in the form of directives, instructions or briefings; (b) to monitor the safe performance of work, apply instruments, devices, equipment and (or) a set (system) of instruments, devices and equipment providing remote video, audio or other recording of the work processes.
8. The Rules do not apply to the performance of electric welding and gas welding work at hazardous production facilities where the hazardous substances specified in paragraph 1 of Appendix No. 1 to Federal Law No. 116-FZ of 21 July 1997 "On Industrial Safety of Hazardous Production Facilities" (Collected Legislation of the Russian Federation, 1997, No. 30; 2017, No. 9, Article 1282, Article 3588) are obtained, used, processed, formed, stored, transported or destroyed.
9. Document flow in the field of labour protection may be maintained in electronic form using an electronic signature or any other method that makes it possible to identify the worker, in accordance with the legislation of the Russian Federation.
10. It shall be prohibited to obstruct passages and driveways inside buildings (structures) and production premises (production sites), so as to ensure the safe movement of workers and the passage of vehicles.
11. Walkways, stairways, platforms and their railings shall be kept in good working order and clean, and those located in the open air shall be cleared of snow and ice in winter and treated with anti-icing agents. The decking of platforms and walkways, as well as their railings, shall be secured and shall prevent the accidental fall of a person. For the period of repair, temporary guarding is installed in place of removed railings. Railings and decking removed for the duration of repair are put back in place immediately after its completion.
12. Welding shops and areas are equipped with general ventilation, and stationary workplaces with local ventilation.
13. Areas for the gas-flame treatment of metals are located in single-storey buildings. Where it is necessary to locate areas for the gas-flame treatment of metals in multi-storey buildings, actions shall be provided for to prevent the spread of harmful substances between floors. Welding, surfacing and cutting of metals involving the release of beryllium and its alloys shall be carried out in isolated premises equipped with exhaust ventilation.
14. In assembly and welding shops, air heating with adjustable air supply shall be used in the cold and transitional periods of the year. In the warm season, natural ventilation through the openable openings of windows, skylights and doors (gates) shall be used in assembly and welding shops. General and local ventilation are not used if the content of harmful substances does not exceed the maximum permissible concentration (hereinafter referred to as the MPC). Where it is impossible to eliminate or reduce the levels of harmful and (or) dangerous production factors to permissible exposure levels because of the nature and conditions of the production process, the work may be carried out provided that the workers are provided with personal protective equipment.
15. A container (storage vessel) with liquefied gas, except for equipment operating under excess pressure used at hazardous production facilities, the requirements for which are established by Federal Norms and Rules in the field of industrial safety, is installed on a site with metal fencing. A passage at least 1 m wide is provided between the container (storage vessel) and the fencing. The container (storage vessel) shall not be subjected to heating. Where a container (storage vessel) is installed in the open air, it is equipped with a canopy protecting it from direct sunlight and precipitation.
16. At the stationary workplaces of electric welders and gas welders, for work in a sitting position, a swivel chair with variable adjustable height and a footrest with an inclined support surface are installed. For work in a standing position, stands (suspensions) are installed that reduce the static load on the welders' arms. It shall be prohibited to reduce the load on the arm by throwing the hose (cable) over the shoulder or by winding it around the arm.
17. At the stationary workplaces of gas welders, a stand with a hook or fork is installed for hanging extinguished torches or cutters during breaks in work. At temporary workplaces, extinguished torches or cutters may be hung on parts of the structure being processed.
18. A stationary workplace intended for automatic and mechanised electric welding in shielding gases and their mixtures is equipped with: 1) welding equipment and workplace tooling in accordance with the requirements of the technological process; 2) devices for removing harmful gases and dust built into the technological tooling or the welding head.
19. When organising workplaces in the areas of electric welding flow-mechanised lines, the following requirements shall be observed: 1) for automated electric welding processes accompanied by the formation of harmful aerosols, gases and radiation exceeding the MPC and the maximum permissible levels (hereinafter referred to as MPLs), remote control and (or) the use of personal protective equipment is provided for; 2) to remove harmful dust and gas emissions, dust and gas receivers are provided, built into or interlocked with the welding automatic or semi-automatic machines, units, portals or manipulators; 3) the control panels of load-lifting vehicles are combined with (located in the immediate vicinity of) the control panels of the electric welding equipment; 4) the equipment and control panels on electric welding flow-mechanised lines are located in one plane, to avoid the need for workers to move vertically; 5) the workplaces of operators at the combined automatic welding control panel are equipped with armchairs or seats with backs made of non-heat-conducting materials; 6) the areas of electric welding flow-mechanised lines are separated by passages from adjacent areas, walls and access roads. The distance from the welding location to passages shall be at least 5 m. Where this requirement cannot be met, non-combustible screens (curtains, shields) are installed at the location where the electric welding work is performed.
20. When performing electric welding and gas welding work with preliminary heating of products, two welders may work in one booth only when welding a single product.
21. Non-stationary workplaces in premises, during welding with an open electric arc or gas cutting/welding of metals, are separated from adjacent workplaces and passages by non-combustible screens (curtains, shields) at least 1.8 m high. When welding in the open air, screens are installed where several welders work simultaneously next to each other and in areas of intensive movement of workers. If screening is impossible, workers exposed to the danger of an open electric arc shall be protected by means of personal protective equipment.
22. Where safe and harmless technological processes cannot be applied, actions are taken to reduce the levels of dangerous and harmful production factors.
23. High-hazard electric welding and gas welding work is performed in accordance with a written directive - a permit to work for the performance of high-hazard work (hereinafter referred to as the permit to work), drawn up by officials authorised by the employer. In the permit to work, the content, place, time and conditions of the work, the necessary safety measures, the composition of the work team and the persons responsible for the organisation and safe performance of the work are defined. Where several types of work requiring a permit to work are performed jointly, a single permit to work may be drawn up, incorporating the requirements for the safe performance of each type of work. The procedure for performing high-hazard work, the drawing up of the permit to work and the duties of the officials responsible for the organisation and safe performance of the work are established by a local regulation of the employer.
24. If electric welding and gas welding work is carried out simultaneously with other types of work requiring a permit to work, a single permit to work may be drawn up, with the mandatory inclusion in it of information on the performance of the electric welding and gas welding work and the appointment of persons responsible for the safe performance of the work, and with the provision of the conditions and procedure for performing the work under the permit to work in accordance with the requirements of the regulatory legal act that approved it.
25. For the performance of electric welding and gas welding work in the protection zones of structures or utilities, the permit to work is issued subject to written approval from the organisations operating those structures and utilities. The approval signature for the performance of the electric welding and gas welding work is placed in the permit to work by an authorised official of the operating organisation before the start of the work.
26. The permit to work is issued for the period necessary to complete the specified scope of work. If dangerous or harmful production factors not provided for by the permit to work arise in the course of the work, the work is stopped and the permit to work is cancelled. The work is resumed only after a new permit to work has been issued.
27. Monitoring of the fulfilment of the actions provided for in the permit to work to ensure the safe performance of the work is carried out by a person determined in accordance with the local regulations of the employer.
28. Drawn-up and issued permits to work are registered in a logbook, in which it is recommended to record the following information: 1) the name of the subdivision; 2) the number of the permit to work; 3) the date of issue; 4) a brief description of the work under the permit to work; 5) the period for which the permit to work is issued; 6) the surnames and initials of the officials who issued and received the permit to work, certified by their signatures with an indication of the date; 7) the surname and initials of the official who received the permit to work closed upon completion of the work, certified by his signature with an indication of the date. The logbook may be maintained, and permits to work may be drawn up, in electronic form using an electronic signature, including a simple electronic signature or an enhanced unqualified electronic signature or an enhanced qualified electronic signature (at the employer's discretion), or any other method that makes it possible to identify the worker or other person, in accordance with the legislation of the Russian Federation.
29. High-hazard work for which a permit to work is issued includes: 1) electric welding and gas welding work performed on the outside and inside of vessels that have contained combustible substances, work in closed reservoirs, in cisterns, in wells, in collectors, in tunnels, channels and pits, in pipelines, work in the fireboxes and flues of boilers, inside hot furnaces; 2) electric welding and gas welding work in explosion-hazardous premises; 3) electric welding and gas welding work performed during the repair of heat-consuming installations, heat networks and equipment; 4) electric welding and gas welding work performed at a height of more than 5 m; 5) electric welding and gas welding work performed in places that are dangerous with respect to electric shock (electric power and nuclear power facilities) and with restricted access (premises where highly toxic, chemical and radioactive substances are used and stored). The list of work performed under permits to work may be supplemented by the employer.
30. Standard high-hazard work of the same type, carried out on a permanent basis and performed under similar conditions by a permanent staff of workers, may be performed without a permit to work being drawn up, in accordance with the labour protection instructions approved for each type of high-hazard work.
31. Before starting electric welding and gas welding work, it shall be verified that the surface of the workpieces and parts to be welded and of the welding wire is dry and cleaned of grease, scale, rust and other contaminants.
32. The surfaces of workpieces and parts to be welded or surfaced that are coated with anti-corrosion primers containing harmful substances are first cleaned of the primer over a width of at least 100 mm from the welding location.
33. Electric welding and gas welding work may be performed from portable ladders and stepladders provided that the welder uses a five-point safety harness and a safety lanyard secured to a safety rope or an anchor bolt above the level of the welder's head, and provided that there is a worker providing safety backup who supports the ladder or stepladder from below.
34. When performing electric welding and gas welding work at height, workers use bags for tools and for collecting electrode stubs.
35. Electric welding and gas welding work at height is carried out after a permit to work has been drawn up and all the actions provided for by the permit to work have been completed.
36. Simultaneous work at different heights along the same vertical line is carried out provided that the workers working at the lower levels are protected from metal spatter and from falling electrode stubs and other objects.
37. When performing electric welding and gas welding work in the open air, canopies of non-combustible materials are erected above the welding installations and welding stations for protection from direct sunlight and precipitation. In the absence of canopies, electric welding and gas welding work is stopped during precipitation. When performing gas welding work in the open air in winter, measures against the freezing of cylinders with carbon dioxide shall be provided for.
38. When performing electric welding work in premises where there is a risk of injury from an electric arc, welders are additionally provided with dielectric gloves, galoshes and mats.
39. When descending into closed vessels through manholes, it shall be verified that the manhole covers are secured in the open position.
40. It shall be prohibited: 1) to work near unguarded or unclosed manholes, openings and wells; 2) to remove the guards and covers of manholes, openings and wells without the permission of the performing authority, even if they interfere with the work. If guards or covers have been removed during the work, they shall be put back in place upon completion of the work.
41. Lighting during the performance of electric welding and gas welding work inside metal vessels is provided by luminaires installed outside or by portable hand-held electric luminaires with a voltage of not more than 12 V.
42. The metal parts of electric welding equipment that are not energised, as well as the products and structures being welded, are earthed for the entire duration of the welding, and on the welding transformer the earthing bolt of the casing is connected to the terminal of the secondary winding to which the return lead is connected. The earthing bolt is located in an accessible place and is provided with the inscription "Earth" (or the conventional "Earth" symbol).
43. Steel busbars and structures may be used as the return lead or its elements. The connection of the individual elements used as the return lead to one another shall be made by bolts, clamps or welding.
44. Cables are connected to welding equipment using crimped or soldered cable lugs.
45. When laying or moving welding leads, measures are taken to prevent their contact with water, oil, steel ropes and hot pipelines, and to prevent spatter of molten metal from falling on them. The distance from welding leads to hot pipelines and to cylinders with oxygen shall be at least 0.5 m, and to cylinders with combustible gases at least 1 m.
46. When welding leads are joined to extend their length, the joint is made by crimping, welding or soldering, followed by insulation of the joints. Joining leads by "twisting" shall be prohibited.
47. Electrode holders for manual welding shall ensure the clamping and quick change of electrodes and shall prevent the possibility of short-circuiting of their bodies to the parts being welded during temporary breaks in work or if they accidentally fall onto metal objects. The use of home-made electrode holders shall be prohibited.
48. All electric welding installations with alternating and direct current sources, when welding in especially dangerous conditions (inside metal vessels, wells, compartments, drums, gas ducts, boiler fireboxes, tunnels), as well as installations for manual welding with alternating current used in especially dangerous premises or outside premises, shall be fitted with no-load cut-off devices.
49. The secondary windings of step-down transformers for portable electric luminaires are earthed. If a step-down transformer is at the same time an isolating transformer, its secondary electric circuit shall not be connected to earth. The use of autotransformers to reduce the supply voltage of portable electric luminaires shall be prohibited.
50. Mobile electric welding installations, as well as portable thermal cutting machines, are disconnected from the electric mains while they are being moved.
51. The control and monitoring of the operation of semi-automatic and automatic stationary and portable plasma machines for the plasma cutting of metal are carried out remotely.
52. The electric motor for feeding welding wire into the pistol torch of hose-type semi-automatic machines for welding in inert gases is connected to a mains supply whose voltage shall not exceed 24 V for alternating current or 42 V for direct current.
53. When gas welding work is performed, the cabinets of acetylene and oxygen stations shall be open and the approaches to all stations shall be clear. The employer ensures the periodic renewal of the distinctive colouring of the cabinets.
54. The placement of acetylene generators in driveways, in places where large numbers of people are present or pass, or near points of air intake by compressors or fans shall not be permitted.
55. When performing gas welding work, it shall be prohibited: 1) to perform gas welding work on vessels and pipelines under pressure; 2) to operate gas cylinders whose examination period has expired, whose body is damaged or whose valves and adapters are faulty; 3) to install on the reducers of gas cylinders pressure gauges that are not sealed, as well as analogue (dial) pressure gauges in which: (a) the state verifier's stamp or a seal with a verification mark is absent; (b) there is no red line on the dial corresponding to the maximum working pressure (applying a red line to the glass of the pressure gauge shall not be permitted; instead of a red line on the dial of the pressure gauge, a plate of sufficiently strong material, painted red and fitting tightly against the glass of the pressure gauge, may be attached to the body of the pressure gauge); (c) when the pressure gauge is disconnected, the pointer does not return to the zero mark of the scale by an amount exceeding half of the permissible error for the given pressure gauge; (d) the verification period has expired; (e) the glass of the pressure gauge is broken or there is other damage that may affect the accuracy of its readings; 4) to attach forks and tees to hoses to supply several torches (cutters); 5) to use hoses not intended for the gas welding and gas cutting of metals or defective hoses, or to wrap them with insulating tape or any other material; 6) to join hoses using lengths of smooth tubing.
56. The serviceability of equipment for the performance of electric welding and gas welding work is checked at least once every six months by workers appointed by the employer as responsible for keeping the relevant type of equipment in good working order.
57. When performing manual arc welding, the following requirements shall be observed: 1) manual arc welding is performed at stationary stations equipped with exhaust ventilation. Where welding work cannot be performed at stationary stations because of the dimensions and design features of the products being welded, local exhaust devices and/or personal respiratory protective equipment are used to remove dust and the gaseous components of the aerosol from the welding arc; 2) the cables (leads) of electric welding machines are located at a distance of at least 0.5 m from oxygen pipelines and at least 1 m from pipelines of acetylene and other combustible gases; 3) electric welding transformers or other welding units are connected to the mains by means of knife switches or starting devices.
58. During manual arc welding, it shall be prohibited: 1) to connect more than one welding transformer or other current consumer to a single knife switch; 2) to repair electric welding installations that are energised; 3) to weld freshly painted structures, apparatus and utilities, as well as structures, apparatus and utilities that are under pressure or electric voltage or are filled with combustible or toxic materials, liquids, gases or vapours; 4) to weld and cut vessels that have contained combustible and flammable liquids or combustible and explosive gases (cisterns, tanks, drums, reservoirs) without these vessels first being cleaned and steamed and the gases removed by ventilation; 5) to use the leads of the earthing network, the pipes of sanitary utility networks (water supply, gas supply, ventilation), the metal structures of buildings or technological equipment as the return lead for electric welding; 6) to use personal protective equipment made of synthetic materials that do not possess protective properties, are destroyed by exposure to the welding arc, may catch fire from sparks and spatter of molten metal, and may sinter on contact with heated surfaces; 7) during breaks in work and upon completion of work, to leave energised electric welding tools at the workplace.
59. Before starting work, a worker performing resistance welding shall: 1) put his workplace in order, prepare the tools and fixtures for work and verify that they are in good working order; 2) check the serviceability of the air and water systems of the resistance welding machine and the presence of oil in the oil distributor (the presence of oil in the oil distributor shall be checked at least once a week); 3) check the presence and serviceability of the safety and interlocking devices of the resistance welding machine and of the control cabinets, the earthing, and the soundness of the insulation; 4) check the operation of the local exhaust ventilation and the silencers; 5) check the presence and serviceability of the protective curtains and of the hinged transparent screens or shields; 6) secure the product to be welded; 7) perform a trial start of the resistance welding machine without welding and verify the proper operation of all its assemblies and the possibility of adjusting the welding cycle.
60. During work, a worker performing resistance welding shall: 1) not allow persons unrelated to the work into the workplace, and not hand over control of the resistance welding machine to unauthorised persons; 2) not lubricate, clean or tidy the machine while it is operating; 3) ensure that the leads do not come into contact with water and that spatter of molten metal does not fall on them; 4) check the electrodes: if the electrodes "stick", immediately stop the resistance welding machine and inform the person in charge of the work; 5) observe the technological regime provided for by the technological process; 6) ensure the safety of the hands during the operation of rollers, electrodes and other moving parts (when welding small parts, make sure that the hands are not pinched by the operating electrode, monitor the serviceability of the compression mechanisms and clamping devices, and prevent their spontaneous actuation); 7) not touch the electrodes and not check the welding points with the hands; 8) not rearrange anything on the resistance welding machine or inside the resistance welding machine while it is operating, and not lean on the resistance welding machine; 9) at least twice per shift, completely clean the welding circuit of flash, spatter of molten metal, oxides and scale. Work on adjusting the resistance welding machine is performed with the knife switch turned off.
61. Before performing spot welding on suspended resistance welding machines, the tightness of all bolted connections shall be checked, and only after that may the resistance welding machine be suspended. In addition to the tongs, the current-carrying cables are suspended from the suspension device. To ensure safety, an additional chain or rope is passed through the second lifting ring.
62. During a break in work, the knife switch of the resistance welding machine shall be switched off and the valves for the water of the cooling system and for the air shall be closed. In winter, constant circulation of the water shall be ensured.
63. If faults in the electrical leads or abnormal operation of the electrical apparatus (time relays, electric valves, starting devices) are detected on the resistance welding machine, or if the supply of electric power ceases, the knife switch of the resistance welding machine shall be switched off immediately and work shall not be started until the faults that have arisen are rectified. Information about the faults that have arisen shall be reported to the person in charge of the work.
64. During the repair, inspection, replacement and cleaning of electrodes, the resistance welding machine shall be disconnected from the sources of supply of electric current, compressed air and water, and signs shall be posted with the inscriptions: 1) on the knife switch of the welding machine - "Do not switch on! People at work"; 2) on the compressed air and water valves - "Do not open! People at work".
65. If flames appear inside the body of the resistance welding machine, the machine shall be stopped immediately, the knife switch shall be switched off, the doors of the machine shall be opened and the fire shall be extinguished with the primary fire-extinguishing equipment intended for this purpose. Information about the faults that have arisen shall be reported to the person in charge of the work.
66. Upon completion of work, a worker performing resistance welding shall: 1) switch off the resistance welding machine in the following order: switch off the electric power supply; switch off the air supply; switch off the water supply; 2) tidy his workplace and put the parts, welded assemblies, fixtures and tools in the places specially designated for them; 3) verify that no smouldering materials remain after the work; 4) report to the person in charge of the work all equipment faults that occurred during the work.
67. When submerged arc welding is performed at stationary stations, the welding installations are fitted with local exhaust devices. The exhaust devices are located directly at the welding point (at a distance of no more than 40 mm from the arc zone, in the direction of weld formation). The use of slot-shaped exhaust devices is recommended.
68. Installations for submerged arc welding shall have: 1) a device for the mechanised feeding of flux into the weld pool; 2) a flux extractor with a storage hopper and a filter (where the air is returned into the premises) for removing used flux from the weld.
69. Installations for submerged arc welding are equipped with mechanised devices for cleaning the slag crust from the weld and simultaneously collecting it. Manual removal of flux may be carried out only in cases where the use of flux extractors is not possible. In such cases, the use of respiratory protective equipment is mandatory.
70. The flux supply and collection system shall provide for the cleaning of the discharged air of dust and gases.
71. The workplaces of welders performing submerged arc welding of pipes and other large-sized structures, including columns, trusses and beams, are equipped with special cabins with a supply air feed, heat and sound insulation of the external surfaces, and a welding process control console.
72. Before performing plasma cutting, the following shall be done: 1) check the operation of the cooling system of the plasma cutting installation; 2) set the required cutting speed; 3) set the flow rate of the plasma-forming medium in accordance with the technological process; 4) check the presence of water in the tray of the cutting table or of the frame of the plasma cutting installation.
73. To protect workers not involved in operating the plasma torch from the visible and ultraviolet radiation of the plasma arc, the plasma torch zone is enclosed with housings or screens made of non-combustible materials. To protect the operators of overhead and other cranes working within sight of the plasma arc, the lower part (one third) of the viewing cabs is glazed with light filters.
74. Rectifying faults in the plasma cutting installation or the plasma torch and replacing failed replaceable parts of the plasma torch may be carried out only with the electric power supply of the installation switched off, and only by adjusters from among the electrical personnel who service the installation and hold an electrical safety group of not lower than III.
75. When the "pilot arc" is ignited, the nozzle opening is directed away from persons working nearby. When the "pilot arc" is ignited by short-circuiting, a special device with an insulated handle at least 150 mm long shall be used.
76. When work is performed under conditions of increased danger of electric shock, workers are provided with appropriate personal protective equipment (dielectric gloves, footwear, mats).
77. Before gas welding and gas cutting work (hereinafter referred to as gas-flame work) is commenced, the workers performing this work check: 1) the tightness of the connection of hoses to the torch, cutter, reducer and safety devices; 2) the serviceability of the apparatus and monitoring instruments (pressure gauges), and the presence of a vacuum in the fuel gas channel of the injector apparatus; 3) the condition of the safety devices; 4) the correctness of the supply of oxygen and fuel gas to the torch, cutter or gas cutting machine; 5) the presence of water in the water seal up to the level of the check cock (plug) and the gas-tightness of all connections in the seal, as well as the tightness of the connection of the hose to the seal; 6) the availability and serviceability of fire extinguishing equipment; 7) the serviceability and verification due date of the pressure gauge on the gas cylinder.
78. Where leaks of oxygen and acetylene from pipelines and gas take-off stations are detected and the faults cannot be rectified quickly, the damaged sections of the pipelines and the gas take-off stations shall be shut off, and the premises shall be ventilated.
79. The thawing of frozen acetylene and oxygen pipelines is carried out only with steam or hot water. The use of open flame and electric heating shall be prohibited.
80. In premises in which gas-flame work is carried out, ventilation is provided to remove the harmful gases released.
81. Gas-flame work, as well as any work using an open flame from other sources, may be carried out at a distance (horizontally) of not less than: 1) from individual cylinders containing oxygen and fuel gases - 5 m; 2) from groups of cylinders (more than 2) intended for gas-flame work - 10 m; 3) from fuel gas pipelines, as well as from gas take-off stations housed in metal cabinets: for manual work - 3 m; for mechanised work - 1.5 m. Where the flame and sparks are directed towards the sources of oxygen and acetylene supply, protective screens made of fireproof material are installed.
82. In the water seal of an acetylene generator, the water level shall be constantly maintained at the height of the check cock (plug). The water level is checked by the worker performing the gas-flame work at least three times per shift, with the gas supply to the seal switched off. At outdoor air temperatures below 0 °C, the water is replaced with a non-freezing liquid. Acetylene generators may be fitted with dry safety seals, which may be operated at outdoor air temperatures above 0 °C.
83. It shall be prohibited to install open-type liquid seals on pipelines for natural gas or propane-butane.
84. Acetylene from a pipeline may be used during gas-flame work only through a station seal. Only one station is connected to one station seal. If a gas take-off station supplies a machine operated by one operator, the number of torches or hoses installed on the machine is limited only by the throughput capacity of the seal. In manual gas-flame work, only one torch or one cutter may be connected to the seal.
85. Air from a shop main with a pressure of more than 0.5 MPa is supplied to the cutter of a thermal machine through a reducer.
86. Where stations for gas-flame work are supplied from gas cylinders, the cylinders are placed in a vertical position in special stands and firmly secured to them with clamps or chains.
87. The stands are equipped with canopies protecting the cylinders from oil falling onto them.
88. Where stations for gas-flame work are supplied from single gas cylinders, safety devices, including flame-arresting ones, are installed between the cylinder reducers and the tools (torches and cutters). The cylinders are placed in a vertical position and secured.
89. During repair or installation work, cylinders containing compressed oxygen may be laid on the ground (floor, platform) subject to the following requirements: 1) the cylinder valves are positioned higher than the cylinder shoes; rolling of the cylinders shall not be permitted; 2) the upper parts of the cylinders are placed on pads with a cut-out, made of wood or other material precluding spark formation. The operation in a horizontal position of cylinders containing gases liquefied or dissolved under pressure (propane-butane, acetylene) shall not be permitted. 3) the valves and reducers on a cylinder shall be protected from contamination and mechanical impact.
90. At a work area for gas-flame work with up to 10 stations, there shall be no more than one spare filled cylinder at each station and no more than ten spare oxygen cylinders and five spare acetylene cylinders at the area as a whole. Where an area with up to 10 stations requires a larger quantity of gas, manifold supply or an intermediate store for keeping cylinders outside the premises of the shop (area) is organised.
91. Oxygen manifolds with up to 6 cylinders for supplying one station for gas-flame work may be installed inside the shop (area). The installation of gas cylinders in places where people pass, loads are moved or vehicles travel shall not be permitted.
92. When operating gas cylinders, it shall not be permitted to use up the gas in them completely. For a specific type of gas, taking into account its properties, the residual pressure in the cylinder is established by the technical documentation of the cylinder manufacturing organisation and shall be not less than 0.05 MPa (0.5 kgf/cm2), unless otherwise provided by the technical specifications for the gas.
93. It shall be prohibited to use gas cylinders with faulty valves or with valves that leak gas.
94. The reducer is connected to a gas cylinder with a special spark-proof spanner, which is kept with the worker at all times. It shall be prohibited to tighten the union nut of the reducer while the cylinder valve is open.
95. To open the valve of an acetylene cylinder and to operate the reducer, the worker shall have a special spark-proof socket spanner. During work, this spanner shall remain on the spindle of the cylinder valve. The use of ordinary spanners to open the valve of an acetylene cylinder and to operate the reducer shall be prohibited.
96. Where gas leakage through the gland of an acetylene valve is detected after the reducer has been connected, the glands are tightened with the cylinder valve closed.
97. During gas-flame work, the valve of an acetylene cylinder is opened by no more than 1 turn to ensure rapid closure of the valve in the event of ignition or gas flashback.
98. When using hoses, the following requirements shall be observed: 1) hoses are used in accordance with their intended purpose: the use of oxygen hoses for supplying acetylene, and of acetylene hoses for supplying oxygen, shall be prohibited; 2) when laying hoses, their flattening, twisting, kinking and crushing by any objects shall not be permitted; 3) where a hose requires repair, its damaged sections are cut out and the individual pieces are joined with special nipples (oxygen hoses are joined with brass nipples, acetylene hoses with steel ones). The minimum length of a section of hose being joined shall be not less than 3 m; the number of joints on a hose shall not be more than two; 4) the points of connection of hoses are carefully checked for tightness by the worker before the start of work and are monitored during the gas-flame work; 5) the fastening of hoses on the connecting nipples of tools and apparatus (torches, cutters, reducers) shall be secure: special clamps are used for this purpose; 6) sparks falling onto hoses, as well as the action of fire and high temperatures on them, shall not be permitted; 7) at least once a month, hoses are subjected to inspection and testing in accordance with the procedure established by the employer's local regulatory act.
99. Metal arriving for gas-flame treatment is cleaned of paint (particularly lead-based paint), oil, scale and dirt to prevent spattering of the metal and contamination of the air with vapours and gases.
100. In the gas-flame treatment of painted or primed metal, the metal is cleaned along the line of the cut or weld. The width of the strip cleaned of paint shall be not less than 100 mm (50 mm on each side). The use of a gas flame for this purpose shall be prohibited.
101. When lighting a hand torch or cutter, the oxygen valve is first opened slightly (by 1/4 or 1/2 of a turn), then the acetylene valve is opened, and after brief purging of the hose the gas mixture is ignited.
102. If the torch or cutter overheats, work is suspended, and the torch or cutter, after its valve has been closed, is cooled until completely cold. A vessel with clean cold water shall be present at the workplace for cooling the torch or cutter.
103. Cleaning of weld seams after the completion of gas-flame work may be commenced only after the working area has been aired with the use of forced ventilation or, where forced ventilation is absent, not earlier than 15-20 minutes afterwards.
104. During breaks in work and at the end of the work shift, the welding equipment is switched off, the hoses are disconnected, and the pressure in blowlamps is fully released.
105. During long breaks in work, in addition to the torches and cutters, the valves at the gas take-off stations, on the apparatus and on the cylinders are closed, and the pressure screws of the reducers are unscrewed until the springs are released.
106. In the event of a flame flashback, the valves (first the acetylene valve, then the oxygen valve) on the cutter, the gas cylinders and the water seal shall be closed immediately. Before the flame is lit again after a flashback, the condition of the water seal and of the gas supply hoses is checked, and the cutter is cooled in a bucket of clean cold water. After each flashback, the worker makes a corresponding entry in the generator's passport.
107. Where gas-flame work is temporarily stopped, the supply of gas to the equipment is suspended.
108. It shall be prohibited to carry out gas-flame treatment with an open flame on equipment under pressure (boilers, pipelines, vessels, cylinders, tanks, drums), as well as on vessels and pipelines filled with combustible, flammable, explosive and toxic liquids and substances.
109. During the installation and repair of vessels, gas-flame work may be carried out at sub-zero ambient air temperatures, provided that the requirements set out in the technical documentation of the manufacturing organisation are complied with.
110. Gas-flame work in confined spaces and hard-to-reach places (tunnels, basements, reservoirs, boilers, tanks, compartments, wells, pits) is performed under a permit to work for work of increased hazard.
111. Before gas-flame work is performed in confined spaces and hard-to-reach places, the following requirements shall be fulfilled: 1) the air of the working area has been checked for the content of harmful and hazardous substances in it and for the oxygen content; 2) the presence of at least two open openings (windows, doors, hatches, portholes, neck openings) has been ensured; 3) continuous operation of local supply and exhaust ventilation has been ensured for the inflow of fresh air and the removal of contaminated air from the lower and upper parts of the confined space or hard-to-reach place; 4) a monitoring post (of at least two workers) has been established to observe the safe performance of the gas-flame work. The monitoring post shall be located outside the confined space or hard-to-reach place to render assistance to the workers performing the gas-flame work.
112. When gas-flame work is performed in confined spaces and hard-to-reach places, welding transformers, acetylene generators and cylinders with liquefied or compressed gas are placed outside the confined spaces and hard-to-reach places in which the gas-flame work is carried out.
113. When gas-flame work is performed in confined spaces, it shall be prohibited: 1) to use apparatus operating on liquid fuel; 2) to use petrol cutters; 3) to leave torches, cutters and hoses unattended during a break or after the completion of work.
114. When gas-flame work is performed, acetylene generators shall be installed in open areas. They may be temporarily installed in ventilated (aired) premises. Acetylene generators are fenced off and placed at a distance of at least 10 m from the place where the gas-flame work is carried out, as well as from the air intake points of compressors and fans. At the places where acetylene generators are installed, signs shall be posted: "No entry for unauthorised persons - fire hazard", "No smoking", "Do not pass with open flame". When operating acetylene generators, the safety measures specified in the technical documentation of the manufacturing organisation shall be observed.
115. When performing gas-flame work, it shall be prohibited: 1) to thaw frozen acetylene generators, valves, reducers and other parts of welding installations with an open flame or red-hot objects; 2) to use tools made of spark-forming material for opening drums containing calcium carbide; 3) to load calcium carbide of oversize granulation into the loading devices of portable acetylene generators; 4) to load calcium carbide into wet loading devices; 5) to move an acetylene generator while there is acetylene in the gas holder; 6) for two workers to work from one safety seal; 7) to force the operation of an acetylene generator; 8) to allow contact of cylinders, as well as of gas supply hoses, with live wires; 9) to allow contact of oxygen cylinders, reducers and other welding equipment with various oils, as well as with oil-soaked clothing and rags; 10) to purge acetylene hoses with oxygen and oxygen hoses with acetylene; 11) to use gas supply hoses whose length exceeds 30 m, and 40 m in construction and installation work; 12) to stretch, twist, kink or pinch gas supply hoses; 13) to use oil-contaminated gas supply hoses; 14) to perform gas-flame work when the ventilation is not operating; 15) to perform gas-flame work inside tanks at an air temperature above 50 °C without the use of isolating personal protective equipment ensuring effective heat protection and the supply of clean air to the breathing zone; 16) to use propane-butane mixtures and liquid fuel when performing gas-flame work in confined and hard-to-reach premises; 17) to allow unauthorised persons to be present in places where gas-flame work is performed.
116. Upon the completion of gas-flame work, the calcium carbide in the acetylene generator shall be used up. The lime sludge removed from the generator is discharged into containers adapted for this purpose and emptied into a sludge pit. Open sludge pits shall be fenced with railings. Closed sludge pits shall be equipped with exhaust ventilation and with hatches for the removal of sludge, and shall have a non-combustible cover. Smoking and the use of open flame within a radius of 10 m of the sludge storage place shall be prohibited. To give notice of the prohibition of smoking and of the use of open flame, corresponding prohibition signs are posted.
117. After the completion of work: 1) it shall not be permitted to leave open the valves of any of the cylinders; the gases shall be released from all lines and the pressure springs of all reducers shall be released; 2) the cylinders shall be disconnected from the lines leading into the premises; 3) from cylinders used in the open air, all apparatus shall be removed, the hoses disconnected and taken to the storage place.
118. The premises in which containers with liquefied carbon dioxide or gas manifolds are placed shall be ventilated. The air temperature in the premises shall not exceed 25 °C.
119. No more than 20 cylinders may be placed at the area for supplying carbon dioxide to welding stations. It shall be prohibited to place extraneous objects and combustible substances at the area for supplying carbon dioxide to welding stations.
120. When replacing empty gas cylinders with filled ones, the valves of the gas cylinders and of the header shall be closed.
121. Gas leakage at connection points shall not be permitted where gas cylinders are arranged in a manifold. Gas leakage is rectified with the valves of the gas cylinders closed and with no pressure in the system.
122. The heater (where welding stations are centrally supplied with carbon dioxide from containers or a manifold system) is supplied with hot water or steam.
123. While gas is being drawn from a container, it shall be prohibited: 1) to carry out repair operations; 2) to warm pipes and apparatus with an open flame; 3) to kink flexible connecting hoses; 4) to tighten connections under pressure.
124. During welding in open areas (outside the shop) in winter, cylinders with carbon dioxide are placed in insulated premises to prevent freezing.
125. It shall be prohibited to thaw a frozen cylinder (or reducer) containing carbon dioxide with a torch flame or a jet of steam. To thaw a cylinder containing carbon dioxide (or a reducer), the drawing of gas from the cylinder shall be stopped, and the cylinder shall be brought into a warm room with a temperature of 20-25 °C and left until warm. A frozen reducer may be thawed with water at a temperature not exceeding 25 °C.
126. To prevent the freezing of carbon dioxide in the reducer, a heater is installed upstream of the reducer. The electric coil of the gas heater installed at the reducer of a cylinder containing carbon dioxide shall not be in contact with the gas cylinder. The heater is powered from an electrical mains supply with a voltage of not more than 42 V and a power of not more than 70 W, precluding the possibility of heating the gas cylinder.
127. The premises in which vessels with liquefied argon, containers or manifolds are placed shall not have a process storey (basement) or recesses of more than 0.5 m in the floor covering.
128. During the operation of a container with liquefied argon, the following requirements shall be observed: 1) the container is emptied by means of an evaporator; 2) valves are opened and closed smoothly, without jolts or impacts; 3) the tightening of bolts and glands on valves and pipelines under pressure shall not be permitted; 4) hoses are disconnected after the argon has evaporated completely; 5) contact of liquid argon with a worker's skin shall not be permitted, to avoid frostbite; 6) when disconnecting hoses, workers shall not stand opposite them, as an ejection of gaseous or droplet argon from the hose is possible.
129. During the operation of containers (storage vessels) and manifolds for the centralised supply of argon, the serviceability of all safety fittings is monitored. Safety valves shall be adjusted, sealed and kept clean.
130. The degreasing of surfaces to be welded shall be carried out with safe water-based cleaning agents.
131. When degreasing surfaces to be welded with organic solvents (acetone, white spirit, ethyl alcohol), the following requirements shall be observed: 1) degreasing is carried out in a separate room equipped with supply and exhaust ventilation and fire extinguishing equipment; 2) solvents with antistatic additives are used for degreasing; 3) degreasing is carried out by a mechanised method; 4) in manual degreasing, the washing of parts with fire-hazardous organic solvents is carried out in special cabinets made of non-combustible materials, inside which metal baths or tables are installed. Ventilation exhausts are arranged above the baths or tables and in the upper part of the cabinets, and the bodies of the baths are earthed; 5) in manual degreasing by wiping, antistatic materials are used; 6) it shall not be permitted to use electric heating appliances or to carry out work involving the formation of sparks and flame.
132. When degreasing surfaces to be welded, it shall be prohibited: 1) to wipe with solvents the edges of items heated to a temperature above 45 °C; 2) to use trichloroethylene, dichloroethane and other chlorine-containing hydrocarbons for degreasing.
133. Used wiping materials (swabs) shall be collected in a special vessel made of unbreakable and non-combustible material with a tightly closing lid.
134. The cleaning and repair of equipment for degreasing surfaces to be welded that contains residues of organic solvents shall be carried out after the equipment has been purged with air or steam until the solvent vapours have been completely removed. During purging, ventilation devices are switched on to prevent contamination of the air in the room with organic solvent vapours.
135. In the storage of raw materials, blanks, semi-finished products, finished products and production waste, the following is provided for: 1) the use of storage methods precluding the occurrence of harmful and hazardous production factors and pollution of the environment; 2) the use of safe storage devices; 3) the mechanisation and automation of loading and unloading operations.
136. In the transportation of raw materials, blanks, semi-finished products, finished products and production waste, the following is ensured: 1) the use of safe transport routes; 2) the use of means of transportation precluding the occurrence of harmful and hazardous production factors; 3) the mechanisation and automation of transportation processes.
137. Raw materials (metal, welding wire, electrodes, fluxes, liquids, solvents) are stored in covered dry premises in accordance with the requirements of the manufacturing organisation's technical documentation for the storage of the specific material. The presence in the air of storage premises of vapours of alkalis, acids and other aggressive substances shall not be permitted.
138. Before being issued for work, welding materials are calcined or dried according to the regimes appropriate to them, in accordance with the technical documentation of the manufacturing organisation.
139. During storage, cylinders containing gases are protected from the action of sunlight and other heat sources. Cylinders installed in premises are placed at a distance of not less than 1.5 m from heating appliances and not less than 5 m from heat sources with an open flame and from furnaces.
140. Cylinders that do not have shoes shall be stored in a horizontal position on frames or racks. In this case, the height of the stack shall not exceed 1.5 m. The valves (stop valves) of the cylinders are closed with safety caps and shall face in one direction.
141. Empty gas cylinders shall be stored separately from cylinders filled with gases.
142. When handling empty cylinders that have contained oxygen or fuel gases, the same safety measures shall be observed as when handling filled cylinders.
143. Upon the completion of work, cylinders containing gases are placed in a place specially designated for the storage of cylinders, precluding access by unauthorised persons.