RISK ASSESSMENT

TITLE: USE OF OXYGEN AND ACETYLENE IN WELDING B.I. SHEET

CONTRACTOR/SUBCONTRACTOR:
.
Oxyacetylene Welding is process for joining two pieces of metal in which the
required high temperature is obtained by the combustion of acetylene gas and
oxygen. The gases are thoroughly mixed in the nozzle or tip of the welding torch
to ensure perfect combustion.

The weld may be formed directly between two adjoining surfaces, but
usually metal from a welding rod is fused in between the surfaces of the
joint.
Oxyacetylene Cutting is a process where the nozzle temperatures are increased
to burn through the material.

Acetylene (C2H2) is extremely flammable and can form and explosive mixture
with air, flammability range 2.4-88 vol% in air. Lighter than air.

Oxygen (O2) Oxidant which also supports combustion and is heavier than air.
Increase levels of oxygen in low ventilated areas or confined spaces are
extremely hazardous.

Job Sequence Hazard Identification Controls

Pre-operational safety Competence & Training Only competent and trained staff are permitted to use
checks & Maintenance oxy – acetylene for welding or cutting. They must be
familiar with the equipment and this risk assessment
and be able to carry out the pre-use checks.

Always inspect the equipment before use, ensure that

Leaking valves or damaged the valves are fitted and secured correctly and
hoses completely close of the gas supply when closed, also
inspect hoses for any signs of damage before use.

Please refer to the production risk assessment covering

gas cylinders. Both compressed cylinders associated
Storage and use of compressed with this process should be secured at all times. When
cylinders. Buildup of an not in use they should be stored in an external cage.
explosive atmosphere with
potential for a confined vapour This equipment should not be left during in non-
cloud explosion from accidental working hours in workshops or on stages and should
release of acetylene gas be stored in the external cylinder cages provided.

On all occasions and at all times in use cylinders to be

housed in chained trolleys.

Oils/greases prohibited for lubrication of oxygen

equipment.
Only replacement parts specifically designed for
Cleaning & maintenance of oxygen use permitted
equipment
Explosive environments and/or enhanced fire/explosion Cylinders on all occasions to be transported in suitable
from release of oxygen to cylinder trolleys by staff trained in manual handling
atmosphere through: techniques;
Cylinders located away from all sources of heat and
flammable materials minimum distance three meters.
 leaks in hose, joints, hose Regulators, gauges, hoses, connections, hose
connections and fittings assemblies, blowpipes, safety devices, etc compliant
with OSH Standards (all inspections to be recorded).
faulty flashback arrestor
Regulators and flame arrestors serviced or replaced
faulty non-return valves every 5 years, and inspected annually by a competent
person and inspection recorded
flashback from blowpipe
Maintenance and examinations of equipment by
damage to cylinder competent person; (all details to be recorded).

damage to regulator Dedicated LEV system for indoor welding equipment,

subjected to annual inspection/testing in accordance
with statutory requirements (all testing/inspections to
be recorded).

Acetylene equipment must not contain copper or come

into contact with silver or mercury which could form
explosive acetylides (any acetylene-derived compound
containing a metal atom, often very explosive).

With LEV in operation hoses are purged of any

flammable mixtures of gases before blowpipe is lit;
Equipment must not be used above manufacturer’s
recommended pressures.

House Keeping Damage to equipment Hoses to be kept clear of sharp edges and abrasive
surfaces, metal splatter to hoses to be avoided, the
correct gas pressures and nozzle size for the job to be
used.

Fire / Flammable Materials Remove all possible combustible material from welding
area, protection for any combustible materials that
cannot be moved from close contact with flame, heat,
sparks or hot slag.

Oil/grease must not come into contact with oxygen

valves or cylinder fittings. No flammable substances
stored within the welding area. Dedicated flammable
storage cupboard

A hot works permit must be in place for these works

and the conditions of the hot work permit complied
with.

No Smoking is permitted in any internal buildings or

Ignition sources
adjacent to these activities. The welding area should be
surrounded by curtain screens.

No welding operations within immediate vicinity of any

abrasive wheel grinding or other process creating
sparks.

Electrical equipment Earthing to LEV ducting to prevent static build up

All portable electric hand tools DOLE certificated

Transportation & Disposal Safe transportation When transporting compressed cylinders, they should
be isolated from valves and secured with chains.

There should be good ventilation and appropriate

markings on the vehicles to inform the
emergency services about what cylinders are on
the vehicle.
 Cylinders must only be disposed or filled by competent
suppliers.
Safe storage of compressed Build-up of explosive Natural ventilation, bottles shielded from direct
cylinders environments. sunlight. Gas bottles securely chained whilst in store.

No other activities to be undertaken in cylinder store.

Cylinder store located away from all sources of heat and

flammable materials, minimum distance three meters.
Ignition sources
No electrical equipment permitted within the
store other than intrinsically safe light fittings, no
naked flames, surfaces or sources of mechanical
energy.
Personal Protective Eyes & face protection A suitable welding shield should be used which protects
Equipment the skin and eyes from UV and light created.

Suitable RPE should be used when using this equipment

Respiratory protective in internal areas or where there is poor ventilation.
equipment Dust masks are not suitable as welding fume consists of
very small particles of condensed vapour.

These particles penetrate dust respirator filters more

easily than larger dust particles and reduce the
effectiveness of filters.

Overalls should be worn which are fire retardant and

cover the arms and neck, hand protection should also be
Overalls, gloves and foot wear. used. Safety boots should also be worn.

First Aid Information for the production medical support is

displayed in workshops and stages.

All accidents must be reported to the production safety

department.

Project Engineer/Safety Officer: Noted By: