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Welding, Joining, and Thermal Cutting Safety

    Title:

    Welding, Joining, and Thermal Cutting Safety

    Publication date:

    9/10/2013

    Effective date:

    8/25/2010

    BRIEF

    Policy Summary

    The Welding, Joining, and Thermal Cutting Safety Program at Berkeley Lab ensures that welding is performed safely and in conformance with applicable safety standards by qualified and authorized personnel in a manner that ensures acceptable joint quality and integrity.
    "Welding" includes all joining processes that use heat to join materials with or without a filler material. Examples of such processes are welding, brazing, soldering, and thermal cutting (e.g., severing or removing metal by localized melting, burning, or vaporizing of the work pieces).

    Who Should Read This Policy

    This policy applies to:

    • Employees who need welding work performed
    • Facilities personnel who will be welding
    • Engineering personnel who will be welding
    • Division personnel performing low-risk welding
    • Facilities management overseeing welding operations
    • Engineering management overseeing welding operations
    • Division management overseeing low-risk welding operations

    To Read the Full Policy, Go To:

    The POLICY tab on this wiki page

    To Read the ES&H Program Details, Go To:

    http://www.lbl.gov/ehs/pub3000/CH33.html

    Contact Information

    Welding Subject Matter Expert
    EH&S Division

    Title:

    Welding, Joining, and Thermal Cutting Safety

    Publication date:

    9/10/2013

    Effective date:

    8/25/2010

    POLICY

    A. Purpose

    The Welding, Joining, and Thermal Cutting Safety Program at Lawrence Berkeley National Laboratory (Berkeley Lab) ensures that welding is performed safely and in conformance with applicable safety standards by qualified and authorized personnel in a manner that ensures acceptable joint quality and integrity.

    "Welding" includes all joining processes that use heat to join materials with or without a filler material. Examples of such processes are welding, brazing, soldering, and thermal cutting (e.g., severing or removing metal by localized melting, burning, or vaporizing of the work pieces).

    B. Persons Affected

    This policy applies to:

    • Employees who need welding work performed
    • Facilities personnel who will be welding
    • Engineering personnel who will be welding
    • Division personnel performing low-risk welding
    • Facilities management overseeing welding operations
    • Engineering management overseeing welding operations
    • Division management overseeing low-risk welding operations

    C. Exceptions

    This policy does not apply to:

    • Subcontractors performing repairs on subcontractor-owned equipment that may be operated at Berkeley Lab. Note that other Berkeley Lab requirements apply to these same subcontractors. See the Construction Health & Safety and sJHA Process – Subcontractor Job Hazards Analysis programs in the ES&H Manual.
    • Subcontractors performing welding where quality and safety requirements are specifically addressed in subcontractor requirements (e.g., structural welding, fabricating components or equipment)

    D. Policy Statement

    1. Requests for welding through the Facilities Division are made via the Work Request Center
      1. The Facilities Division will follow its internal welding procedures (ADMN-070, Facilities, Welding and Brazing, and OPER-346, Facilities Welding and Brazing).
    2. Requests for welding on scientific equipment are made to the Engineering Division.
      1. The Engineering Division will follow its internal welding procedure.
      2. An Engineering or Safety Note will be prepared for high-risk welds.
    3. Perform a Job Hazards Analysis (JHA) and follow Integrated Safety Management (ISM) to identify hazards and controls for low-risk welding (e.g., soldering, spot welding, and torch brazing).
      1. Should a scientific division need to perform other types of welding, specific policies and procedures should be developed and implemented with the oversight of Environment, Health & Safety (EH&S) Welding Subject Matter Expert Joe Dionne (ext. 7586).
    4. Obtain a Hot Work Permit for:
      1. Resistance spot welding
      2. Open-flame welding processes
      3. Arc-welding processes
    5. Perform an Exposure Assessment prior to performing welds to ensure vapors, fumes, gases, heat, noise, and radiation are controlled.
    6. Complete training requirements for welding to be performed.
    7. Implement control measures identified in:
      1. JHA
      2. Hot Work Permit
      3. Exposure Assessment
      4. Division-specific welding procedures
    8. Perform welding process according to control measures.
    9. File Hot Work Permits with the Berkeley Lab Fire Department.

    E. Roles and Responsibilities

    Managers, supervisors, and employees have the responsibility to adhere to the provisions of this policy.

    Role

    Responsibility

    Division Directors

    • Ensure that welding performed in their divisions is done in accordance with the Welding, Joining, and Thermal Cutting Safety Program, and only by individuals qualified and authorized to do so
    • Ensure that documented processes are used to authorize individuals within their divisions to request welds, weld plans, assign risk categories, and/or perform welding

    Engineering Division

    Performs high-risk welded joints on research equipment and assemblies

    Engineering Division Director

    • Designates qualified welding engineers (see Section 33.5, Roles and Responsibilities), or procures these services from a qualified vendor to provide welding guidance for research applications
    • Ensures the review and approval of high-risk welding designs for research equipment or assemblies prepared by vendors and Berkeley Lab personnel

    Facilities Division

    Responsible for high-risk joints (see Section 33.6, Definitions) performed on Berkeley Lab infrastructure (e.g., buildings, utility piping systems, seismic restraints, etc.)

    Facilities Division Director

    • Ensures that qualified welding engineers (see Section 33.5, Roles and Responsibilities) provide welding guidance for building or infrastructure applications
    • Ensures the review and approval of high-risk welding designs for building infrastructure, equipment, or assemblies prepared by vendors and Berkeley Lab personnel

    Designated Welding Engineers

    Designated welding engineers specialize in relevant welding codes, welding design, welding drawing standards, material properties, and quality aspects of welds. A welding engineer may be appointed by his or her division director as a designated welding engineer. Welding engineering services can be procured from external vendors (e.g., Consolidated Engineering, Inc.).
    Designated welding engineers are responsible for:

    • Providing Berkeley Lab staff with advice and guidance on weld integrity and welding codes compliance
    • Reviewing and approving welding-related designs/drawings on behalf of their respective division directors

    Work Leads

    Ensure that only qualified and authorized workers perform welding, and that the authorizations are documented in the JHA

    Environment, Health & Safety Division

    • Provides guidance to Berkeley Lab staff on welding-related occupational safety and health hazards and the graded approach, and assists divisions in developing welding policies and procedures
    • Assists divisions in assessing worker exposures to hazardous airborne agents and safety hazards during welding, as requested by workers and/or work leads or division safety coordinators

    F. Definitions/Acronyms

    Term

    Definition

    High-risk welded joint

    A welded joint that, if it fails, has the potential to cause severe injury or death, and/or the release of hazardous materials. Joints on engineered seismic bracing and pressure vessels typically contain high-risk joints.

    Low-risk welded joint

    A welded joint that, if it fails, does not have a recognized potential to cause injury. The risk of property damage due to such a failure is nil to moderate. Examples include welded joints on lower-value equipment, and welding of most plumbing systems (water, nonhazardous gas, vacuum).

    Welding

    Processes that use heat to join materials with or without a filler material. Examples of such processes are welding, brazing, soldering, and thermal cutting (e.g., severing or removing metal by localized melting, burning, or vaporizing of the work pieces).

    G. Recordkeeping Requirements

    None

    H. Implementing Documents

    Document Number

    Title

    Type

    07.07.031.001

    Welding, Joining, and Thermal Cutting Safety

    Program

    07.07.031.002

    Work Process A, Welds Requiring a Facilities Work Request

    Process

    07.07.031.003

    Work Process B, Welds for Scientific Research Equipment

    Process

    07.07.031.004

    Work Process C, Low-Risk Welds Using ISM and JHA Processes

    Process

    07.07.031.005

    Work Process D, Hot Work Permit and Associated Controls

    Process

    07.07.031.006

    Work Process E, Exposure Assessment

    Process

    07.07.031.007

    Work Process F, Training

    Process

    07.07.031.008

    Work Process G, Hazard Control

    Process

    07.07.031.009

    Work Process H, Safe Work Processes

    Process

    I. Other References

    • ANSI Z49.1:1999, Safety in Welding, Cutting, and Allied Processes
    • ANSI Z49.1:2005, Safety in Welding, Cutting, and Allied Processes
    • ANSI/ASME Z87.1:2003, Occupational and Educational Personal Eye and Face Protection Devices
    • ANSI Z87.1:1989, American National Standard Practice for Occupational and Educational Eye and Face Protection

    J. Contact Information

    Welding Subject Matter Expert
    EH&S Division

    K. Revision History

    Date

    Revision

    By whom

    Revision Description

    Section(s) affected

    Change Type

    9/10/2013

    1.1

    D.Best

    Reviewed 8/29/2013

    Publ & Next Review Dates

    Minor

    1/2/2012

    1

    J. Dionne

    Rewrite for wiki

    all

    Minor

    DOCUMENT INFORMATION

    Title:

    Welding, Joining, and Thermal Cutting Safety

    Document number

    07.07.031.000

    Revision number

    1.1

    Publication date:

    9/10/2013

    Effective date:

    8/25/2010

    Next review date:

    9/10/2016

    Policy Area:

    Industrial Hygiene and Safety

    RPM Section (home)

    ESH

    RPM Section (cross-reference)

    none

    Functional Division

    EH&S

    Prior reference information (optional)

    PUB-3000, Chapter 33

    Source Requirements Documents

    • 10 CFR 851, Worker Safety and Health Program 
    • 29 CFR 1910, Subpart I, Personal Protective Equipment
    • 29 CFR 1910, Subpart Q, Welding, Cutting and Brazing
    • 29 CFR 1926, Construction, Subpart J, Welding and Cutting
    • 29 CFR 1926, Safety and Health Regulations for Construction, Subpart E, Personal Protective and Life Saving Equipment

    Implementing Documents

    Document Number

    Title

    Type

    07.07.031.001

    Welding, Joining, and Thermal Cutting Safety

    Program

    07.07.031.002

    Work Process A, Welds Requiring a Facilities Work Request

    Process

    07.07.031.003

    Work Process B, Welds for Scientific Research Equipment

    Process

    07.07.031.004

    Work Process C, Low-Risk Welds Using ISM and JHA Processes

    Process

    07.07.031.005

    Work Process D, Hot Work Permit and Associated Controls

    Process

    07.07.031.006

    Work Process E, Exposure Assessment

    Process

    07.07.031.007

    Work Process F, Training

    Process

    07.07.031.008

    Work Process G, Hazard Control

    Process

    07.07.031.009

    Work Process H, Safe Work Processes

    Process

    Other References

    • ANSI Z49.1:1999, Safety in Welding, Cutting, and Allied Processes
    • ANSI Z49.1:2005, Safety in Welding, Cutting, and Allied Processes
    • ANSI/ASME Z87.1:2003, Occupational and Educational Personal Eye and Face Protection Devices
    • ANSI Z87.1:1989, American National Standard Practice for Occupational and Educational Eye and Face Protection

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