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idWelding, Joining, and Thermal Cutting Safety
Card
labelBrief

Title:

Welding, Joining, and Thermal Cutting Safety

Publication date:

8/14/2020

Effective date:

8/14/2020

BRIEF

Policy Summary

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).

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:

ES&H Manual Chapter 33

Contact Information

EHS Subject Matter Expert for Welding
Environment, Health, and Safety (EHS) Division

Card
labelPolicy

Title:

Welding, Joining, and Thermal Cutting Safety

Publication date:

8/14/2020

Effective date:

8/14/2020

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 or 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 hazards analysis 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 the EHS Welding Subject Matter Expert.
  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 the:
    1. Work Planning and Control activity.
    2. Hot Work Permit.
    3. Exposure Assessment.
    4. Division-specific welding procedures.
  8. Perform the 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 and 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.

Activity leads

Ensure that only qualified and authorized workers perform welding, and that the authorizations are documented in Activity Manager.

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 (e.g., water, nonhazardous gas, and 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 WPC 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 Z49.1:2012, 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

EHS Subject Matter Expert for Welding
EHS 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

12/4/2018

1.2

H. Toor

Update ANSI standard to 2012

Other references

Minor

8/15/2020

1.3

H. Toor

Reference update to Cal/OSHA to reflect 10 CFR 851 variance

Source requirements

Minor

Card
labelDocument Information

DOCUMENT INFORMATION

Title:

Welding, Joining, and Thermal Cutting Safety

Document number

07.07.031.000

Revision number

1.3

Publication date:

8/14/2020

Effective date:

8/14/2020

Next review date:

8/14/2025

Policy Area:

Industrial Hygiene and Safety

RPM Section (home)

ESH

RPM Section (cross-reference)

none

Functional Division

EHS

Prior reference information (optional)

ES&H Manual, Chapter 33

Source Requirements Documents

  • 10 CFR 851, Worker Safety and Health Program
  • California Code of Regulations, Title 8, Electrical Safety Orders (ESO), General Industry Safety Orders (GISO), and Construction Safety Orders (CSO)
    • ESO Group 1. Low-Voltage Electrical Safety Orders (Sections 2299–2599)
    • GISO 5150, Ventilation and Personal Protective Equipment Requirements for Welding, Brazing and Cutting
    • GISO 4850–4853, Electric Welding, Cutting, and Heating
    • GISO 4794–4848, Gas Systems for Welding and Cutting
    • GISO 3380–3400, Personal Protective Equipment
    • CSO 1530, General Requirements of Mechanical Ventilation Systems
    • CSO 1536, Ventilation Requirements for Welding, Brazing, and Cutting
    • CSO 1537, Welding, Cutting, and Heating of Coated Metals
  • National Fire Protection Association (NFPA) 51B-2009 Standard for Fire Prevention During Welding, Cutting, and Other Hot Work (Chapters 3–7)

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 WPC 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 Z49.1:2012, 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
Show If
grouprpm2-admins
Card
labelAdditional Information

ADDITIONAL INFORMATION

Title:

Welding, Joining, and Thermal Cutting Safety

Document number

07.07.031.000

Revision number

1.3

Publication date:

8/14/2020

Effective date:

8/14/2020

Next review date:

8/14/2025

Policy Area:

Industrial Hygiene and Safety

RPM Section (home)

ESH

RPM Section (cross-reference)

none

Functional Division

EHS

Author name/contact info

H. Toor



Revision 0 publication date

8/25/2010

Retirement date

n/a

Prior reference information (optional)

PUB-3000, Chapter 33



Inputs from more than one Functional Area?

No

List additional Functional Areas & contacts




Inputs from more than one Policy Area?

No

List additional Policy Areas & contacts




30-day notification needed?

No

30-day start date

n/a

30-day end date

n/a



LDAP protected?

No



Need TABL reminders?

No

Frequency

n/a

Brief reminder text:

n/a



Approval Sheet for this revision received (date) [Note: author is responsible}


Keyword search words, phrases:

  • Weld, welding, torch brazing, braze, brazing, solder, soldering, thermal cutting, hot work, hot work permit, fabricating, spot welding, high-risk weld, low-risk weld, resistance spot welding, open-flame welding, arc-welding

New terms that need to be added to Glossary/Acronym list:

  • (list items not found and context (Policy Area name) – full definition would be included in Policy)

Implementing Documents restricted to department/functional use

Document number

Title

Type

ANSI Z49.1:2012

Safety in Welding, Cutting, and Allied Processes

Consensus Standard

ANSI/ASSE Z87.1:2003

Occupational and Educational Personal Eye and Face Protection Devices

Consensus Standard

ANSI Z87.1:1989

American National Standard Practice for Occupational and Educational Eye and Face Protection

Consensus Standard

Side bars:
Side bar 1 location (cite by Policy Section # - for example: Section 4.E.2)

Sidebar 1 text:

Sidebar 2 location

Sidebar 2 text:

Sidebar 3 location

Sidebar 3 text: