Rules of labor protection during welding. Organization of safe electric welding work
7 Occupational health and safety at work
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General safety requirements.
An electric welder, starting work, must check the availability and serviceability of equipment, grounding devices, protective fences and devices.
The electric welder and the auxiliary worker are obliged to keep clean and tidy workplace, notclutter up passages and driveways, stack workpieces and finished goods in designated places.
An electric welder and an auxiliary worker is prohibited from:touch the electrical wiring and housings of operating electric motors installed on the equipment;
independently connect electric welding equipment to electrical network;
stand under a lifted and moved load;
carry out work, smoke in workshops, at the workplace and in areas where flammable materials and gases are used and stored.
The electric welder and auxiliary workers are required to know the rules and techniques for providing first aid to the victim.
Safety requirements before starting work.
Before starting work, the electric welder must put on overalls, safety shoes, a hat, gloves (if necessary, take special safety measures against electric shock - dielectric gloves) and protective equipment (helmet, shield).
An electric welder is allowed to perform work in the presence of personal protective equipment.
Under special working conditions at the workplace of an electric welder (the presence of additional harmful or dangerous production factors), it is necessary to use additional personal protective equipment against the effects of these factors.
To protect the eyes and face from the harmful effects of radiant arc energyChange
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a helmet or visor with special light filters should be used in accordance with the strength welding current: E-1 - up to 74A, E-2 - from 75 to 200A, E-3 - from 290 to 2400A or previously produced light filters ES-100, ES-300 and ES-500.
To protect against splashes of molten metal, the light filters are covered with colorless glasses, which become contaminated during operation and must be replaced. The electric welder is forbidden to work with damaged glass or shield.
Handy workers working together with welders, depending on the working conditions, should wear masks or goggles with light filters used in welding.
The electric welder should have a light box made of non-conductive material for storing and carrying tools and electrodes.
The electrician must:
check the reliability of the contacts of the grounding conductors with the bodies of welding units, transformers and automatic machines, metal frames power distribution boards, auxiliary equipment, as well as with welding tables, plates, stands, etc.;
connect the grounding wires of each device directly to the grounding system (it is forbidden to use the grounded case of one device to ground another);
check the serviceability of magnetic starters, switches and other starting devices, as well as the insulation of current-carrying wires so that if they are accidentally touched, electric shock does not occur;
check the illumination of the workplace; in case of insufficient lighting of the welding place, it is allowed to use a portable electric lamp with a voltage not exceeding 42 or 12 V (respectively, under conditions of increased danger of electric shock and especially dangerous conditions) with a protective grid that protects the bulb of the electric lamp from damage, an insulated handle and a serviceable wire havingChange
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double insulation.
Before starting work, the electric welder must turn on the ventilation, and when working in common areas, install a fence around the welding site with portable shields or screens.
on less than three sides.
In case of malfunctions in electrical equipment, an electrician should be called. It is forbidden to remove them on your own.
If it is necessary to work outdoors, protective canopies are installed above the welding equipment to protect the workplace of the electric welder from rain and snow.
It is forbidden to place electric welding wires near acetylene and oxygen hoses.
Wires laid through doors, hatches and various openings must be protected from mechanical damage using wooden boxes or pipes.
Safety requirements during work.
In the process of performing work, hands, shoes and clothes should always be dry.
It is necessary to work with a serviceable electric holder, the handle of which is made of fire-resistant insulating material.
During a break in work, the electric welding installation is de-energized, and the electric holder is suspended on a special tripod.
It is forbidden for an electric welder to independently connect welding transformers and other welding equipment to the mains (this is the responsibility of an electrician).
The parts to be welded must be dry, free from rust and dirt.
Repair containers and weld tanks that were used for storage and transportation liquid fuel, flammable liquid or gas, only after thorough cleaning and flushing hot water with caustic soda, steaming and drying. When welding inside the container, lighting is used from a source with a voltage not higher thanChange
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12 V.
Welding work is carried out with open hatches, plugs and necks with mandatory forced ventilation. The electric welder must periodically take breaks in work and leave the tank. When welding inside the tank, an observer is required to monitor compliance with safety requirements and take measures to assist the electric welder in case of an accident.
When changing the workplace, it is prohibited to drag electrical wires along the floor or ground. You should roll them into a bay.
When working at a height where there are loose objects, no people are allowed under the place of work. It is necessary to have a safety belt and a bag for storing tools, electrical wires and cinders.
The electrician is prohibited from:
work without a helmet, protective shield or goggles with appropriate light filters (this requirement also applies to auxiliary workers);
open and remove the guards of current-carrying parts of the equipment;
repair welding equipment;
weld apparatuses, vessels and pipelines under pressure;
carry out welding and cutting at a distance of less than 5 m from flammable or flammable materials and objects.
Safety requirements in emergency situations.
In case of noticed malfunctions of the equipment and tools used or the occurrence of an emergency during the performance of work, the worker must:
stop working;
warn workers of the danger;
notify the work manager and contribute to the elimination of the emergency, as well as its investigation in order to develop emergency response measures;
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carry out the elimination of the most urgent malfunctions in compliance with safety requirements in accordance with the instructions for labor protection;
in case of an accident, provide first aid to the victims and immediately notify the work manager (head of the unit), preserving the situation in which the accident occurred.
Measures fire safety.
An electric welder and an auxiliary worker must know the location of fire extinguishing equipment and be able to use them. The use of fire extinguishing equipment for other purposes is prohibited:
During operation, sparks of molten metal should not be allowed to enter and electrode cinders should not be thrown onto combustible structures and materials. For cinders, it is necessary to have a fireproof box.
It is forbidden to store combustible and flammable materials in the premises where welding is carried out. If solvents and other combustible flammable materials are used (or were previously used) in the room, then welding can only be done with the permission of the administration and in agreement with the fire department.
Safety requirements at the end of work.
The electrician must:
disconnect the welding equipment from the mains;
disconnect the wire with the electric holder from the welding equipment and put them away for storage in a specially designated place;
carefully inspect the workplace and take measures to exclude the possibility of a fire;
in the event of a fire, immediately call the fire brigade and take measures to eliminate the source of ignition with available means;
clean the glass that protects the light filter of the helmet-mask (shield) from metal splashes, put away the tool and protective equipment in the place provided for storage.
Introduction
Welding is one of the leading technological processes for the manufacture and repair of various metal structures in various industries, construction and transport. Compared to other methods of their manufacture (cast, forged, riveted, etc.), welded structures are lighter and less labor intensive. At the same time, metal savings range from 10 to 50%.
Electric welding work refers to work with a high degree of danger. This is due to the fact that electric arc welding is accompanied by the release of a large amount of dust, gases, heat, as well as the radiation of visible and invisible infrared and ultraviolet rays. The chemical composition of the emitted gases and dust mainly depends on chemical composition welded metals, electrode rod and its coating. Chromium, manganese, zinc, titanium, etc. are the most harmful substances that make up the metal to be welded, the filler material and the electrode rod. Systematic and prolonged exposure to a polluted atmosphere adversely affects the health of workers.
In the work of welders, accidents are also associated with clogging and injury of the eyes, burns of the body, bruises of the hands and feet, and electric shock.
Electric shock is especially dangerous when removing cinders, accidentally turning on the machine's body in the network, a faulty welding machine or grounding network, involuntary connection of the machine, etc.
Electric welders working in conditions that do not meet the requirements of safety regulations and industrial sanitation may experience acute and chronic poisoning: pneumoconiosis, damage to the mucous membranes of the eyes from radiant electric energy welding arc and invisible ultraviolet rays; overheating of the body - thermal shock, bruises, wounds and burns, and there is also a danger of electric shock.
The main organizational measures that ensure the safe performance of electric welding work are the exclusion of traumatic conditions of the production environment by creating and implementing the most rational technological process using modern and safe welding equipment, as well as increasing the level of professional skills, knowledge, skills for the safe performance of welding work, consciousness and discipline welders and their assistants.
1. Organization of the workplace (post) of an electric welder and the availability of collective and individual protection equipment
A workplace is a job assigned to workers or a team of working sections of a production area, which is equipped with equipment and tools in accordance with the requirements of the technological process, in this case welding, as well as safety requirements.
As noted, depending on the type and dimensions of the welded structure, the organization of the welding area, etc. Workplaces of welders can be stationary or non-stationary.
At stationary workplaces, welded products, as a rule, of small dimensions and weight, are supplied and removed from the workplace by auxiliary workers, and the welder, when performing welding, is in a workplace limited by the cabin.
At non-stationary workplaces, the product is stationary during welding, and the welder moves from seam to seam along the product, or moves from product to product. In this case, as a rule, large-sized and heavy products are welded.
Depending on the type of workplace of the welder, its organization, as well as the equipment and equipment of its equipment and tools, also depends. Workplaces for welders are equipped with:
a) stationary workplaces: welding equipment, devices for welding and tools; devices for feeding and cleaning parts; devices for fastening or placing parts during welding; devices for ventilation, as a rule, stationary; welder's cabin;
b) non-stationary jobs; welding equipment, devices for welding, tools; devices for fastening or placing units or products during welding; portable devices for ventilation of the welding zone; devices (portable) to protect the welding zone from arc radiation.
From the correct organization of the workplace of the welder, its equipment with the necessary equipment, tools and fixtures, the correct placement of this equipment in the workplace depends on the efficiency of his work and productivity.
The main elements of the organization of work of welders in the workplace, on which the highest labor productivity and high quality, will be the following:
a) timely receipt of the assignment;
b) the availability of appropriate equipment, its maintenance in working condition and its correct placement;
c) timely delivery of materials, blanks, parts, etc. to workplaces;
d) high reliability of equipment and high quality of materials;
e) effective quality control welded joints;
f) maintaining good order in the workplace.
It follows from the foregoing that the organization of the welder's workplace in each specific case must be carefully thought out and scientifically substantiated, since the efficiency of his work depends on this.
To protect welders, auxiliary and auxiliary workers from the radiant energy of welding arcs burning nearby in permanent places welders arrange for each welder a separate cabin (Fig. 1) ranging in size from 2 × 2 to 2 × 3 m (excluding the platform, comma equipment) and a height of 1.8 - 2 m. For better ventilation of the cabin, the walls do not bring it to the floor by 15 - 20 cm. The material for the walls of the cabin can be thin iron, plywood, tarpaulin, impregnated with fire composition, or other fire-resistant materials. Rice. 1. Layout of the welding booth: 1 - arc power source; 2 - grounding; 3 - power supply starter; 4; 5 - direct and reverse conductive wires; 6 - table; 7 - ventilation; 8 - rug; 9 - electrodes; 10 - shield; 11 - electrode holder; 12 - chair; 13 - waste box; 14 - doorway The cabin frame is assembled from steel pipes or angle steel. To prevent the radiant energy of the welding arc from entering the rest of the room, the cabin doorway is usually covered with a tarpaulin curtain on rings. To reduce the absorption of light energy by the walls of the cabin, they are painted in light matte colors. Painting welding shops and especially welding booths in dark colors is not recommended due to the deterioration of general illumination during breaks in welding. Cabin floors must be brick, cement, concrete or other fire-resistant material. Welding areas must be sufficiently well lit by daylight or electric light. However, even properly equipped natural or artificial lighting may not be sufficient if windows, skylights and fixtures are poorly maintained and ceilings and walls are dirty. Glasses in windows and lamps of artificial lighting of welding rooms must be cleaned at least four times a year, and the rooms must be painted at least once a year. Artificial lighting of welding shops and booths should be combined - from general and local lighting. Illumination of workplaces - not less than 80 - 100 lx. Welding machines should be located either in the cabin or outside it. The presence of welding machines in the cabin is convenient for regulating the welding current, reduces the number of electrical wires from the machines to the workplace, but hampers the welder and worsens working conditions. Welding transformers are usually installed in cabins, as they take up little space. When performing welding work in the assembly shop, welding transformers can be installed both in separate rooms and in the shop near the workplace. The shroud must always be put on the transformer and properly grounded. Stationary welding equipment in the workshop is fenced with a mesh or barrier. The passages between the equipment and the walls are made at least 1 m wide. The rotating parts of the machines are covered with casings, the machine bodies are grounded. In manual arc welding, local exhaust ventilation, a welding table or a conductor, a wall shelf for small tools and fixtures, a chair with a back and other necessary equipment are installed in the welder's cabin. In mass welding of parts of the same type, a rotary jig is used instead of a welding table, in which the products are assembled and welded. The use of conductors facilitates the work of assemblers and welders, speeds up the production process, improves the quality of work and makes it safer. When welding small heterogeneous products, welding tables are used. The table top is made of cast iron with a thickness of 20 - 25 mm and a turntable of the same thickness is installed in it. The wheel is rotated by a mechanism driven by the welder's foot. On the side of the table is a box for storing tools and accessories. One leg of the table has a clamping device for attaching the return wire. Electric welding posts, where you can work while sitting, are provided with a comfortable chair with a back. The seat height can be adjusted with a special lifting device. At the workplace of the welder, racks should be installed for storing parts that require repair. They hang out on the racks or make inscriptions with bright indelible paint indicating the permissible load capacity of the rack. Depending on the overall dimensions of the products to be welded, fixed welding tables for sitting work are made no more than 500-700 mm high, the products to be welded are installed on such a table in a position convenient for welding. It is advisable to use manipulator tables equipped with screw lifting and turning mechanisms that allow you to put the product to be welded in the desired position. The cabin must be ventilated by local suction with an air supply of 40 m3/h for each worker (Fig. 1). If the parts to be welded have a large length of the seams, it is possible to arrange ventilation exhausts with flexible sleeves. Their movement during the welding process is consistent with the movement of the welding arc along the part. Rice. 2. Scheme of suction of gases released during welding from the welding station: 1 - air duct; 2 - gate; 3 - air inlet; 4 - stamped grating; 5 - visor The ventilation suction must be located so that the gases released during welding pass away from the welder. A box with a set of electrodes is installed at the workplace, as well as a box for cinders. The work of a welder outside the cab or outside a special room, such as in the process flow of disassembly and assembly shops, requires the implementation of additional measures to guarantee labor safety. First of all, these are electrical safety issues associated with the use of longer current-carrying wires, with the presence of the welder on the product itself or, which is much more dangerous, inside the product. Particular attention should be paid to the organization of the workplace when working inside tanks, tanks, boilers, wells and in other enclosed or small spaces, since here there is a danger not only of electric shock, but also of poisoning. To maintain a normal air environment when working in confined spaces, it is necessary to equip forced ventilation. The lack of such ventilation can lead to a flash and even an explosion of the gas-air mixture formed as a result of the accumulation of combustible vapors and gases. In wells, deep channels and trenches, in addition to explosive mixtures, carbon dioxide and carbon monoxide can also accumulate during welding. Therefore, working in such an atmosphere can cause poisoning. Before you start organizing jobs in such dangerous places, you need to take a sample for air analysis. Do this with the help of gas analyzers. You can start working only if the analysis confirms the absence of harmful and explosive vapors and gases in the air. In the process of working in confined spaces, it is necessary to supply clean atmospheric air to the work area of the welder using a blower or provide the worker with a hose gas mask of the PSh-2 or PSh-1 brand and a rescue belt with a strong rope attached to it. Cleaning the surfaces of parts before welding, as well as cleaning the seams after welding, is performed using a notch, steel brushes, a chisel and a hammer or portable machines equipped with an emery wheel (wire brush). To clean the seams from slag and metal splashes, welders and their assistants use pneumatic chisels, which greatly facilitates the work and speeds up the cleaning process. These operations require proper eye protection with safety goggles with clear lenses. When welding heavy and bulky products, the welder's workplace must be provided with a crane, winch, hoist and other lifting mechanisms necessary for tilting the product. The workplace of the welder should be equipped with improved devices: first of all, various base plates, stops, clamps, ties and spacers. Particularly needed are universal rotary devices - rotary tables, rollers, faceplates, etc., which allow you to quickly turn the product into the desired position during welding, which creates convenience for the work of welders and assemblers. To protect the eyes and face of welders from the harmful effects of the radiant energy of the welding arc, a shield or mask with special light filters should be used, depending on the strength of the welding current: E-1 - up to 75 A, E-2 - from 75 to 200 A, E-3 - from 200 to 400 A, ES-100, ES-300, ES-500. To protect the light filters from the outside, they are covered with colorless glasses, which are replaced with new ones as they get dirty. Auxiliary workers must be provided with goggles or masks with B-2 or B-3 light filters. When stripping welding seams workers are provided with goggles. 1.2 Providing workers with personal protective equipment Electric welders must work in overalls: a cotton suit with fire-resistant impregnation and canvas gloves. To avoid splashing metal behind the top of the boots, trousers should be worn loose. The choice of PPE for the face and organs of vision should be made depending on the methods, modes and types of work, radiation intensity, individual features vision. The personal protective equipment used must comply with the requirements of GOST 12.4.011 - 89. To protect against the harmful effects of the radiant energy of the welding arc, the eyes, face and neck must be covered with a special helmet or shield (Fig. 3). Rice. 3. Shield (a) and helmet (b) electric welder Shields and helmets are made of material that does not transmit ultraviolet rays, has low thermal conductivity and does not ignite from sparks. The material can be dark-colored sheet fiber or plywood painted with fire-retardant paint in matt black. A rectangular cutout is made in the front part of the shield and helmet, into which a protective glass filter is inserted. Transparent glass is additionally inserted into the shield or helmet from the outside to protect the light filter from metal splashes of molten metal. Do not replace the filters with any other glasses or a set of colored glasses, as this can lead to eye disease. Light filters manufactured by our industry are a plate of dark glass measuring 121 × 69 mm These glasses do not transmit ultraviolet rays at all, and infrared rays pass only in the range from 0.1 to 4% of their total amount. For electric welders, protective glasses of the E-1 to E-4 series are produced. The assistant workers of the welder and other persons working with him are required to wear safety glasses with glasses from B-1 to B-3. The choice of specific types of personal protective equipment should be carried out depending on the type of work and the substances and materials used. Protective equipment issued on an individual basis must be kept by the employee or at his workplace during work. The choice of PPE should be determined depending on the level of contamination of the air and product surfaces with toxic substances, the intensity of noise, vibration, the microclimate at the workplace and the nature of the work performed. RPE are used in the case when ventilation does not provide the required air purity of the working area, provided for by the requirements of GOST 12.1.005 - 88. When the maximum permissible noise levels are exceeded, workers must be provided with PPE for the hearing organs: earmuffs, helmets or earplugs. Hearing PPE should be selected based on the frequency spectrum of noise in the workplace. Types and groups of PPE for hearing organs should be selected in accordance with the requirements of GOST 12.4.051 - 87. Workers using personal protective equipment should be instructed on the rules for using these equipment and how to check their serviceability. Overalls should be harmless, comfortable, not restrict the movement of the worker, not cause discomfort, protect against sparks and splashes of molten metal, welded product, moisture, industrial pollution, mechanical damage, meet sanitary and hygienic requirements and working conditions. The choice of overalls depending on the welding methods and working conditions should be made in accordance with the recommendations of GOST 12.4.044 - 87 and GOST 12.4.010 - 75. To protect hands during welding, workers should be provided with mittens, mittens with leggings or gloves made of spark-resistant material with low electrical conductivity. It is forbidden to use gloves and overalls made of synthetic materials such as lavsan, kapron, etc., which do not have protective properties, are destroyed by welding arc radiation and can ignite from sparks and splashes of molten metal, and sinter when in contact with heated surfaces. To protect the legs from burns from splashes of molten metal, mechanical injuries, hypothermia when working outdoors in winter, overheating when welding heated products, as well as from electric shock, especially when working in closed vessels, compartments, workers must be provided with special footwear. Safety shoes with open lacing and metal nails are not allowed. Technical condition of the equipment Cleaning of the unit and starting equipment should be carried out daily after the end of work. On the body of the welding transformer or converter, the inventory number, the date of the next measurement of the insulation resistance and belonging to the workshop must be indicated. Installations for electric welding must comply with the requirements of the relevant sections of the Rules for the Arrangement of Electrical Installations, the Rules for the Technical Operation of Consumer Electrical Installations and the Safety Rules for the Operation of Consumer Electrical Installations. The insulation resistance of the current-carrying parts of the welding circuit must be at least 0.5 MΩ. Measurements of the insulation resistance of welding wires are documented in protocols. Each electric welding machine is connected to an individual switch with a wire of the appropriate section, while the distance between the machine and the wall is at least 0.5 m. The control elements of electric welding machines (knife switches, package switches, buttons, starters, etc.) must have reliable latches or guards to prevent their spontaneous or accidental switching on (off). When using several welding transformers at the same time, they must be placed in such a way that the distance between them is at least 0.35 m, and the width of the passages is at least 0.8 m. Places of hot work and placement of electric generators must be cleared of combustible materials within a radius of at least 5 m. Electric welding in refrigerators under construction can only be carried out in chambers and compartments freed from combustible materials. Welding machines must have protective devices on the mains side. The open circuit voltage of the welding transformer on the low side must not exceed 75...110 V. The case of the electric welding machine, the secondary winding of the transformer and the object to be welded should be reliably grounded before connecting them to the mains, and this grounding should not be disturbed until the machine is disconnected from the mains. To connect the ground wire on the body of the electric welding machine, in an accessible place, it is necessary to install a bolt with a diameter of 5 ... 8 mm, and provide it with the inscription: "Earth". Above the terminals of the welding transformers there should be visors and inscriptions: “High side” and “Low side”. Diagrams for connecting welding transformers to a network with a voltage of 380 and 220 V are shown in fig. 4 and 5. A steel bus of any profile, a welding plate, a rack or the welding structure itself can serve as a return wire if their cross section provides a safe flow of welding current from the point of view of possible heating. Rice. 4. Scheme of connecting a welding transformer to a 380 V network: 1 - grounding bolts; 2 - grounding wire of the network; 3 - NRV; 4 - supply phase wires; 5- welding transformer; 6 - electric holder; 7 - welded part Rice. 5. Scheme of connecting a single-phase welding transformer to a 220 V network: 1 - welding transformer; 2 - supply phase wire; 3 - NRV; 4 - electric holder; 5 - welded part; 6 - grounding bolts; 7 - neutral wire; 8 - ground wire The individual elements of the return conductor must be connected to each other with bolts, clamps or clamps. The electrical wiring between the welding machine and the electric holder must be made of wire in accordance with state standard, taking into account the current strength and compliance with safety conditions. It is necessary to take measures against damage to the insulation on the wires (cables) and exclude their contact with water, oil, steel ropes, hoses with combustible gases and hot pipelines. The use of electric welding wires with damaged braid or insulation is prohibited. If it is not possible to replace the damaged wire, then it is necessary to enclose it in a rubber hose. The length of the wires between the supply network and mobile welding machines should not exceed 10 m, and the wires should be protected from mechanical damage. Welding wires should be connected by hot soldering, welding, using couplings with an insulating sheath, and the soldered and welded joints of the wires must be carefully insulated. The handle of the electrode holder for manual welding is made of a heat-insulating dielectric material. The electrode holder must provide a reliable clamp and a quick change of electrodes, as well as exclude the possibility of a short circuit of the electrode holder body on the workpiece being welded during temporary interruptions in work or if it accidentally falls on metal objects. The electrode holders must provide the possibility of gripping the electrode in at least two positions: perpendicular and at an angle of 115° or more to the axis of the electrode holder. It is necessary that the design of the electrode holder allows the replacement of the electrode in a time not exceeding 4 s. The current-carrying parts of the electrode holders must have reliable insulation with a resistance of at least 5 MΩ to prevent their accidental direct contact with the workpiece being welded or the welder's hands. The insulation of the handle must withstand without breakdown the test voltage of 1500 V with a frequency of 50 Hz for 1 min. The temperature of the outer surface of the handle during nominal operation should not increase by more than 55 °C. It is necessary that transverse section handles in the place where the welder’s palm was wrapped around fit into a circle with a diameter of not more than 40 mm. The electrode holders must have sufficient mechanical strength. Additional welding tools include screw clamps, wire brushes, stamps, chisels and hammers. To connect the wire to the product, screw clamps are used, into which the end of the wire is soldered with hard solder. Clamps must ensure tight contact with the workpiece to be welded. To clean the seams and remove slag, wire brushes are used, manual and electrically driven. Hallmarks, chisels and hammers are used to mark seams, cut out defective areas, and remove spatter and slag. To store the electrodes during welding at the installation, canvas bags 300 mm long are used, suspended from the welder's belt. In workshop conditions, for this purpose, glasses of the same length are used, made from a piece of pipe with a diameter of 50 ... 75 mm, with a welded bottom-stand. Welding wires are used to supply current from the welding machine or transformer to the electrode holder and the workpiece to be welded. The electrode holder is supplied with a flexible insulated rubber wire woven from a large number of annealed and tinned copper wires with a diameter of 0.18 ... 0.2 mm. Before starting work, the electric welder is obliged to check the insulation of the electric wire and the electrode holder, the presence and correctness of the grounding of the body of the welding machine, the secondary winding of the transformer, the workpiece to be welded and the switch housing, the reliability of the connections of the electric wires with the machine, and also make sure that there are no flammable substances at the workplace (distance from the place of production electric welding work to flammable objects should be at least 10 m, and with a wind directed towards flammable substances - at least 20 m). To ground welding converters and welding transformers, you must: connect the ground bolt on the body of the welding converter with a four-wire hose cable to the ground wire; to power a single-phase welding transformer, use a three-core hose cable with a grounding conductor, which is connected at one end to the body, and at the other - to the grounding bolt on the YARV; ground the low side of the welding transformer (on the side of the wire connected to the workpiece to be welded). The electric welding machine must be checked regularly, at least once a month: for the absence of a short circuit to the body; integrity of the ground wire; serviceability of the insulation of the supply wires (insulation resistance should be at least 0.5 MΩ); no exposed live parts; no short circuit between the high and low voltage windings. 3. Safety measures during electric welding Persons not younger than 18 years of age who have passed a medical examination and special technical training and have certificates for the performance of these works are allowed to perform electric welding. Women are not allowed to do welding work inside containers (tanks, reservoirs). For all electric welders, an annual knowledge test is required to extend the validity of the certificate for the right to perform welding work. The welder's workplace, located in the open air, is protected from wind, rain and snow, protected by portable screens, protecting workers in the neighborhood from the action of the radiant energy of the welding arc. Cleaning of the surfaces of parts before welding, as well as cleaning of seams after welding, is carried out with steel brushes, a chisel and a hammer or an emery wheel, while safety glasses with transparent glasses must be worn. When welding heavy and bulky products, the welder's workplace is provided with lifting mechanisms (crane, winch) and a hoist. Important for the safety of the welder is the correct wiring and laying of wires to welding stations, welding machines, transformers, and especially to mobile welding installations, where the device of a conventional network is excluded. The current-carrying network of welding installations must consist of well-insulated wires. It is impossible to lay without insulation and the wire going to the workpiece to be welded (return wire). It is impossible to ignite the arc without warning others about it and before bringing the safety shield or helmet into working position, remove the shield or helmet from the face until the arc stops burning. Before starting welding, the electric welder puts on a canvas suit with fire-resistant impregnation - loose trousers, a jacket with closed pocket flaps, boots with a closed top, a hat, dielectric gloves or mittens, which must be dry, without traces of oil. Protective devices are being put in order - a helmet-mask and a rubber dielectric mat or rubber dielectric boots. It is necessary to carefully examine and check the reliability of the contact and fastening of the grounding conductors with the housings of welding transformers, welding machines, welding tables, metal frames of current distribution boards and other auxiliary equipment that may be energized, check the serviceability of starting and disconnecting devices - knife switches, magnetic starters, switches , as well as the insulation of current-carrying conductors. The electrode in the electrode holder is replaced in canvas gloves. 4. Instruction on labor protection for electric welding General safety requirements 1. Persons not younger than 18 years of age who have the appropriate qualifications, who have received introductory briefing and initial briefing at the workplace on labor protection, who have passed the knowledge test on electrical safety, have been trained in safe working methods and have the appropriate certificate, are allowed to independently perform electric welding work. Women are not allowed to perform electric welding work inside the tank (boilers, tanks, tanks). 2. An electric welder who has not undergone a timely re-instruction on labor protection (at least 1 time in 3 months) and an annual test of knowledge on labor safety should not start work. 3. When applying for a job, an electric welder must undergo a preliminary medical examination, and in the future - periodic medical examinations within the time limits established by the Ministry of Health and Medical Industry of Russia. 4. An electric welder is obliged to comply with the internal labor regulations established at the enterprise. 5. The electric welder must be aware that the dangerous and harmful factors that may affect him in the process of work are: electricity; ultraviolet, visible and infrared radiation; elevated temperature, molten metal; harmful gases and dust (aerosol). 5.1. An electric current strikes a worker in violation of electrical safety rules. Passing through the human body, it has a thermal, electrochemical, mechanical and biological effect on the body. Electric current is invisible and therefore not perceived as a source of danger. 5.2. The ultraviolet rays generated during electric welding cause burns to the face, hands and lead to inflammation of the eyes. Visible rays act on the retina and vascular membrane of the eyes, and infrared rays act on the lens and cornea of the eye. 5.3. The temperature of the electric arc reaches 4000 C, while the parts to be welded heat up significantly and touching them causes a burn. A hot part looks no different from a cold one and therefore is not perceived as a source of danger. In addition, during electric welding, drops of liquid metal are sprayed, which, falling on the body, cause burns. 6. An electric welder must use only those tools, fixtures and equipment with which he is trained and instructed. 7. The electric welder must work in special clothing and special footwear, if necessary, use other personal protective equipment. 8. In accordance with the Model Industry Standards for the free issue of special clothing, special footwear and other personal protective equipment, an electric welder is issued: suit with flame retardant impregnation; leather boots; tarpaulin mittens; protective helmet. For outdoor work in winter, additionally issued: cotton jacket with insulating lining; cotton trousers with insulating lining; 9. The electric welder must inform his immediate supervisor about the observed violations of safety requirements at his workplace, as well as about malfunctions of equipment, devices, tools and personal protective equipment and not start work until they are eliminated. 10. The electric welder must observe the rules of personal hygiene. Wash your hands with soap before eating. For drinking, use water from devices specially designed for this purpose (saturators, drinking tanks, fountains, etc.). Safety requirements before starting work 1. Before starting work, the electric welder must: 1.1. Check the availability and serviceability of personal protective equipment, put them on, fasten the cuffs of the sleeves of the suit. At the same time, the suit jacket (jacket) should not be tucked into trousers, and trousers should be released over boots (felt boots). 1.2. Inspect and prepare your workplace, remove all unnecessary items without cluttering up the aisles. Check the condition of the floor in the workplace. If the floor is slippery or wet, ask for it to be mopped or do it yourself. 1.3. Make sure that the welding equipment, wires are in good condition; the presence and serviceability of the grounding of the welding unit, the welding table and the vise installed on it. Check the serviceability of starting, regulating and measuring instruments, as well as, according to the readings of the instruments, the voltage at the terminals of the generator or transformer. Arrange the welding wires so that they are not subjected to mechanical damage and high temperatures, and also do not come into contact with moisture. Check the availability and proper operation of local suction and fire extinguishing equipment at the workplace. 1.4. Make sure that there are no flammable and combustible materials near the welding site (combustible materials must be at least 5 m away from the welding site). 1.5. if it is necessary to connect a mobile electric welding unit to the mains (without a plug), as well as to repair it or replace fuses, call an electrician on duty (electrician). 1.6. Connect welding wires only by hot soldering, welding or using sleeves with screw terminals into a block made of unbreakable insulating material, and the heads of the clamping screws should be sunk into the body of the block. connect welding wires with a twist; touch live parts with your hands; repair electrical equipment. Safety requirements during work 1. During work, the electric welder must: 1.1. To carry out electric welding work in specially allocated and equipped places for this purpose. 1.2. When carrying out work outside a specially designated place, protect the place of electric welding with a screen, mobile shields, at least 1.8 m high. 1.3. Make sure that hands, special clothing and special shoes are always dry. 1.4. Perform electric welding work at a permanent workplace only after turning on the local suction. 1.5. Take or move objects at the welding station only in gloves. 1.6. When carrying out electric welding work in damp places and rooms, as well as inside containers, use additional personal protective equipment (dielectric gloves, galoshes, rubber mats). 1.7. For work sitting or lying down, require a special mat on a felt pad. 1.8. Monitor the reliability of the grounding of the object being welded; wire insulation must not be damaged, 1.9. Welding is carried out using an electrode holder, the design of which allows for reliable fastening of the electrode and its safe replacement. 1.10. When carrying out electric welding work directly on the car, first ground the frame or body of the car and cover the fuel tank with a sheet of iron to prevent sparks from falling on it. Require removal of the fuel tank before welding on or near the fuel tank. 1.11. Carry out welding work inside the tank, in a trench, well, etc., only after obtaining a work permit and observing the safety measures specified therein. At the same time, an assistant must always be located outside the hatch (manhole) of the tank, insuring the work of the electric welder. 1.12. Move the electric welding machine only after disconnecting it from the mains. 1.13. For short breaks in work, put the electrode holder on a special device - a tripod. 1.14. Use electrodes suitable for the welding current. 1.15. Turn off the welding machine at any time away from the workplace. 2. An electric welder is prohibited from: work with a shield or helmet that has gaps and cracks in the glasses; work at a permanent workplace without local suction included; look at yourself and allow others to look at the electric arc without protective equipment (masks, goggles, shields); to carry out electric welding work in the open air without a canopy during rain and snowfall; cut and weld metal canopy; carry out welding work in a room where flammable substances and gases are located; to carry out welding work on vessels, pipelines and apparatus under pressure; use pipes, rails, etc. metal objects as a return wire; warm up the electrode on a grounded table or other objects. Safety requirements in emergency situations 1. An electric welder must immediately inform the employer about each accident that he witnessed, and provide the victim with first aid, call a doctor or help deliver the victim to a health center or the nearest medical facility. If an accident occurs with the electric welder himself, he should, if possible, contact the health center, report the incident to the employer or ask someone around to do it. 2. If you feel pain in your eyes, stop work immediately and inform your employer about this. Safety requirements at the end of work 1. Upon completion of work, the electric welder is obliged: 1.1. Turn off the electric welding installation, when working on automatic and semi-automatic devices, turn off the water; when welding in a shielding gas environment, close the cylinder valve and relieve pressure on the reducer. 1.2. Turn off ventilation. 1.3. Tidy up your workspace. Remove wires, fixtures and tools in the place provided for them or hand them over to the pantry. 1.4. Remove personal protective equipment and put them in the place intended for them. Timely hand over special clothing and other personal protective equipment for dry cleaning (washing) and repair. 1.5. Wash your hands with soap and take a shower. 1.6. Notify your immediate supervisor of any deficiencies discovered during work. 5. Fire safety measures for electric welding Production and auxiliary premises for the production of electric welding must comply with fire safety requirements in accordance with the requirements of GOST 12.1.004 - 91 and be provided with primary fire extinguishing equipment in accordance with the requirements of the Fire Safety Rules in Russian Federation, as well as fire equipment in accordance with the requirements of GOST 12.4.009 - 83 and have a degree of fire resistance according to the classification of fire safety industries. Prior to the start of electric welding work carried out in the room, an analysis of air samples from the upper points of the room and devices prepared for repair should be carried out. Upon completion of electric welding, surfacing, cutting, the employee should not leave the workplace without making sure that there is no source that can cause a fire at the place of work and in adjacent premises. All workers must be trained in the rules for eliminating primary fires and the correct use of primary fire extinguishing equipment. When performing electric welding, combustible structures must be protected by permanent or portable barriers, and combustible floors must be protected by metal sheets. Portable fences should be made of sheet steel. Flammable organic solvents in the preparatory compartments must be stored only in the amount agreed with the fire authorities. Places for the production of electric welding and gas flame works on this, as well as on the lower tiers (in the absence of fireproof protective flooring or flooring protected by fireproof material) must be freed from combustible materials within a radius of at least 5 m, and from explosive materials and equipment (gas generators, gas cylinders, etc.) - at least 10 m. Each welder's work station must be equipped with primary fire extinguishing equipment, and workers must have the skills to use them. Hand-held foam, aerosol, carbon dioxide-bromoethyl fire extinguishers are designed to extinguish incipient fires when flammable solid and liquid substances are ignited, with the exception of those that chemically interact with fire extinguishing agents, intensifying combustion or creating an explosion hazard. Foam fire extinguishers must not be used to extinguish electrical equipment and electrical installations that are energized. Carbon dioxide fire extinguishers are designed to extinguish any combustible substances, with the exception of alkali metals, as well as substances that can burn without air. Powder fire extinguishers, depending on the brand of powder, are designed to extinguish flammable liquids and gases, electrical installations under voltage up to 600V (PSB), extinguishing alkali metals (PS-1, SI), flammable liquids and gases, smoldering materials (wood, paper, coal) - powder fire extinguishers P-1 and PF. electric welder emergency firefighter protection Conclusion If workers do not comply with the technology for the production of electric welding, safety requirements, industrial sanitation and fire safety, traumatic situations arise and the effects of harmful and dangerous production factors are manifested. At present, it is necessary to intensify and raise the level of work on training and advanced training not only for managers, chief specialists and specialists of repair and maintenance enterprises and farms, but also for electric welders to ensure technical, fire, environmental safety and labor protection during electric welding using new technologies , as well as during the installation of equipment for livestock and poultry farms, when performing agricultural work; when performing work on the organization of labor protection and safety control, on attestation of workplaces for working conditions, on certification of work for compliance with labor protection requirements; when compiling a safety data sheet; determination of production factors of working conditions using portable kits technical means control of working conditions in the production of electric welding works. List of used literature 1. Efremova O.S. Occupational safety from A to Z. Ed. 4th, revised. and additional - M.: Publishing house "Alfa-Press". 2007. - 516 p. Zabruskov A.P., Filatov L.S. Safety precautions at the repair enterprises of agriculture. Moscow: Rosselkhozizdat. B.I. Zotov, V.I. Kurdyumov Life safety at work. - 2nd edition., revised. and additional - M.: Kolos S, 2004. - 432 p. 4. POT RM-020-2001 Intersectoral rules for labor protection during electric and gas welding (approved by the Decree of the Ministry of Labor of the Russian Federation of October 09, 2001 No. 72)<#"justify">5. L.S. Filatov Safety measures at agricultural repair enterprises. - 2nd edition, revised. and additional - M.: Rosselkhozizdat, 1978 TYPICAL INDUSTRY INSTRUCTIONS FOR LABOR SAFETY WHEN PERFORMING ELECTRIC WELDING WORKS. Approved: Order of the Ministry of Agriculture and Food of the Russian Federation on November 23, 1994 N 289 Fire protection of the adhesive tape production workshop In this building, there may be an open fire (for example, electric welding), appliances with a high temperature of the working surface (various ...
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RULES ON LABOR SAFETY DURING MAINTENANCE AND RUNNING REPAIR OF TRACTION ROLLING STOCK AND CRANES ON... Relevant in 2017
2.7. Safety requirements for welding
2.7.1. When performing welding work, it is necessary to comply with the requirements of GOST 12.3.003, GOST 12.1.019, GOST 12.1.030, Rules for the Design and Safe Operation of Hoisting Cranes (Machines), Sanitary Rules for Welding, Surfacing and Cutting of Metals, Instructions for Welding and Surfacing Works repair of diesel locomotives, electric locomotives, electric trains and diesel trains, Fire Safety Rules in the Russian Federation, Fire Safety Rules for Railway Transport.
Cylinders with compressed gases, their operation, transportation and storage must comply with the requirements of the Rules for the Design and Safe Operation of Pressure Vessels.
2.7.2. The areas of specially designated premises for performing welding work must comply with the requirements of SNiP 2.09.04.
2.7.3. Welding work must be carried out by welders who have passed the tests in accordance with the Rules for the certification of welders, who have a certificate of the established form.
2.7.4. When performing welding work, welders and workers who work with them must be in overalls, safety shoes and use other personal protective equipment and safety devices (goggles, shields), depending on the type of welding and the conditions for its use.
2.7.5. Before performing welding work at height, from scaffolding or scaffolding, it is necessary to take measures against fire of wooden elements and splashes of molten metal on people, as well as install primary fire extinguishing equipment (fire extinguisher, container with water, box with sand).
2.7.6. It is not allowed to carry out welding work near flammable and flammable materials, as well as at a distance of less than 5 m from freshly painted places on the TPS and cranes. When a TPS (crane) is located on railway tracks contaminated with oil products, it is prohibited to carry out welding work.
2.7.7. It is not allowed to store kerosene, gasoline and other flammable materials in the welding area.
2.7.8. Welding wires from the power source to the welder's workplace must be protected from mechanical damage. Welding wires can be suspended at a height that ensures the safety of workers, or passed under the rails in the gaps between the sleepers.
It is forbidden to use a rail as a return wire.
2.7.9. During rain, welding work should be carried out under canopies or covers that ensure the safety of work.
2.7.10. Welding work on containers under pressure is not allowed.
2.7.11. The housing of a stationary or mobile welding machine or transformer, as well as the workpiece to be welded, must be reliably grounded or grounded at all times during welding.
2.7.12. The presence of greasy or oil stains on gas welding equipment and tools is not allowed. Frozen gas generators and gearboxes should be thawed in a warm room or hot water. It is not allowed to use an open flame for warming them.
2.7.13. To prevent the impact of the welding arc on other workplaces, welding sites must be fenced with portable screens, shields or special curtains with a height of at least 1.8 m.
2.7.14. Temporary jobs for electric welders located in the body of the TPS (crane), indoors or outdoors, must be protected by portable shields or screens.
2.7.15. Sheds, covers, portable shields, screens, curtains used in the performance of welding work must be made of fireproof materials.
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On the handle of the shield there is an additional fiber visor (it can be easily replaced if it is damaged), which protects the mittens from sunbathing.
Arc welding emits dust and gases that are harmful to the health of welders. To prevent poisoning, it is necessary to use harmless coatings for electrodes and fluxes in semi-automatic welding. Welding stations must be equipped with supply and exhaust ventilation to remove dust and gases.
It must be remembered that when working in boilers and other metal structures connected to the ground, the welder must avoid touching metal structures and uninsulated current-carrying parts of the welding circuit. Under these conditions, the welder is obliged to work on rubber mats, in a rubber helmet, galoshes and dielectric gloves.
In connection with the special danger of working in boilers and similar metal structures, the person responsible for their production is obliged to establish special supervision over the work of the electric welder and ensure the immediate interruption of the current supply at his signal.
Unofficial edition
POT RM-020-2001
Cross-industry rules
on labor protection during electric and gas welding
Coming into effect
<*>Collection of legislation of the Russian Federation. 1999. N 29. Art. 3702.
1.1.4. The rules apply to stationary, portable and mobile electric and gas welding installations equipped and used indoors or outdoors, designed to perform technological processes of welding, surfacing, cutting (separation and surface) fusion and welding using pressure, including:
Arc and plasma welding, surfacing, cutting;
Atomic - hydrogen welding;
Electron - beam welding;
Laser welding and cutting (welding and cutting with a light beam);
Electroslag welding;
Welding by contact heating;
Contact or diffusion welding, arc welding;
Gas
Metal cutting. welding;
1.1.5. On the basis of the Rules in the organization, taking into account specific conditions, in the prescribed manner, instructions on labor protection, technological and operational documents for the relevant processes (works) are developed or brought into line with them.
2.13.2. Works on spraying and cutting metal using propanebutane or natural gas, as well as using open fire from other sources are allowed at a distance (horizontally) of at least:
From groups of cylinders (more than 2) intended for conducting gas-flame operations - 10 m;
From gas pipelines of combustible gases, as well as gaseous posts located in metal cabinets:
a) for manual work - 3 m;
2.13.3. Metal cutting using propane - butane mixtures is allowed in open areas and in workshops. The use of propane-butane mixtures and liquid fuel on ships under construction and repair in enclosed and hard-to-reach areas is not allowed.
2.13.4. Metal supplied for welding or flame cutting must be free of paint (especially lead-based), oil, scale, dirt to prevent metal spatter and air pollution by evaporation and gases.
When welding and cutting painted, primed metal, it must be cleaned along the cut line or seam. The width of the strip to be cleaned from paint must be at least 100 mm (50 mm per side).
The use of a gas flame for this purpose is not permitted.
2.14 . Safety requirements for gas cutting and welding in closed vessels, compartments
2.14.1. GOM in closed vessels, compartments.
GOM in confined spaces and hard-to-reach places (tanks, boilers, cisterns, tunnels, basements, etc.) is performed according to a permit for especially dangerous work.
2.14.2. GOM, carried out in confined spaces and hard-to-reach places, must be carried out under the following conditions:
The presence of at least two openings (windows, doors, hatches);
Thorough cleaning of the air and checking for the content of harmful substances in the air of the working area before starting work;
Checking the values of fire hazard indicators in accordance with the requirements of GOST 12.1.004;
The absence in the air of a concentration of explosive substances exceeding 20% of the lower explosive limit;
Implementation of special ventilation with the help of local exhausts from stationary and mobile units, if general ventilation does not provide normal working conditions;
Installations of a control post for monitoring workers and an observer.
2.14.3. When gas welding, cutting or heating metal surfaces inside closed and hard-to-reach rooms (compartments and sections of vessels, reservoirs, boilers, tanks, etc.), in addition to the general exchange ventilation of the workshop, it is necessary to have a continuously operating supply and exhaust ventilation that ensures the inflow of fresh and outflow of contaminated air from the bottom and upper parts enclosed space or hard-to-reach area.
If there is insufficient oxygen (less than 19%) in the air of the tank or compartment, work in it is not allowed. Prior to carrying out gas-flame work inside double-bottom and side compartments, oil and coal pits, as well as in tanks that are a place of accumulation of harmful gases or heated air, local supply and exhaust ventilation must be installed and put into operation, doors, hatches, necks and windows are open available in these premises.
2.14.4. When GOM in rooms of small volumes (vessels, compartments, tanks, etc.) it is recommended to use general ventilation at the rate of 4000 - 5000 cubic meters. m of air per 1 cu. m of burned acetylene.
2.14.5. When working in confined spaces and hard-to-reach places, the welding transformer, acetylene generator, cylinders with liquefied or compressed gas should be placed outside the tanks in which welding is performed.
2.14.6. GOM in compartments is allowed to be carried out only in tarpaulin or asbestos clothing.
2.14.7. Simultaneous production of electric welding and gas-flame works inside the tanks is not allowed.
2.14.8. It is not allowed to use power cutters when performing gas-flame work in tanks, wells and other closed containers.
2.14.9. Lighting during welding work inside metal containers should be carried out using lamps installed outside, or hand-held portable lamps with a voltage of not more than 12 V.
2.14.10. When GOM in confined spaces is prohibited:
Use equipment that runs on liquid fuel;
Leave unattended burners, cutters, sleeves during a break or after finishing work;
Weld and cut vessels under pressure or containing explosive or toxic substances.
2.15 . Safety requirements for the organization and conduct of gas welding and gas cutting work, depending on the type and method of welding and working conditions during their implementation
2.15.1. Prior to starting work related to welding or the use of fire, permission from the local fire authorities must be obtained with a preliminary analysis of air samples from the upper points of the room and devices prepared for repair in order to make sure that there is no explosive concentration of acetylene. The content of acetylene in the sample should not exceed 0.3 mg/l.
2.15.2. In case of detecting oxygen and acetylene leaks from pipelines and gas dispensing stations and if it is impossible to quickly eliminate faults, the damaged section must be turned off, and the room must be thoroughly ventilated.
Warming of frozen acetylene and oxygen pipelines should be carried out only with steam or hot water. The use of open flames and electric heating is prohibited.
2.15.3. The number of torches or cutters installed on a machine is limited by the valve capacity. In manual gas flame operations, only one burner or cutter can be connected to the valve.
2.15.4. In rooms where flame treatment of metal is carried out, there must be ventilation to remove harmful gases released during these works.
In the event of a ventilation failure, gas cutting and welding is prohibited.
2.15.5. The power supply of gas cutting machines in workshops must comply with the requirements of current safety regulations and the arrangement of electrical installations.
2.15.6. Gas supply to shops, workshops and areas of gas-flame work should be carried out:
Through gas pipelines from acetylene and oxygen stations, as well as from distribution ramps with more than 10 permanent posts for gas welding and cutting, if the arrangement of gas pipelines is irrational, from oxygen and acetylene cylinders and from portable acetylene generators with a number of posts of 10 or less;
From other sources of gas supply (pipelines of natural gas and other combustible gases, tanks with liquid fuel, etc.).
2.15.7. Oxygen ramps for powering one post with up to 6 cylinders are allowed to be installed inside the workshop.
2.15.8. All shop and inter-shop gas pipelines must be grounded, the electrical resistance between the grounding device and any point of the gas pipeline must comply with the PUE.
2.15.9. In the water lock of the post, the level of water or other liquids must be constantly maintained at the height of the control tap. When using a dry valve, check its status "closed - open". The check should be carried out at least three times per shift with the gas supply to the valve turned off.
2.15.10. On gas pipelines for natural gas or propane-butane, it is prohibited to install open-type liquid valves. The liquid level in the closed type valve must be constantly maintained at the height of the control cock. Checking the liquid level should be carried out at least three times per shift with the gas supply to the valve turned off.
2.15.11. When the equipment is powered from a gas pipeline with a gas pressure above 0.15 MPa (1.5 kgf / sq. cm), a pressure regulator (reducer) must be installed at each working station on the gas pipeline.
2.15.12. The air supply to the cutter of the heat machine from the workshop line with a pressure of more than 0.5 MPa must be carried out through a reducer.
2.15.13. When supplying posts with combustible gas and oxygen from cylinders, the latter must be installed in a vertical position in special racks and firmly attached to them with clamps or chains.
When powered from single cylinders, a safety device should be installed between the cylinders, reducers and the tool (torch and cutter).
On the racks there must be canopies that protect the cylinders from getting oil on them (for example, from an overhead crane). Cylinders must be located at least 1 m from heating devices and at least 5 m from open flame heat sources and stoves.
There should not be more than one spare filled cylinder per station and more than ten oxygen and five acetylene spare cylinders in the area and in the flame processing workshop. If you need a site with the number of posts up to 10 in in large numbers gas should be organized outside the premises of the site (workshop) ramp supply or intermediate storage of cylinders.
2.15.14. Oxygen sampling from cylinders must be carried out up to a residual gas pressure in the cylinder of at least 0.05 MPa (0.5 kgf / sq. cm).
2.15.15. Before starting gas welding and cutting, the following checks should be made:
a) tightness and strength of gas hose connection to the burner (torch) and reducers;
b) the presence of water in the valve to the level of the control cock and the tightness of all connections in the valve for gas passage, as well as the tightness of the hose connection to the valve.
2.15.16. Disassembly and repair of cylinder valves must be carried out by the plant (workshop) that fills the cylinders with gas.
In cases where gas cannot be used due to a malfunction of the cylinder valves, the cylinder must be sent to the factory (workshop) - the filler with the inscription in chalk: "Caution", "Full".
2.15.17. Installation of racks with cylinders in the aisles and driveways is prohibited.
2.15.18. It is forbidden to allow contact of cylinders, as well as hoses with current-carrying wires, which should be paid attention to Special attention those production sites where electric welding and gas-flame processing of metals are simultaneously used.
2.15.19. The connection of the reducer to the cylinder must be carried out with a key that is constantly with the welder (gas cutter). Tightening the union nut of the reducer with the cylinder valve open is prohibited.
2.15.20. To open the valve of the acetylene cylinder and to control the gearbox, the worker must have a special socket wrench. This key must be on the cylinder valve spindle at all times during operation.
The use of ordinary wrenches for these purposes is prohibited.
2.15.21. In cases where gas leakage is detected through the gland of the acetylene valve after the reducer is connected, the glands must be tightened with the cylinder valve closed.
The operation of a cylinder with a gas-permeable valve is prohibited. Such a cylinder with an inscription in chalk about a valve malfunction must be sent to the plant (workshop) - the filler.
2.15.22. Burners, cutters, hoses, reducers, valves, water locks and other equipment must be in good condition. The valves must reliably shut off the gas, and the glands must not let the gas through. Operation of equipment with leaks is prohibited.
Note. During operation, as a rule, the acetylene cylinder valve valve should open 0.7 - 1 turn in order to ensure that the valve closes quickly in the event of ignition or kickback.
2.15.23. Hoses must be used in accordance with their purpose. Do not use oxygen hoses to supply acetylene, or vice versa.
2.15.24. Hoses during gas welding must be protected from possible damage. When laying the hoses, they must not be flattened, twisted or kinked.
Do not use oily hoses. Hoses should not be exposed to sparks, fire or heavy objects, as well as exposure to high temperatures. Hoses should be inspected and tested at least once a month.
2.15.25. When using manual equipment, it is forbidden to connect plugs, tees, etc. to the hoses. to power several burners (cutters).
2.15.26. The length of hoses for gas welding and cutting should not exceed 30 m, and for installation work - 40 m.
2.15.27. The use of defective hoses, as well as winding them with insulating tape or other material, is prohibited. If it is necessary to repair the hose, the damaged places must be cut out, and the individual pieces connected with special nipples. It is forbidden to connect hoses using segments of smooth tubes.
The minimum length of the section of joined hoses must be at least 3 m; the number of joints on the hoses should not be more than two.
2.15.28. Attachment of hoses to the connecting nipples of equipment (torches, cutters, reducers, etc.) must be reliable; special clamps must be used for this purpose. It is allowed to tie the hoses with soft annealed steel (knitting) wire at least in two places along the length of the nipple. Hose connections must be carefully checked for tightness before and during work. On the nipples of water locks, the hoses must be tightly put on, but not fixed.
2.15.29. Gas-flame work (welding, cutting, gouging, gas smelting of metal defects and product heating) should be carried out at a distance of at least 10 m from portable generators, 1.5 m from gas pipelines, 3 m from gas folding posts during manual work and 1, 5 m - with machine. The specified distances refer to gas-flame work, when the flame and sparks are directed in the direction opposite to the gas supply sources.
In the case of directing flames and sparks towards power supplies by gases, measures must be taken to protect them from sparks or exposure to flame heat by installing metal screens.
2.15.30. Work on cutting metal using propane - butane or natural gas, as well as using open flame from other sources is allowed at a distance (horizontally) of at least:
From groups of cylinders (more than 2) intended for conducting gas-flame work - 10 m;
From individual cylinders with oxygen and combustible gases - 5 m;
From gas pipelines of combustible gases, as well as gas collapsing posts located in metal cabinets:
a) for manual work - 3 m;
b) during mechanized work - 1.5 m.
2.15.31. Metal cutting using propane - butane mixtures is allowed in open areas and in workshops.
2.15.32. Metal supplied for welding or flame cutting must be free of paint (especially lead-based), oil, scale, dirt to prevent metal spatter and air pollution by evaporation and gases.
The use of a gas flame for this purpose is prohibited.
2.15.33. When igniting a hand torch or cutter, welders and cutters should first slightly open the oxygen valve, then open the acetylene valve and, after briefly purging the hose from air, ignite the combustible gas mixture.
2.15.34. Long breaks from work (lunch break)
etc.), except for burners and cutting torches, the valves on oxygen and acetylene cylinders or on gas folding stations must be closed, and the pressure screws of the gearboxes must be turned out until the spring is released.
If the burner (torch) overheats, the work must be suspended, and the burner (torch) is extinguished and cooled to cool completely; to cool the torch, each welder (cutter) must have a vessel with clean cold water.
2.15.35. In the event of a backfire, immediately close the valve on the burner (torch), on the cylinders and on the water seal. Before the flame is re-ignited, the condition of the shutter must be checked after a blowback, and the hoses must be checked after each blowback.
2.15.36. In the event of a temporary cessation of work on gas cutting machines, during adjustment, installation of copiers, etc. the supply of gases and electric current to the machine must be stopped.
2.16 . Safety requirements for the performance of gas-flame work
When performing gas-flame work, the following requirements must be met:
2.16.1. In welding shops, at sites, general ventilation should be equipped, at stationary workplaces - local ventilation, ensuring the reduction of the content of harmful substances in the air of the working area not higher than the MPC, in accordance with GOST 12.1.005.
2.16.2. Before the start of the GOM, a check should be made:
Tightness of sleeves connection to the burner, cutter, reducer, safety devices and other equipment;
Serviceability of the equipment, presence of rarefaction in the channel for combustible gas of the injector equipment;
Status of safety devices;
Correct supply of oxygen and combustible gas to the burner, cutter or gas cutting machine;
Correctness and serviceability of current supply and grounding;
Availability and serviceability of fire extinguishing equipment.
2.16.3. In case of detecting leaks of oxygen and combustible gas from pipelines and gas stations and if it is impossible to quickly eliminate the malfunctions, the damaged section must be turned off and the room thoroughly ventilated.
Heating of frozen gas pipelines should be carried out only with steam or hot water. The use of open flames and electric heating is prohibited.
2.16.4. Gas supply of shops, workshops and sections of the GOM should be carried out:
through gas pipelines from acetylene and oxygen stations, as well as from distribution ramps with more than 10 permanent posts for gas welding and cutting.
from other sources of gas supply (pipelines of natural gas and other combustible gases, tanks with liquid fuel, etc.).
2.16.5. Oxygen ramps for powering one post for gas welding and cutting with up to 6 cylinders are allowed to be installed inside the production facility.
2.16.6. It is forbidden to fill systems and pipelines with oxygen without their preliminary degreasing.
2.16.7. On gas pipelines for natural gas or propane-butane, it is prohibited to install open-type liquid valves. The liquid level in the closed type valve must be constantly maintained at the height of the control cock. Checking the liquid level should be carried out at least three times per shift with the gas supply to the valve turned off.
2.16.8. When powering equipment for GOM from a gas pipeline with a gas pressure above 0.15 MPa, at each work station for gas welding and cutting on a gas pipeline, a pressure regulator must be installed, which serves to reduce gas pressure.
2.16.9. When supplying posts for gas welding and cutting with combustible gas and oxygen from cylinders, the latter must be installed in a vertical position in special racks and firmly attached to them with clamps or chains.
On the racks there must be canopies that protect the cylinders from getting oil on them (for example, from an overhead crane). Cylinders should be at least 1 m away from heating devices and 5 m away from heat sources with open flames.
When powered from single cylinders, safety devices, including flame arresters, should be installed between the cylinder reducers and the tool (torch, cutter, etc.).
At the GOM production site, there should not be more than one spare cylinder filled with combustible gas and oxygen for each post and no more than ten oxygen and five acetylene spare cylinders.
If there is a need for a GOM site with up to 10 gas welding and cutting posts in a large amount of gas, a ramp feed or an intermediate storage of cylinders located outside the site should be organized.
2.17 . Requirements for the storage and operation of gas cylinders
2.17.1. Gas cylinders must be stored and used in accordance with the requirements of the Rules for the Construction and Safe Operation of Pressure Vessels.
2.17.2. When storing cylinders in open areas, sheds protecting them from exposure to precipitation and direct sunlight must be made of non-combustible materials.
2.17.3. Flammable gas cylinders with shoes must be stored in a vertical position in special nests, cages and other devices that prevent them from falling.
Cylinders that do not have shoes must be stored in a horizontal position on frames or racks. The height of the stack in this case should not exceed 1.5 m, and the valves should be closed with safety caps and turned in one direction.
2.17.4. Empty cylinders should be stored separately from cylinders filled with gas.
2.17.5. Gas cylinders may be transported, stored, issued and received only by persons who have been trained in handling them and have a corresponding certificate.
2.17.6. During the operation, storage and movement of oxygen cylinders, measures must be taken to protect cylinders from contact with materials, workers' clothing and cleaning materials that have traces of oils.
2.17.7. Gas cylinders must be protected from shock and direct sunlight. Cylinders must be installed at a distance of at least 1 m from heating appliances.
2.17.8. During breaks in work, at the end of the work shift, the welding equipment should be turned off. The hoses must be disconnected and the blowtorches completely depressurized.
2.17.9. Upon completion of work, gas cylinders should be placed in a place specially designated for storage of cylinders, excluding access by unauthorized persons.
2.18 . electrical safety requirements
2.18.1. The operation of electrical equipment of thermal cutting machines and PN must be carried out in accordance with the requirements of the Rules for the Installation of Electrical Installations and the Interindustry Rules POT R M-016-2001.
2.18.2. Wires and cables for powering electrical equipment of machines and installations must have reliable insulation and protection against mechanical damage.
2.18.3. The electrical equipment of thermal cutting machines must be grounded. For stationary machines, the frame or rail track is subject to grounding, for portable machines - the machine body.
2.18.4. All shop and intershop gas pipelines must be grounded. The electrical resistance between the grounding device and any point of the gas pipeline should not exceed 100 ohms.
2.18.5. Welding circuits of welding power sources should not have galvanic connections with circuits connected to the network.
Separate elements of the welding circuit, as well as segments of welding cables, when increasing the length, must be connected with detachable couplings. It is forbidden to use twisted welding circuit connections with bare cable. The current-carrying cables of the welding circuit must be insulated along the entire length and protected from mechanical damage.
2.18.6. The control circuits of thermal cutting machines must be equipped with a minimum protection that excludes (regardless of the position of the controls) the spontaneous switching on of thermal cutting machines when a sudden loss of voltage is restored.
Portable thermal cutting machines must be disconnected from the electrical network during their movement.
2.18.8. The controls of thermal cutting machines must be provided with inscriptions or symbols indicating the controlled object to which they relate, its purpose and state: "on", "off", "brake", "running", etc.
2.18.9. Metal shafts of manual drives, handles, flywheels must be isolated from live parts of thermal cutting machines and have electrical contact with non-removable parts of the product, on which the grounding element is located.
2.18.10. During electric welding, equipment, apparatus and fixtures must be used that meet the requirements of the current standards and norms for the relevant welding equipment. The open circuit voltage of the welding power sources must not exceed the maximum values specified in the standards for the relevant equipment.
2.18.11. For arc welding it is necessary to use insulated flexible cables designed for reliable operation at maximum electrical loads, taking into account the duration of the welding cycle.
2.18.12. The connection of welding cables should be made by crimping, welding or soldering, followed by insulation of the connection points.
2.18.13. Connection of cables to the welding equipment must be carried out using crimped or soldered cable lugs.
2.18.14. When laying or moving welding wires, care must be taken to prevent damage to their insulation and contact with water, oil, steel ropes and hot pipelines. The distance from welding wires to hot pipelines and cylinders with oxygen must be at least 0.5 m, and with combustible gases - at least 1 m.
2.18.15. In electric welding machines and their power sources, live elements must be covered with protective devices.
2.18.16. Electrode holders used in manual arc electric welding with metal electrodes must comply with the requirements of current standards.
2.18.17. The electric welding installation (converter, welding transformer, etc.) must be connected to the power source through a knife switch and fuses or a circuit breaker, and if the open circuit voltage is more than 70 V, automatic shutdown of the welding transformer must be used.
2.18.18. Metal parts of electric welding equipment that are not energized, as well as welded products and structures, must be grounded for the entire time of welding, and for a welding transformer, in addition, the grounding bolt of the housing must be connected to the secondary winding terminal, to which the return wire is connected.
2.18.19. As a return wire or its elements, steel tires and structures can be used if their cross section ensures that the welding process is safe under heating conditions.
current. The interconnection of individual elements used as a return wire must be reliable and be carried out with bolts, clamps or welding.
2.18.20. It is forbidden to use ground wires, pipes of sanitary networks (water supply, gas pipelines, etc.), metal structures of buildings, technological equipment as a return wire for electric welding.
2.18.21. The body of any electric welding installation must be grounded. Machines in which the implementation of protective earthing is difficult, must be equipped with protective shutdown devices that ensure that all phases of the network are turned off when mains voltage appears in the welding circuit. To connect the ground wire on electric welding equipment, a bolt located in an accessible place with the inscription "Earth" (with the symbol "Earth") must be provided. Sequential connection of several devices to the grounding conductor is prohibited.
2.18.22. To supply current from the source to the electrode holder of the manual arc welding installation, a flexible wire in a rubber sheath must be used. The use of wires with insulation or sheathed from combustible polymeric materials is prohibited. Welding wires must be connected by hot soldering, welding or using sleeves with an insulating sheath.
The distance from welding wires to hot pipelines and cylinders with oxygen must be at least 0.5 m, and with combustible gases - at least 1 m.
2.18.23. Flexible wires, as well as metal tires of sufficient cross section, welding plates and the welded structure itself can serve as a return wire connecting the workpieces to be welded with the welding current source.
The use of the grounding network of metal building structures of the building, communications and non-welding technological equipment as a return wire is prohibited. The interconnection of individual elements used as a return conductor must be carried out by welding, clamping or clamping. When welding circular seams, it is allowed to connect the return wire to the welded product using a sliding contact.
2.18.24. On installations or automatic lines with a large service front, emergency shutdown buttons should be located at a distance of no more than 10 m from each other. The control buttons used in such cases should have latches that provide only a forced return of the contacts to their original state. Control panels are equipped with interlocks that exclude the possibility of parallel control from different panels, an alarm system, as well as emergency buttons to turn on the installation (line).
2.18.25. The scheme for connecting several welding current sources when working on one welding arc should exclude the possibility of obtaining a voltage between the product and the electrode that exceeds the highest open-circuit voltage of one of the welding current sources.
2.18.26. All electric welding machines with alternating current and direct current for welding in especially dangerous conditions (inside metal containers, wells, compartments, on pontoons, etc.), as well as manual welding machines with alternating current used in especially dangerous rooms or outside premises, must be equipped with devices for shutting off idling or limiting its voltage to 12 V no later than 1.0 s after opening the welding circuit.
The limiter, made in the form of a separate attachment, must be grounded with a separate conductor.
2.18.27. Closed spaces of tanks, boilers, metal containers, compartments, etc. when performing welding, surfacing and cutting, they should be illuminated with the help of lamps installed outside, or hand-held portable lamps with a voltage of not more than 12 V.
The transformer for portable lamps should be installed outside the workpiece to be welded, and its secondary winding should be grounded.
The use of autotransformers to lower the supply voltage of luminaires is prohibited.
2.18.28. Electrode holders for manual arc welding and cutting with metal carbon electrodes must meet the requirements of current standards.
It is forbidden to leave electric welding tools under voltage at the workplace.
Mobile electric welding installations must be disconnected from the mains during their movement.
2.18.30. Connection and disconnection from the network of electric welding installations, as well as monitoring their good condition during operation, must be carried out by the electrical personnel of this enterprise, having a qualification group for electrical safety not lower than III.
2.18.31. Due to the likelihood of exposure to electric current, all personnel servicing electric welding installations must be trained and certified for the appropriate qualification group in electrical safety.
2.18.32. Electric welders who have undergone special training may be assigned, in accordance with the established procedure, a qualification group for electrical safety III and above with the right to connect and disconnect electric welding installations.
2.18.33. When performing welding work inside tanks, the employer is obliged to provide employees with rubber dielectric galoshes, gloves, and a rubber helmet. When working lying down, a rubber mat must be used. The use of metal shields is prohibited.
2.19 . Fire requirements
2.19.1. Production and auxiliary premises for the production of gas and electric welding, as well as workplaces of workers employed in acetylene, oxygen and filling plants, must comply with fire safety requirements in accordance with the requirements of GOST 12.1.004 and be provided with primary fire extinguishing equipment in accordance with the requirements of the Rules fire safety in the Russian Federation, as well as fire equipment in accordance with the requirements of GOST 12.4.009 and have a degree of fire resistance according to the classification of fire safety industries.
2.19.2. Prior to the start of gas and electric welding work carried out in the room, an analysis of air samples from the upper points of the room and devices prepared for repair should be carried out in order to make sure that there is no explosive concentration of acetylene. The content of acetylene in the sample should not exceed 0.3 mg/l.
2.19.3. Upon completion of gas and electric welding, surfacing, cutting, the employee should not leave the workplace without making sure that there is no source that can cause a fire at the place of work and in adjacent premises. All workers must be trained in the rules for eliminating primary fires and the correct use of primary fire extinguishing equipment.
2.19.4. When performing gas and electric welding work, combustible structures must be protected by permanent or portable barriers, and combustible floors must be protected by metal sheets. Portable fences should be made of sheet steel.
2.19.5. Flammable organic solvents in the preparatory compartments must be stored only in the amount agreed with the fire authorities.
2.19.6. Places for the production of electric welding and gas flame works on this, as well as on the lower tiers (in the absence of fireproof protective flooring or flooring protected by fireproof material) must be freed from combustible materials within a radius of at least 5 m, and from explosive materials and equipment (gas generators, gas cylinders, etc.) - at least 10 m.
2.20 . Modes of work and rest
2.20.1. The work and rest regimes of employees engaged in all types of gas-flame processing of metals, the production of acetylene and oxygen, are determined by the internal labor regulations of the organization.
2.20.2. The work and rest regimes of workers performing work under the influence of hazardous and harmful production factors are determined taking into account the relevant regulatory legal acts for these conditions.
2.21 . Requirements for the selection and use of personal protective equipment (PPE)
2.21.1. Workers engaged in the production of gas-flame and electric welding work must be provided with personal protective equipment, in accordance with the Rules for providing workers with special clothing, special footwear and other personal protective equipment.
2.21.2. The personal protective equipment used must comply with the requirements of GOST 12.4.011.
The choice of specific types of personal protective equipment should be carried out depending on the type of work and the substances and materials used.
Protective equipment issued on an individual basis must be kept by the employee or at his workplace during work.
2.21.3. The choice of PPE should be determined depending on the level of contamination of the air and product surfaces with toxic substances, the intensity of noise, vibration, the degree of electrical safety, the microclimate at the workplace and the nature of the work performed.
2.21.4. RPE are used when ventilation does not provide the required air purity of the working area, provided for by the requirements of GOST 12.1.005.
2.21.5. The choice of PPE for the face and organs of vision should be made depending on the methods, modes and types of work, radiation intensity, and individual vision.
2.21.6. To protect the eyes from radiation, sparks and splashes of molten metal and dust, goggles of the ZP and ZN type must be used.
The choice of goggles should be made in accordance with the requirements of OST 21-6-87.
Light filters are allowed.
2.21.7. For manual and mechanical gas cutting, manual welding, gas gouging, gas smelting of metal defects and during heating of products and PN, gas welders and gas cutters should be provided with closed-type goggles with glasses of the TS-2 brand, having the density of light filters GS-3, when using burners (cutters) with an acetylene flow rate of up to 750 l / h, GS-7 - up to 2500 l / h and GS-12 - over 2500 l / h.
Auxiliary workers who work directly with a welder, cutter or a worker performing PN are recommended to use safety glasses with glasses of the SS-14 brand with P-1800 light filters.
2.21.8. To protect the face during welding, cutting, hardening, cleaning, heating and PN, workers must be provided with shields in accordance with the requirements of GOST 12.4.023.
NF - with head mount, shield body - light filtering;
KF - helmet-mounted shields, the body of the shield is light-filtering;
RF - a shield with a handle, the body of the shield - light filtering.
2.21.9. When carrying out electric welding and gas-flame works, the affecting noise should not exceed the values provided for by the requirements of GOST 12.1.003.
When the maximum permissible noise levels are exceeded, workers must be provided with PPE for the hearing organs: earmuffs, helmets or earplugs.
2.21.10. Hearing PPE should be selected based on the frequency spectrum of noise in the workplace. Types and groups of PPE for hearing organs should be selected in accordance with the requirements of GOST 12.4.051.
2.21.11. Workers using personal protective equipment should be instructed on the rules for using these equipment and how to check their serviceability.
2.21.12. Overalls should be harmless, comfortable, not restrict the movement of the worker, not cause discomfort, protect against sparks and splashes of molten metal, welded product, moisture, industrial pollution, mechanical damage, meet sanitary and hygienic requirements and working conditions. The choice of overalls depending on the welding methods and working conditions should be made in accordance with the recommendations of GOST 12.4044 and GOST 12.4.010.
2.21.13. When performing work on welding, surfacing, cutting, as well as when the ambient temperature is above 50 degrees. C, clothing must provide effective thermal protection.
2.21.14. To protect hands during welding, surfacing, welding and cutting, workers must be provided with mittens, mittens with leggings or gloves made of spark-resistant material with low electrical conductivity.
2.21.15. It is forbidden to use gloves and overalls made of synthetic materials such as lavsan, kapron, etc., which do not have protective properties, are destroyed by welding arc radiation and can ignite from sparks and splashes of molten metal, and sinter when in contact with heated surfaces.
2.21.16. To protect the legs from burns from splashes of molten metal, mechanical injuries, hypothermia when working outdoors in winter, overheating when welding heated products, as well as from electric shock, especially when working in closed vessels, compartments, workers must be provided with special footwear.
2.21.17. Safety shoes with open lacing and metal nails are not allowed.
III . REQUIREMENTS FOR PRODUCTION PREMISES AND SITES
3.1 . Requirements for the volume, location of the structure of the premises
3.1.1. For each stationary workplace of a gas welder or gas cutter, in addition to the area occupied by equipment and passages, at least 4.5 square meters must be allocated. m.
3.1.2. GOM sections with a significant excess of sensible heat and with a significant formation of welding aerosol should be placed in one-story buildings. If it is necessary to locate GOM sites in multi-storey buildings, measures should be taken to prevent the spread of harmful production factors between floors.
3.1.3. Welding, surfacing and cutting of metals with the release of beryllium and its alloys should be carried out in isolated, specially equipped rooms.
3.1.4. The categories of explosion and fire hazard of the premises must comply with the requirements of NPB 105-95 "Determination of the categories of premises and buildings in terms of explosion and fire hazard."
3.2 . Lighting Requirements
3.2.1. The technology of flame treatment of metals belongs to the second category of visual work in terms of accuracy. Natural and artificial lighting must meet the requirements building codes and rules.
3.2.2. Welding shops, areas and stationary workplaces must have natural and artificial lighting. Artificial lighting is divided into the following types: working, emergency (for continuing work), evacuation (emergency lighting for evacuating people).
3.2.3. The illumination of working surfaces in workshops should not be lower than those given in SNiP 23-05-95.
3.2.4. Artificial lighting should be provided mainly by a general uniform or localized lighting system, as well as a combined (general plus local) lighting system.
General uniform lighting should be arranged in workshops where large products are processed. General localized lighting should be used in the presence of fixed workplaces, taking into account the latter.
3.2.5. Combined lighting should be arranged in rooms where work is carried out to control defects. weld and other works related to the categories of visual work I, Ia and IIIb.
3.3 . Requirements for industrial premises and microclimate
3.3.1. In the working area of industrial premises of assembly and welding shops, sections and stationary workplaces, optimal or permissible combinations of temperature, relative humidity and air velocity should be provided, taking into account excess sensible heat, the severity of the work performed and periods of the year in accordance with SanPiN 2.2.4.548 .
3.3.2. To maintain a normal temperature in the working area during cold and transitional periods of the year, heating systems should be provided. In large assembly and welding shops, as a rule, air heating with controlled supply should be used.
air. The amount of air, direction of its flow and temperature are calculated for specific conditions. In the warm season, in the assembly and welding shops, natural ventilation should be used through the openings of windows, lanterns and gates.
3.3.3. Compliance with the optimal parameters of the microclimate is mandatory in places of temporary rest for workers. To ensure microclimatic conditions, air curtains should be installed near open openings.
Infrared radiation at permanent workplaces for welding, surfacing and cutting metals of heated products (taking into account the use of thermal protection means) should not exceed the levels established by the technical regulatory documentation.
With thermal irradiation up to 140 W / sq. m, the speed of air movement at workplaces should be increased by 0.2 m/s in comparison with the requirements of the technology.
If it is impossible by technical means to reduce the thermal exposure of workers to 140 W/sq. m requires the use of an air shower.
IV . REQUIREMENTS FOR LOCATION OF PRODUCTION EQUIPMENT AND ORGANIZATION OF WORKPLACES
4.1 . Requirements for the placement of production equipment
4.1.1. The requirements for the placement of production equipment and the organization of workplaces in assembly and welding shops and at sites comply with the requirements of Section IV of the Regulations POT R M-019-2001.
4.1.2. Welding, surfacing and cutting with an open arc of products of medium and small sizes in stationary conditions should be carried out in ventilated, specially equipped cabins. Cabins must be open-topped, made of non-combustible materials, a gap of at least 50 mm should be left between the skin and the floor, and when welding in a shielding gas environment, at least 300 mm. The area of the cabin must be sufficient to accommodate the welding equipment, table, fixtures and products to be welded. The free area in the cabin for one welding station cannot be less than 3 sq. m.
A cabin for two posts or more, as well as workplaces on production and conveyor lines, should be separated by fencing panels that separate welders from each other and provide enough space for everyone.
4.1.3. At stationary workplaces in the "standing" position, it is necessary to install special supports (suspensions) that reduce the static load on the welders' hands. It is forbidden to ease the load on the arm by transferring the hose (cable) over the shoulder or winding it around the arm.
4.1.4. Unauthorized persons are prohibited from being in places where welding, surfacing, cutting are performed.
It is necessary to provide fences that protect welders working next to or below the tier from radiation, sparks and splashes of molten metal, accidental falling of electrode stubs, etc.
4.1.5. Workplaces of welders indoors when welding with an open arc must be separated from adjacent workplaces and passages by fireproof screens (screens, shields) with a height of at least 1.8 m. When welding outdoors, fences should be placed in case of simultaneous work of several welders close to each each other and in areas of heavy traffic. If shielding is not possible, exposed persons must be protected with personal protective equipment.
4.1.6. During the performance of welding, surfacing and cutting of metals in the open air, shelters (canopies) from the weather must be built above the installations and welding stations. Welding equipment is placed in metal containers. In the absence of sheds, welding, surfacing and cutting operations should be stopped during rain or snowfall.
4.1.7. Places of welding work outside permanent welding posts must be determined by the written permission of the manager or specialist responsible for fire safety.
4.1.8. When performing welding work at a height of more than 5 m, scaffolding and platforms made of non-combustible materials should be installed. Electric welders are required to use safety belts and safety ropes with carabiners, as well as special bags for tools and collecting electrode cinders.
4.1.9. In the production of welding, surfacing and cutting of heated products, additional measures must be taken to prevent possible overheating. It is necessary to shield or cover the heated product to be welded, the arrangement of cabins or radiation cooling surfaces that reduce irradiance to 140 W/sq. m.
4.1.10. When welding with preheating, the work of two welders in one cabin is allowed only when welding one product.
4.1.11. The temperature of covered and open heated surfaces of products at workplaces should not exceed 45˚С.
4.1.12. When performing electric welding and gas-flame work inside containers or cavities of structures, workplaces must be provided with exhaust ventilation. The speed of air movement inside the container (cavity) should be 0.3 - 1.5 m / s.
4.1.13. Work inside containers at air temperatures above 50˚С is prohibited without the use of special insulating personal protective equipment that provides effective thermal protection and clean air supply to the breathing zone.
4.1.14. When gas cutting and welding products, a permanent workplace should be equipped with a rationally arranged table or device that serves to hold and move the workpiece. These devices should provide a comfortable position for the body of the worker, and when welding or manually cutting small parts, the ability to perform work while sitting.
4.1.15. Hand torches, torches, gearboxes, hoses and gas cutting machines in use must be assigned to specific workers.
4.1.16. The use of acetylene from the pipeline during gas welding is allowed only through the post gate. One post can be attached to one gate. If a gas station feeds a machine operated by one operator, then the number of burners or hoses installed on the machine is limited only by the throughput of the gate. In manual gas flame operations, only one burner or cutter can be connected to the valve.
4.1.17. At stationary workplaces of electric welders, gas welders and cutters, a rack with a hook or fork should be installed for hanging extinguished burners or cutters during work breaks. At temporary workplaces, extinguished burners or cutters can be hung on parts of the structure being processed (brackets, measuring devices, longitudinal stiffeners, etc.).
4.1.18. Work at unenclosed or uncovered hatches, openings, wells, etc. prohibited.
4.1.19. It is forbidden without the permission of the master to remove the fences and covers of manholes, openings, wells, etc., even if they interfere with work.
If guards or covers have been removed during operation, they must be replaced at the end of work.
4.1.20. When descending into closed containers through the hatch, make sure that the hatch cover is securely fastened in the open position.
4.2 . Job organization requirements
4.2.1. During the work of gas welders and gas cutters, the cabinets of acetylene and oxygen posts must be open, the approaches to all posts must be free and not cluttered. Periodically, as needed, the distinctive color of the cabinets should be restored.
4.2.2. Placement of acetylene generators in driveways, places of mass location or passage of people, as well as near places of air intake by compressors or fans is not allowed.
4.2.3. During breaks in work, at the end of the work shift, the welding equipment should be turned off. The hoses must be disconnected and the blowtorches completely depressurized.
4.2.4. Requirements for operating modes, equipment maintenance procedures under normal operating conditions and in an emergency should be established in accordance with the instructions for the safe operation and maintenance of stationary and portable machines, as well as technological and regulatory technical documentation on labor safety and industrial sanitation.
4.2.5. During long breaks in work, the valves on the gas dismantling stations, equipment and cylinders should be closed, and the adjusting screw of the gearbox should be turned out until it is completely released by spring pressure.
4.2.6. Stationary machines with a marching speed of more than 6 m/min must be equipped with a seat or a platform for joint movement of the operator with the machine, providing ease of machine control.
4.2.7. Management and control of stationary machines must be carried out from the control panel. The controls must be provided with clear inscriptions, symbols indicating the controlled object to which they relate, its purpose and state (emergency stop, power cut, etc.) or the position of the control in accordance with the requirements of regulatory documents.
4.2.8. If stationary machines have more than one control element for the same parameter, the possibility of simultaneous control of this parameter from different posts should be excluded.
4.2.9. The controls that start and stop the thermal cutting process must comply with current safety requirements.
4.2.10. The control and monitoring system for the operation of semi-automatic and automatic plasma stationary and portable machines must be carried out remotely. Before the "standby arc" appears, the open-circuit voltage must be applied to the plasma torch by turning on the "Start" button, which is not secured by blocking. After excitation of the "standby arc", the "Start" button should be automatically blocked. Removal of voltage from the plasma torch when the arc is turned off or broken should also be performed automatically.
4.2.11. The control panels of stationary machines must have a "Stop general" button that provides power off and gas supply to the cutter or burner. The "Stop General" button should be red, mushroom-shaped, oversized and protrude above the surface of the control panel.
4.2.12. Electric wires and cables for powering electrical equipment of machines and installations must have external insulation and protection against mechanical damage (casings, hangers, cable laying device, cables).
4.2.13. When assembling and repairing vessels, welding is allowed at negative ambient temperatures if the requirements stipulated in the standards, technical conditions or instructions for assembling and repairing vessels are met.
4.2.14. Before starting plasma cutting, you must:
Check the operation of the cooling system;
Set the required cutting speed;
Set the flow rate of the plasma-forming medium in accordance with the technological process;
Check for water in the cutting table or frame tray.
4.2.15. To protect workers not associated with the maintenance of the plasma torch from visible and ultraviolet radiation of the plasma arc, the plasma torch area must be protected by casings or screens made of non-combustible materials. To protect the operators of overhead and other cranes operating in the zone of visibility of the plasma arc, it is necessary to glaze the lower part (one third) of the observation cabin with light filters of the C-5 and C-6 types.
4.2.16. Troubleshooting the machine, the plasma torch, replacing failed replaceable parts of the plasma torch should be done only when the power of the installation is turned off and only by servicemen servicing this installation, who have a qualification group for electrical safety not lower than III.
4.2.17. When igniting the "standby arc", the nozzle opening must be directed away from those working nearby. When igniting the "standby arc" by closing, use a special device with an insulated handle at least 150 mm long.
4.2.18. At the workplace, there must be a rubber dielectric carpet underfoot, which, in terms of terms and standards, must meet the requirements of GOST 12.4.034.
V . REQUIREMENTS FOR INITIAL MATERIALS AND BLANKS, THEIR STORAGE AND TRANSPORTATION
5.1. Materials used in equipment used for gas welding, cutting and similar processes must comply with the requirements of GOST 29090.
5.2. Materials that come into contact with gases during operation must be resistant to the chemical, mechanical and thermal effects of these gases under any operating conditions. Chemically unstable materials in direct contact with gases must ensure their normal functioning in the temperature range from minus - 20˚C to +60 ˚C.
5.3. Special requirements are imposed on the materials used when working with acetylene. For the manufacture of parts in contact with acetylene, it is not allowed to use:
Copper and alloys containing more than 65% copper (excluding mouthpieces and tips of torches and cutters);
Materials containing copper, including ceramic-metal, fibrous and finely dispersed (for flame arresting, filtering, etc. elements with a large surface);
Silver and its alloys (excluding hard solders);
Zinc (excluding anti-corrosion coatings);
Aluminum, except casting.
5.4. The raw materials (metals, electrodes, solders, fluxes, welding wire, gases and liquids) used in the performance of welding, surfacing and cutting operations must not have a harmful and dangerous effect on workers and must comply with the grades and requirements specified in the technology.
5.5. The surface of workpieces, parts and welding wires to be welded must be dry, free from scale, grease, rust and other contaminants.
5.6. Degreasing of surfaces for welding should be carried out using solutions, the composition of which is approved for use by the sanitary authorities.
Do not use trichlorethylene, dichloroethane or other chlorinated hydrocarbons for degreasing.
5.7. Containers for degreasing solutions must be special, unbreakable, with a capacity of not more than 200 cubic meters. cm with forced supply of a solution for wetting tampons. Used swabs should be collected in a special container made of unbreakable and non-flammable material with a tight lid.
5.8. It is forbidden to wipe the edges of products heated to temperatures above 45 ° C with solvents.
5.9. IN cold period metal, blanks and products to be welded must be supplied to the workshop in advance so that by the beginning of welding their temperature is not lower than the air temperature in the workshop.
5.10. Welding materials (electrodes, fluxes) used for welding, surfacing and cutting must be calcined or dried before starting work under the conditions recommended by the technological passport for this grade of material.
5.11. It is not allowed to use in welding, surfacing, cutting welding materials that do not have a sanitary and hygienic assessment.
5.12. Surfaces of parts (products) to be welded and deposited, coated with anti-corrosion primers that contain harmful substances, are subject to obligatory pre-cleaning from soil over a width of at least 100 mm from the welding point.
5.13. Welding consumables (electrodes, fluxes, wires) must be stored in covered dry rooms. The presence of vapors of alkalis, acids and other aggressive substances in the air of warehouses is not allowed.
Storage of welding wire, fluxes and electrodes must comply with the requirements of the technical passport for this grade of material.
VI . RESPONSIBILITY FOR VIOLATION OF THE RULES
Persons guilty of violating labor protection legislation are held accountable in accordance with the established procedure.