UPF PROJECT PROCEDURE

Title: UPF AND CUTTING SAFETY Document Number: UPF-CP-225WCS Revision: 000 Page: 1 of 13

Prepared by:

. 05/09/16 . Brian Garrett, Date BNI UPF ES&H Lead

Approved by: . 05/09/16 . Ed Kelley, Date BNI UPF ES&H Manager

Approved by: . 05/09/16 .

Gary Hagan, Date UPF ES&H Manager

Concurrence by: . 05/09/16 . Lynn Nolan, Date UPF Manager of Construction

. 05/10/16 . James W. Sowers, Date UPF Quality Assurance Manager

05/11/16

Effective Date

RC-UPF DMC This document has been reviewed by a Y-12 DC / RC-UPF DMC UCNI-RO and has been determined to be 05/10/16 15:15 UNCLASSIFIED and contains no UCNI. This review 05/10/16 15:32 does not constitute clearance for Public Release. Name:______Date:______05/09/16

UPF-CP-225WCS Revision 00 Page 2 of 13 UPF Welding and Cutting Safety

Revision History

Revision Reason/Description of Change Initial issue. 000

UPF-CP-225WCS Revision 00 Page 3 of 13 UPF Welding and Cutting Safety

Table of Contents

1.0 PURPOSE ...... 4 2.0 GENERAL ...... 4 Description ...... 4 Acronyms ...... 4 Definitions ...... 4 3.0 RESPONSIBILITIES ...... 5 Construction Manager ...... 5 Field Safety Manager...... 5 Field Safety Representative ...... 5 Discipline Superintendent ...... 5 Supervisor ...... 5 Worker...... 5 4.0 WELDING AND CUTTING CONTROLS ...... 5 Fire Prevention ...... 5 Protection of the General Area ...... 6 Exposure Controls ...... 6 Cylinder “Use Status” ...... 8 4.5 Other Gas Welding, Cutting, and Heating Equipment ...... 8 4.6 Welding or Cutting with Electrical Equipment ...... 9 ...... 11 5.0 RECORDS ...... 11 6.0 REFERENCES ...... 11 Source References ...... 11 Interfacing References ...... 11 7.0 EXHIBITS / APPENDICES / FIGURES ...... 111 7.1 Appendix A – Welding Filter Lenses and Plates ...... 112

UPF-CP-225WCS Revision 00 Page 4 of 13 UPF Welding and Cutting Safety

1.0 PURPOSE This procedure provides safety and health requirements for welding and thermal cutting activities performed on the UPF construction site and other support areas.

2.0 GENERAL Description This procedure is applicable to welding, cutting, heat-treating, grinding, and other welding operations in support of Uranium Processing Facility (UPF) construction operations. Acronyms CM Construction Manager DS Discipline Superintendent FSM Field Safety Manager FSR Field Safety Representative UPF Uranium Processing Facility Definitions Combustible Material - A material that, in the form in which it is used and under the conditions anticipated, has the potential to ignite and burn. Enclosed Spaces - Any space, other than a confined space, which is enclosed to the extent that natural ventilation is not favorable. Exothermic Welding - A welding process, including, but not limited to Thermite or Cad- Welding, that produces coalescence of metals by heating them with superheated liquid metal resulting from a chemical reaction between a metal oxide and aluminum, with or without the application of pressure. , where used, is obtained from the liquid metal. Flammable Material – Materials (solid, liquid, or gas) that are easily ignited and capable of burning rapidly. Fuel Gas - Acetylene; hydrogen; natural gas; LP-Gas; methylacetylene-propadiene, stabilized; and other liquefied and non-liquefied flammable gases that are stable because of their composition or because of the conditions of storage and utilization Gas(es) – Propane, argon, nitrogen, mixed gases, or other fuel gases used with or without oxygen for cutting and welding activities. Gas Cylinders “In Storage” - A gas cylinder is considered “In Storage” when it is reasonably anticipated that gas will not be drawn from the cylinder within 24 hours (overnight hours included). In Use - Gas Cylinders “In Use” - A gas cylinder is considered “In Use” when it is reasonably anticipated that gas will [ibid] be drawn from the cylinder within 24 hours, based on the welding work being planned. Mechanical Ventilation – Work environment air movement systems are of two types for the purpose of this procedure: UPF-CP-225WCS Revision 00 Page 5 of 13 UPF Welding and Cutting Safety

 General Mechanical Ventilation – Systems that move air for an identified area (building or room) such as roof or wall exhaust fans. Coppus blowers, used for areas without established general mechanical ventilation, are also considered general ventilation.  Local Exhaust Ventilation – Air movement systems, equipped with freely movable intake hoses or hoods that can be placed close to a source, and have a determined capacity, can remove airborne fumes and dust and maintain safe breathing conditions. Welding/Cutting Operations – Processes such as , oxy-fuel gas welding, metal inert gas (MIG) welding, grinding, open-flame soldering, brazing, thermal spraying, oxygen cutting, and arc cutting.

3.0 RESPONSIBILITIES Construction Manager – has the overall responsibility for ensuring the implementation of this procedure, ensuring that all project personnel actively participate; and provides worker support, facilities, and other resources necessary to effectively carry out this procedure. Field Safety Manager - has the overall authority for interpretation of the regulations associated with the procedure and the interpretation of the procedure as to intent and application. Field Safety Representative – has the responsibility of compliance oversight with the procedure through periodic field inspections and is responsible for supplying technical advice and interpretation of the environmental, safety, and health codes included in the procedure. Discipline Superintendent – is responsible for being thoroughly familiar with this procedure and their individual responsibilities regarding compliance with and implementation of this procedure, pre-planning work activities to identify the appropriate work controls and ensuring workers understand the requirements of the procedure. Supervisor – is responsible for ensuring the applicable safety controls and processes are incorporated into planning and execution of the work and that the workers are implementing and complying with this procedure within their area of responsibility. Worker – is responsible for understanding and complying with the requirements of this procedure.

4.0 WELDING AND CUTTING CONTROLS Fire Prevention  Welding operations performed outside designated hot work areas are allowed only after a Hot Work Permit is generated per procedure Y17-95-64-877, Hot Work Permit. o Fire watches are activated through the Hot Work Permit and roles are defined in procedure UPF-CP-227, Safety Watches.  For compressed gas cylinder requirements reference procedure UPF-CP-225, Compressed Gas Cylinders.

UPF-CP-225WCS Revision 00 Page 6 of 13 UPF Welding and Cutting Safety

Protection of the General Area Locate welding equipment, machines, cable and other apparatus so that it does not present a hazard to personnel. Keep passageways, ladders, and stairways clear. Route hoses, cords and leads so they do not create a tripping hazard and are not subject to physical damage. Post signs, in accordance with procedure UPF-CP-214, Barricade and Signs, as needed. Exposure Controls 4.3.1 Eye and Face Protection To protect worker’s eyes and face during welding and cutting activities, the following actions shall be performed:  Use eye and face protection equipment (welding helmets) that meet requirements specified in American National Standards Institute Z87.1-1968, Practice for Occupational and Educational Eye and Face Protection (See Appendix A). o When two or more welders, or a welder’s helper are exposed to each other’s arc, wear appropriate filter lens protection. o When working in areas not protected from arc by screening, wear appropriate filter lenses.  Protect workers or other persons adjacent to the welding areas from the radiant energy and spatter of welding and cutting by use of non-combustible or flame-resistant screens or shields. Position screens to allow air circulation.  During orbital pipe welding, the welder and observers shall use either helmets or hand shields to protect against flashes and radiant energy.  Welder’s ears and throat shall be protected from direct radiant energy from the arc and from direct weld spatter.  Ensure welding helmets and hand shields are free of leaks and openings, and free of highly reflective surfaces. 4.3.2 Head Protection When use of a hard hat affects the safe performance of work or is infeasible due to the physical obstructions in the work area, soft cap welding hoods can be used. Reference procedure UPF-CP-205, Personal Protective Equipment, for instructions. 4.3.3 Protective Clothing

The following requirements shall be applied in the use of protective clothing:

 Protective clothing shall be selected to minimize the potential for ignition, burning, trapping hot sparks, or electric shock.  Ensure clothing provides sufficient coverage to minimize skin burns caused by sparks, spatter, or radiation.  Ensure protective gloves are made of flame-resistant material and are in good repair. Welding and cutting tasks require the use of gauntlet style gloves.  Use flame-resistant aprons to protect the front of the body when additional protection against sparks and radiant energy is needed. UPF-CP-225WCS Revision 00 Page 7 of 13 UPF Welding and Cutting Safety

 For heavy welding/cutting activities producing excessive sparks and slag (e.g arc gouging), use flame-resistant leggings or other equivalent means to give added protection to legs.  During overhead welding, cutting or other burning operations, wear cape sleeves or shoulder covers with bibs made of leather or other flame-resistant material. 4.3.4 Ventilation Protection for Welding, Cutting, and Heating 4.3.4.1. General Welding, cutting, and heating activities performed under normal conditions with adequate natural ventilation do not require additional mechanical ventilation or respiratory protective equipment, except where an unusual physical or atmospheric condition exists that can cause an unsafe accumulation of contaminants. 4.3.4.2. General Mechanical Ventilation When required, general mechanical ventilation shall be of sufficient capacity and so arranged as to produce the number of air changes necessary to maintain welding fumes and smoke within safe limits. As a general rule, provide a minimum ventilation flow rate of 2,000 cubic feet per minute per welder or a room air change every 5 minutes. Items for consideration include:  The type and size of space (e.g. enclosed space)  The type of welding, cutting, or burning activity (e.g. MIG or arc cutting)  Number of workers performing welding or burning activities 4.3.4.3. Local Exhaust Ventilation Local exhaust ventilation shall consist of freely movable hoods (e.g. welding fume extractor) intended to be placed by the welder or burner as close as feasible to the point off operation. This system shall be arranged to remove fumes and smoke at the source and minimize the concentration of them in the worker’s breathing zone. Requirements for local exhaust shall be determined through ES&H evaluation and outlined in the JHA. 4.3.4.4. Special Materials  When welding, cutting or heating in enclosed spaces which involve metals, listed below, having a content equal to or greater than the percentage shown, use local exhaust, hoods, or other means approved by ES&H. TABLE 1.

Material % Volume

Zinc See 4.3.5, Removing Protective Coatings

Manganese > 3.0% Filler Material or base metal

Cadmium > 3.0% Filler Material or base metal

Chromium > 1.0% Filler Material or base metal

 When using the materials in Table 1 in the open air, protect workers by appropriate means determined through ES&H evaluation and outlined in the JHA.  Other nearby workers exposed to the same atmosphere as the welders or burners shall be protected in the same manner as the welder or burner. UPF-CP-225WCS Revision 00 Page 8 of 13 UPF Welding and Cutting Safety

4.3.5 Removing Protective Coatings  When in a confined or enclosed space, prior to welding on a material covered with a protective coating, remove coating a minimum of 4 inches to minimize toxic fumes evolution during welding, or as otherwise directed through the hazard control process.  When in other areas (open air), prior to welding on a material covered with a protective coating, remove coating a minimum of 2 inches, or as otherwise directed through the hazard control process, from the heat affected area.  For either case presented above, if specified coating minimums removal distance cannot be achieved, contact ES&H to determine if an exposure assessment has been or needs to be performed to determine controls.  During removal process (grinding or other method), utilize the work control process to mitigate potential exposures resulting from coating removal activities. 4.3.6 Cleaning Compounds Follow the manufacturer’s instructions and precautions in the use of cleaning materials with regard to toxicity or flammability. 4.3.7 Welding, Cutting, and/or Heating in Confined Spaces

 For ventilation controls and other hazard mitigation actions while working in confined spaces, see procedure Y73-750, Confined Spaces.  Fuel gas and oxygen manifolds and cylinders shall not be taken into confined spaces.  When welding or cutting is suspended for an appreciable time, including lunch or breaks, torch valves will be closed and removed from the confined space, and the gas supplies positively shut off outside the confined space.  Remove cylinder regulators at the end of shift. Cylinder “Use Status” A gas cylinder configured to have gas drawn from it to perform welding or cutting work is considered “In use”. Gas cylinders can remain in an “In Use” configuration as long as gas will be drawn within a 24 hour period.  When cylinders are configured for “in use”, but gas will not be drawn for a period of time, cylinder valves will have caps installed until gas is required.  When gas cylinders are in use, the welding cart is to be tagged indicating the craft using the cylinders, the discipline superintendent/subcontractor, and the date cylinders were configured for welding work. Other Gas Welding, Cutting, and Heating Equipment 4.5.1 Hoses The following requirements shall be performed or verified:  Ensure fuel gas hose and oxygen hose are easily distinguishable from each other, using different color marked hoses, repetitive labeling, or easily recognized surface characteristics.  Inspect all in use hoses at the beginning of each working shift.  If hoses are found to be damaged/defective, tag (Danger-Defective Tool/Equipment Do Not Use) and return to a controlled area.  Do not interchange oxygen and fuel gas hoses. UPF-CP-225WCS Revision 00 Page 9 of 13 UPF Welding and Cutting Safety

 Do not use a single hose having more than one gas passage.  When parallel sections of oxygen and fuel gas hoses are taped together, verify that no more than 4 inches out of 12 inches are covered by tape.  Use only hose couplings that cannot be unlocked or disconnected by means of a straight pull without rotary motion.  Ensure gas hose storage boxes are ventilated.  Check hose connections for leaks, after assembly or repair and before lighting the torch.  Do not use flames to check for gas leaks. 4.5.2 Torches The following requirements shall apply when using torches:  Inspect torches at the beginning of each shift for leaking shutoff valves, hose couplings and tip connections.  Before lighting the torch for the first time each day and after a cylinder change, hoses shall be purged individually. Do not purge hoses into confined spaces or near ignition sources.  Use a friction lighter, stationary pilot flame, or other suitable sources of ignition. Do not use matches, cigarette lighters, or welding arcs for lighting torches.  Flashback arrestors and reverse flow check valves are required to be installed at the torch on both the fuel gas and oxygen inlets. Flashback arrestors and reverse flow check valves can either be built into the torch or installed inline. o Flashback arrestors and reverse flow check valves are not required on propane torches (e.g., weed burners) equipped with a built-in excess shut-off valve located on the tank end of the hose assembly. 4.5.3 Regulators and Gauges The following requirements shall apply when using torches:  Verify that oxygen and fuel gas pressure regulators, including their related gauges, are the correct equipment for the task and are in proper working order while in use.  Inspect union nuts and connections on regulators before use to detect faulty seats which can cause leakage when the regulators are attached to cylinder valves or hoses. Replace damaged nuts or connections.  Before a regulator is removed from a cylinder, close cylinder valve and release the gas from the regulator.  Inline flashback arrestors and reverse flow check valves are required to be installed at the regulator discharge on both the fuel gas and oxygen regulators. Welding or Cutting with Electrical Equipment 4.6.1 Operating Instructions

 Prior to starting welding and cutting activities, all welding leads and ground connections will be inspected to make certain the connections are properly made.  Report any faulty or defective equipment to the supervisor.  Protect welding equipment from moisture intrusion and wet environments.  Verify that no leaks exist in the cooling water, , or engine fuels that can adversely affect the safety of a welder. UPF-CP-225WCS Revision 00 Page 10 of 13 UPF Welding and Cutting Safety

 When arc welding work is left unattended or suspended for an appreciable time, including lunch, the user will turn off the welding unit’s power switch, remove the , and place the holders so that accidental electrical contact cannot be made with other workers or conducting objects.  Multiple Welding Units (A bank of welders) - When not in use, perform the following: o Remove metal and carbon electrodes from holders to eliminate danger of electrical contact by personnel or conducting objects. o Place holders so that they cannot make electrical contact with persons, conducting objects, flammable liquids, wet earth, or compressed gas cylinders.  Protect welding leads or cords that cross a roadway from damage by underground burial or equally effective methods. 4.6.2 Manual Electrode Holders Only manual electrode holders, specifically designed for arc welding and cutting, and of a capacity capable of safely handling the maximum rated current required by the electrodes, shall be used. 4.6.3 Welding Cables and Connectors The following requirements for welding cables and connectors shall apply:  Ensure all arc welding and cutting cables are of the completely insulated, flexible type, capable of handling the maximum current requirements of the work in progress, taking into account the duty cycle under which the arc welder or cutter is working.  Do not use welding cables with splices within 10 feet of the electrode holder.  Tag out cables in need of repair, per procedure UPF-CP-200, General Safe Work Practices. 4.6.4 Ground Returns and Machine Grounding The following requirements shall be applied for grounding:  Verify that ground return cables have a safe current carrying capacity equal to or exceeding the specified maximum output capacity of the arc welding or cutting unit which it services.  Do not use pipelines containing gases or flammable liquids, or conduits containing electrical circuits as a ground return.  Ensure arc welding and cutting machine frames are grounded. o Grounding of the welding machine frame will be checked and special attention given to safety ground connections of portable welding machines. o For grounding circuits by other than by means of the structure, ensure that the circuit between the ground and the grounded power conductor has resistance low enough to permit sufficient current to flow to cause the fuse or circuit breaker to interrupt the current.  Inspect ground connections to ensure that they are mechanically strong and electrically adequate for the required current.  All direct current (DC) welding machines operating on one structure (e.g. one pipe system, I-beam) shall be connected with the same polarity. All alternating current (AC) welding machines operating on one structure shall be connected to the same phase of the supply circuit and with the same instantaneous polarity. UPF-CP-225WCS Revision 00 Page 11 of 13 UPF Welding and Cutting Safety

 Ensure work return (ground) lead connections are as close to the point of welding as possible. Exothermic Welding  Exothermic welding molds are to be dried thoroughly before igniting charge and provided with a cover. When the charge from exothermic welding has been ignited, the operator stands several steps away (at least 120 inches away from the charge) and wears goggles.  Bulk storage of exothermic welding materials shall be maintained in a detached shed at least 30 feet from the main buildings.  Storage sheds shall be maintained in a dry condition, posted as “NO HOT WORK / OPEN FLAME”, and kept locked.  Where storage near the point of use is necessary, keep it at least 10 feet away from that point and limited to a supply necessary for one workday. Use an approved flammable liquid storage cabinet, keep the area dry and the cabinet locked.  Containers for the starting material shall be closed tightly after each use.

5.0 RECORDS All records generated as a result of this procedure are maintained in accordance with Y15-101, Records and Controlled Documents, and Y15-95-800, UPF Document Management.  None.

6.0 REFERENCES Source References  29 CFR 1926 Subpart J, Welding and Cutting  NFPA 51B, Standard for Fire Prevention during Welding, Cutting, and Other Hot Work  ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes  Bechtel Core Process – 211, Fire Prevention and Protection  Bechtel Core Process – 225, Compressed Gas Cylinders Interfacing References  UPF-CP-200 – General Safe Work Practices  UPF-CP-225 – Compressed Gas Cylinders  Y73-750 – Confined Space  UPF-CP-205 – Personal Protective Equipment  UPF-CP-214 – Barricades and Signs  UPF-CP-227 – Safety Watches  Y17-95-64-877 – Hot Work Permit

7.0 EXHIBITS / APPENDICES / FIGURES Appendix A – Welding Filter Lenses and Plates

UPF-CP-225WCS Revision 00 Page 12 of 13 UPF Welding and Cutting Safety

Appendix A – Welding Filter Lenses and Plates

Blended Table of 1910 Subpart Q, 1926 Subpart E and ANSI Z49.1-2005 Guide for Shade Numbers Areas marked (*) is information from tables in 1910 Subpart Q and 1926 Subpart E Shade numbers are given as a guide only and may be varied to suit individual needs. Minimum Suggested* Electrode Size - in. Arc Current Protective Shade No. Process (mm) (Amperes) Shade (Comfort) Shielded Metal Arc Welding (SMAW) Less than 3/32 (2.4) Less than 60 7 10 (*) 3/32 - 5/32 (2.4 - 4.0) 60 - 160 8 10 5/32 - 1/4 (4.0 - 6.4) 160 - 250 10 12 More than 1/4 (6.4) 250 - 550 11 14 (GMAW) Less than 60 7 — and Flux Cored Arc Welding (FCAW) 60 - 160 10 11 160 - 250 10 12 250 - 500 10 14 Less than 50 8 10 (GTAW) 50 - 150 8 12 150 - 500 10 14 Air Carbon Arc Cutting (CAC-A) (Light) Less than 500 10 12 (Heavy) 500 - 1000 11 14 (PAW) Less than 20 6 6 to 8 20 -100 8 10 100 - 400 10 12 400 - 800 11 14 Plasma Arc Cutting (PAC) Less than 20 4 4 20 - 40 5 5 40 - 60 6 6 60 - 80 8 8 80 - 300 8 9 300 - 400 9 12 400 - 800 10 14 Stud Welding — — 3 or 4 Torch Brazing (TB) — — 3 or 4 Soldering — — 2(*) Torch Soldering (TS) — — 2 Carbon Arc Welding (CAW) — — 14 — — 10 -14(*)

UPF-CP-225WCS Revision 00 Page 13 of 13 UPF Welding and Cutting Safety

Appendix A: Welding Filter Lenses and Plates (Continued)

Plate Thickness Suggested* Shade No. in. mm (Comfort) Oxyfuel Gas Welding (OFW) Light Under 1/8 Under 3 4 or 5 Medium 1/8 to 1/2 3 to 13 5 or 6

Heavy Over 1/2 Over 13 6 or 8 Oxygen Cutting (OC) Light Under 1 Under 25 3 or 4 Medium 1 to 6 25 to 150 4 or 5 Heavy Over 6 Over 150 5 or 6 *As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.