Oxy-fuel welding and cutting: Beyond the risk assessment

When it comes to oxy-acetylene welding or cutting,
consideration needs to be given towhat should happen
after the risk assessment has taken place – and this is
where many companies fall short says Paul Woodford

If using oxy-acetylene welding &
cutting equipment in the working
environment, there is a legal
requirement under the Management of
Health & Safety at Work Regulations
(S.I. 3242 of 19999) to carry out a formal
risk assessment. This provides a careful
examination of what could cause harm
to people so that companies can weigh
up whether enough precautions have
been taken or more should be done to
prevent harm to the workforce. While
the law does not expect companies to
eliminate all risks, the onus is on
protecting people where it is ‘reasonably
practicable’. As this is a legal
requirement, it is reasonable to assume
that the overwhelming majority of
companies carry out risk assessments.

Those that don’t may feel the full weight
of the law in the event of an incident.

When it comes to oxy-acetylene welding
or cutting, consideration needs to be
given to what should happen after the
risk assessment has taken place – and this
is where many companies fall short, since
from here on in, it’s more about Codes of
Practice rather than any legally binding
requirement.

So what is the Code of Practice?
The British Compressed Gases
Association is recognised by the Health
and Safety Executive as an independent
expert with the confidence and knowledge
to lay down in “Code of Practice CP7 –
The Safe use of Oxy-Fuel Equipment
(Individual Portable or Mobile Cylinder
Supply),” all the essential practices. It is
worth pointing out that failure to comply
with this Code is not in itself an offence,
but, in case of an incident, a company
may be invited to explain how its
operation ensured at least an equal level
of safety to that provided by CP7.

CP7 provides detailed information on
the continuing inspection of oxy-fuel
equipment, its safe use, its maintenance
and its replacement within safe time
limits as well as manufacturers’
recommendations.

The latest version is Revision 5: 2008
and it includes terminology and
definitions of equipment within this
category including properties of gases,
process hazards, the application of the
Pressure Systems Safety Regulations,
safety precautions for equipment,
provision of safety devices, operational
safety, cylinder handling and storage,
preparation for use, closing down and
maintenance procedures. A Tabulated
Guidance on Maintenance spells out
visual and physical inspection procedures,
tests, replacement refurbishment intervals
and guidelines for regulators, flashback
arrestors, hose assemblies, blow pipes and
cylinder valves with integrated pressure
regulators (VIPR). This critical
information and adaptation of the
procedures discussed is vital for all
companies to follow in order to maximise
the benefits of having carried out the risk
assessment.

How to actually carry out the
inspections, checks and procedures as
laid out in the Code of Practice is a
further area of consideration. Do you
have experienced in-house staff to carry
out these tasks? Do you know a third
party, such as your equipment supplier,
who may undertake this work? Do you
need to get an existing employee to
obtain Gas Inspection Certification or
indeed be recertified if he has undertaken
this work in the past? The essential
requirement is for the employee to be
demonstrably competent, which may be
by a combination of training and
experience.

If companies do not already have
qualified personnel, there are
opportunities for them to attend training
courses in order to become formally
competent. Selecting actual courses is a
matter of choice. It pays to shop around
and compare course prices and content.

Any course that offers delegates
certification by London City and Guilds is
definitely worthy of consideration and
most likely to bring the peace of mind –
and competence – that you require.

Standards and practices relating to
oxy-fuel cutting and welding safety are the
subject of continual change – especially
with the globalisation of national and
European standards. Your gas inspectors
need to be kept fully up to date to keep
you onside and your workplace and staff
safe.

Paul Woodford is product manager for Gas
Equipment, Murex Welding Products