Torch Cutting Identifying Potentially Dangerous Materials Terry McWhorter, CSP Use this material at your own risk. It is provided for discussion and informational purposes only. The David J. Joseph Company does not make any representations, express or implied, regarding the use, accuracy or applicability of this information. In no event shall DJJ be held liable for any damages or costs whatsoever related to the use of his information. These materials are presented “as-is” and “as available.” DJJ emphasizes the importance of consulting qualified professional advisors on safety programs and concerns.

Torch Cutting – Identifying and Addressing Potential Dangers • • • •

Contractor Evaluations Safety program requirements Dual inspection process Identifying potential hazards in torching area • Training

Contractor Accident • Track roller assembly was being torched into thirds. This photo shows three complete cuts and one partial cut.

• Location of nitrogen tensioning cylinder • Position of contractor torch cutter

Contractor Accident

Photo 1

• Section of cylinder wall found approximately 15 feet from track assembly

Photo 2

• Section of cylinder wall found several hundred feet to west in the parking lot (est, > 10 lbs.)

Contractor Accident

• Bolt hole spacing on cover • Sheet steel cylinder (15 inches) matches bolt cover found on scrap spacing on track yard roadway a few assembly hundred feet to west.

Contractor Evaluations • Meet with torching contractors – Gain general knowledge about their organizations – Safety policies – Training – Approach to supervision – Attitudes toward safety – Explain our expectations

Torching Safety Program Requirements • New employee training • Torching safety policies – – – –

PPE Torch use and maintenance Safe cutting practices Specific cutting procedures

• Respirator policy/training – Pulmonary function test – Fit testing – Respirator selection, care and maintenance

Torching Safety Program Requirements (cont.) • Lead program requirements – Biological testing • Lead blood levels semi-annual

– Air Monitoring • Once per quarter if over PEL

– Facility controls • • • •

Warning signs Laundering Dirty/clean rooms Eating/drinking/smoking rules

– Training

Dual Inspection Process • Joint effort between our “Qualified Inspector” and contractor crew supervisor • Thorough inspection every time scrap is laid out and before torching commences • Purpose is to detect any hazards (springs, accumulators, tensioners, tanks, fluids, shifting scrap, etc.) that might be present • Scrap deemed safe to cut will be marked with a green “O”. • Scrap with potential hazards will be marked with a red “X” and set aside for further evaluation • Torchmen are trained to only cut green circle scrap (Refer to safety guideline document for more detail)

Potential Hazards • Fire/Flashback/Explosions – Flammable liquids/vapors – Combustible liquids • Oils, greases – Combustible Materials – Compressed gases • Stored energy – Springs – Hydraulics – Units charged with gas or air – Coils/Cables under tension • Falling/shifting material

Fire/Flashback/Explosions  Acceptance criteria  Must have hole at least 12 inches cut into them for inspection.  No liquids or sludges inside  Look for multiple compartments  Must be free of combustible vapors, measured with an LEL meter

 Shear whenever

possible

Fire/Flashback/Explosions • Axle Housings • Several gallons of oil

• Hydraulic Cylinders/ Shock Absorbers

• Pressurized oil

Fire/Flashback/Explosions  Not always obvious  Feller-Buncher (used in

logging industry)  This fuel tank looks like a counter weight

Stored Energy • • • •

Springs Hydraulics Units charged with gas or air Coils/Cables under tension

Springs under tension • Compressed springs contain massive stored energy • Many are hidden by cover plates • Cut the necessary number of coils to relieve tension • Make sure rod is in place and do not cut rod

Caterpillar Dozer Example

Springs under tension • Cut spring first before downsizing material (cutting steel around spring first could cause spring to dislodge under tension and project out)

Coils under tension • Steel & wire coils can cause injury when tension is released during torching. • Face open end during cutting • Allow for the spreading of material when torching. Stand on this side when cutting

Do not stand on this side! Stand on this side when cutting

This is where the steel is going when cut

Hydraulic Accumulators • Energy storage device used in an hydraulic system in which hydraulic oil is held under pressure by an external source. • This external source could be: – Compressed gas (inert) – Spring – raised weight • Types of gas-charged – Diaphragm – Bladder – Piston

Hydraulic Accumulators Applications • Purpose is to hold pressure so the supply circuit can respond more quickly to any temporary demand and smooth pulsations • Supplement pump flow • Maintain system pressure – Compensate for pressure loss due to leaks – Emergency power supply, ensure fail-safe operations • Absorb shock • Dispenser for pressurized lubricants • Noise Attenuation

Where can we find accumulators? • Mobile equipment – Track assemblies – tensioners designed to keep tracks on rollers – Brake systems – Steering systems – Servo systems – Shock absorbers – suspension, crane booms – Back pressure devices – grapples, buckets

• Anything with hydraulics

Where can we find accumulators?

JLG Manlift

 Volvo L150

Brake System

Cat 773

Front/Rear Shocks

Cat IT 28G Cat IT 28G

Accumulators – How do we handle?  Identify through

inspection and set aside. Never torch!  Arrange for hydraulics expert to evaluate and service and/or..  Set in designated location and arrange for disposal

Accumulators

Falling/Shifting Scrap • Plan the cut – How many cuts? – Where will the pieces fall? (away from you and others)

• Take a safe position • Do not cut when the falling piece requires you to move out of the way • Never stand on scrap while torching

Falling/Shifting Scrap • Stage scrap so rotating parts don’t shift during processing.

Planning • Material layout

– How many cutters? Who’s cutting what? – Start away from torch pot then work back. – Setup access & exit paths during material layout.

• Inspect area

– Dual inspection each time scrap is laid out – Mark items to identify what cannot be cut – Make sure scrap is positioned to fall safely

• Inspect torching equipment and PPE • Fire protection – Dunk tanks – Extinguisher – Water buckets

Dual Inspection in Action • Concrete Mixer

Look for Warning Stickers

Dual Inspection in Action

Dual Inspection in Action Bolted inspection covers

Dual Inspection in Action

Dual Inspection in Action

Dual Inspection in Action 

• Terex Accumulators

Multiple springs

• Stamping Dies

Use this material at your own risk. It is provided for discussion and informational purposes only. The David J. Joseph Company and it’s affiliates, subsidiaries, officers, managers, employees and agents (collectively, “DJJ”) does not make any representations, express or implied, regarding the use, accuracy or applicability of this information. User’s of this material must implement their own safety program and shall maintain complete responsibility for the accuracy and appropriate application of this information. In no event shall DJJ be held responsible nor liable for any indirect, direct, incidental, special, or consequential damages or costs whatsoever resulting from or related to the use or misuse of this information, whether based on contract, tort, strict liability or otherwise. These materials are presented “as-is” and “as available.” DJJ emphasizes the importance of consulting experienced and qualified attorneys, government agencies, safety experts, advisers, consultants, and other professionals to assure the best results for your safety program and for addressing any particular safety concerns. Please note that some jurisdictions may not allow the exclusion of certain damages, so some of the above exclusions may not apply to you.