Safety Protocol 001: Comprehensive Plasma Cutting Emergency Procedures¶

Protocol ID: U5M4-SAFE-001 Context: Master emergency response protocol covering all plasma cutting incident types, evacuation procedures, and post-incident requirements Hazard Level: Very High — Plasma cutting produces simultaneous electrical, thermal, radiation, respiratory, and noise hazards

Potential Hazards¶

Immediate Life-Threatening Hazards¶

Electrocution: 200-300V DC open circuit voltage can cause cardiac arrest. DC current causes sustained muscle contraction, preventing the victim from releasing the conductor
Severe burns: Plasma arc (25,000-45,000°F), molten metal ejection, hot workpiece contact. Third-degree burns possible from brief contact
Fire/explosion: Spark ignition of combustibles, cutting containers with residual flammable vapors, dust collection system fires
Asphyxiation: In enclosed spaces, plasma cutting consumes oxygen and produces toxic gases (ozone, NOx, metal fumes)

Delayed-Onset Hazards¶

Arc eye (photokeratitis): UV corneal damage — symptoms appear 6-12 hours after exposure
Metal fume fever: Zinc oxide inhalation — symptoms appear 4-12 hours after exposure (galvanized steel)
Chronic respiratory disease: Repeated exposure to metal fumes, hexavalent chromium (stainless steel), or other carcinogens
Hearing damage: Cumulative noise exposure above 85 dB

Required Precautions & Procedures¶

Before ANY Plasma Cutting Operation¶

Complete pre-cut safety inspection (see U5M4-ACT-002 for procedure)
Verify all emergency equipment is accessible and functional:
E-stop: tested
Fire extinguisher: charged, correct type (ABC or CO₂), within 15 feet
Eyewash station: functional, water flowing
First aid kit: stocked
AED: charged and accessible
Ensure at least one other person is present in the shop — never plasma cut alone
Clear all combustibles within 35 feet (NFPA 51B)
Deploy welding screens around the cutting area
Verify ventilation is operating
All personnel in the area: PPE verified or behind screens
Fire watch person designated (may be the operator if no other hot work is occurring)

During Operation¶

Operator within arm's reach of E-stop at all times
No unauthorized personnel within 35-foot perimeter
Continuous monitoring for fire, fume, arc stability, and material security
No reaching into cutting zone while machine is armed (power supply on)
Verbal alert before initiating any arc

Post-Operation¶

Fire watch for minimum 30 minutes
Mark all hot metal with "HOT" (soapstone or heat marker)
Do not leave the area until fire watch is complete
Document any incidents, near-misses, or safety observations
Power off all equipment, verify main disconnect is off

Emergency Response¶

Response Priority Order¶

For any emergency: STOP → ALERT → ACT → REPORT

STOP: Press E-stop. Remove yourself from danger. Assess the scene
ALERT: Shout "EMERGENCY!" to alert others. Assign someone to call 911
ACT: Perform the appropriate response (see below)
REPORT: Document and report to supervisor

Electrical Shock¶

E-stop / main disconnect — DO NOT touch the victim if still energized
Use non-conductive object to separate victim from circuit
Call 911
Check breathing and pulse. Begin CPR if no pulse. Use AED if available
Treat for shock: keep victim warm, elevate legs (if no spinal injury suspected)
Even if victim seems fine → MUST go to hospital (cardiac arrhythmia risk)

Severe Burns (Second/Third Degree)¶

E-stop. Remove source of burn if safe to do so
Cool with running water for 20 minutes minimum (NOT ice)
Do NOT remove clothing stuck to the burn
Do NOT apply any substances (ice, butter, ointment)
Cover loosely with sterile dressing
Call 911 for: burns >10% body area, face/hands/feet/genitals, third-degree, electrical burns, inhalation burns
Treat for shock: keep victim calm, warm, and still

Fire¶

E-stop plasma cutter
Assess fire size — can you fight it safely?
If small (wastebasket-size or less): P.A.S.S. technique with extinguisher
If growing or large: EVACUATE via nearest exit, close doors, pull fire alarm, call 911
Do NOT re-enter the building until cleared by fire department
If a person's clothing is on fire: STOP-DROP-ROLL, smother with welding blanket

Arc Eye (Photokeratitis)¶

Move affected person to dim/dark area
Apply cool, wet compresses to closed eyes
Do NOT rub eyes. Do NOT apply eye drops without medical direction
OTC pain relief (ibuprofen) as needed
Seek medical attention — severity may worsen over 6-12 hours
Document exposure: time, duration, shade worn (if any), material being cut

Metal Fume Inhalation¶

Move to fresh air immediately
If conscious and breathing: monitor, encourage rest, hydrate
If severe respiratory distress: call 911, administer O₂ if available/trained
Provide medical responders with: material type, cutting duration, PPE worn
Metal fume fever is self-limiting (24-48 hours) but requires medical evaluation
Hexavalent chromium exposure (stainless steel): requires medical monitoring per OSHA

Evacuation Procedure¶

When the fire alarm sounds or evacuation is ordered: LEAVE IMMEDIATELY
Press E-stop on your way out if within reach — do not go back for it
Use the nearest exit — do not use elevators
Assist anyone who needs help evacuating
Meet at the designated assembly point
Instructor/supervisor accounts for all personnel
Do NOT re-enter until the building is cleared by emergency services

PPE Requirements¶

PPE Item	Specification	Standard
Welding helmet	Shade 8-12, auto-darkening recommended	ANSI Z87.1
Safety glasses (under helmet)	Impact-rated, side shields	ANSI Z87.1
FR jacket/shirt	Long sleeve, snapped/buttoned	ASTM F1506
Leather gloves	14" gauntlet, heat resistant	CE EN 12477
Leather boots	Steel/composite toe, 8" shaft	ASTM F2413
Hearing protection	NRR 25+	ANSI S3.19
Respirator (minimum)	P100 half-face	NIOSH approved
Respirator (galvanized/stainless)	P100 + OV cartridge	NIOSH approved

Last Updated: 2026-03-19