SECTION 2 - SAFETY AND RECOMMENDED PRACTICES

NLB's warranty will be voided if non-NLB manufactured replacement parts

are used. NLB's warranty is void as to any damages caused to the equipment
and to exclude any liability as a result of injury, if such damage or injury can
be linked to the substandard replacement part.

2.1 - Safety Precautions That Must Be Observed By User

Refer to the SAFETY section before operating any high-pressure water jetting
components. DO NOT operate this or any high-pressure water jetting component or
system without first reading and understanding the SAFETY section. If the safety
section is missing from this binder, call NLB at (800) 227-7652 for a free copy.
Safety Signs: All NLB high-pressure water jetting equipment has safety signs
strategically placed on the equipment. If any become marred, painted over, or in any
manner unreadable, contact NLB for free replacements. These signs are furnished
as an aid to training employees and as a reminder to operators and their fellow
employees. The safety signs are not intended to be used as a substitute for a
specific company training program covering the operation and safety of the
equipment. It is the supervision's responsibility to call these signs to the attention of
all personnel.

2.1.1 - Operator Safety Equipment

NLB offers complete operator safety suits for high-pressure waterblasting

operations and recommends the use of all operator and jobsite safety equipment
that is available. NLB also offers operation, maintenance & parts manuals and
jobsite barrier marking tape.

The use of hearing protection is advised when operating this equipment.

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2.1.2 - Pre-Service Safety Checklist
The Pre-Service Safety Checklist is attached to all NLB high-pressure water jetting
units. If it becomes marred, painted over, or in any manner unreadable, contact NLB
for a free replacement.
Identical printed forms are available from NLB. In addition to checking off the
information on the unit decal, the job foreman should also fill out and sign one (1) of
the printed forms to be maintained in the company.

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2.1.3 - Recommended Safety Procedures Decal

The Recommended Safety Procedures Decal is attached to all NLB high-pressure

water jetting units. If it becomes marred, painted over or in any manner unreadable,
contact NLB for a free replacement.

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2.2 - Safety Aspects of High-Pressure Water Cleaning Systems
For maximum operational safety, the following equipment and manual procedures
must be used where applicable:

2.2.1 - Equipment

High-Pressure Pump: The principle component of the high-pressure water jetting

cleaning system is usually a positive displacement high-pressure pump which
discharges water into a common manifold to which flexible hoses or lances with
nozzles or other cleaning or cutting accessories are attached. The pumps are
appropriately powered and can be either mobile or permanently mounted. They
shall never be operated above NLB's recommended operating pressure.
Relief System: The system shall be equipped with an automatic relief device on the
discharge side of the pump, adjusted so that the maximum allowable working
pressure of the system is not exceeded by more than 3%.
Pressure Gauge: The system shall be equipped with a gauge to indicate the
pressure being developed.
Filter or Strainer: The water system shall be equipped with a filter or strainer to
prevent particles from entering the high-pressure pump and damaging the plungers.
Dump System: The system shall be equipped with a device which will by-pass the
flow or dump the discharge pressure to a safe level immediately when actuated. An
operator shall control this dump system.
Hose Assembly: Hose assemblies used on the discharge side of the pump shall
have a safety factor of 3.0 based on the manufacturer's rated minimum burst
pressure.
Fittings/Valves: All fittings and valves used in the discharge side of the pump shall
have a safety factor of 3.0 based on the tensile strength of the materials.
Electrical Controls:All electrical controls handled by personnel shall either be
fail-safe, low voltage or protected with an approved ground fault circuit interrupter.

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2.2.2 - Personal Protective Equipment

It is essential that each operator wear the appropriate protective equipment to

accomplish the job safely. The following is a list of NLB recommended safety
equipment:
Body Protection: Liquid resistant suits.
Head Protection: Head protection equipment - hard hats.
Eye and Face Protection: Protective eye and face equipment - face shields.
Foot Protection: Steel-toed boots.
Hand Protection: NLB safety gloves.
Ear Protection: Ear plugs or other suitable protection shall be worn when noise
level exceeds OSHA recommended levels.
Recommendation: The safety engineer or someone thoroughly familiar with the
potential hazards to be found at the location where the work is being performed
should be consulted prior to starting work to determine potential environmental
and/or personal problems peculiar to that specific task. If any are determined to
exist, appropriate action must be taken prior to starting the job.

2.2.3 - Pre-Operational Procedures

Planning: Pre-job planning shall take place prior to start of any job. Personnel
familiar with the equipment to be cleaned and the environment of the work area
shall meet with the personnel who will be doing the cleaning or cutting and outline
the potential hazards of the work area, environmental problems and safety
standards.
Check List: A safety and equipment checklist shall be used.
Barricades: Barricades shall be erected to enclose hazardous areas. Barricades
may be rope, safety tapes, barrels, etc. as long as an effective visible barrier is
provided.
Hook-Up: Inspect all hoses and fittings for evidence of excessive wear and
damage prior to installing. Hoses should be laid out in a safe and orderly manner.
Hoses, pipes, and fittings shall be supported to prevent excessive sway, vibration, or
stress on end connections. Hoses should be protected to prevent kinking or
excessive wear.
Nozzles: Before installing the nozzle, the system shall be completely flushed with
sufficient water to remove air and foreign particles. Inspect all nozzles for damage
and/or plugged orifices before installing. The high-pressure water jetting unit should
be shut-off and disconnected before installing nozzles.

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2.2.4 - Operation Procedures

Work Area: All personnel working or entering the barricaded area while cleaning or
cutting is in progress shall wear the required protective equipment in accordance
with the job conditions.
Pressuring System: Pressure shall be increased slowly on the system while being
inspected for leaks and/or faulty components. All leaks or faulty components shall
be repaired or replaced. System shall be de-pressurized to effect repairs.

Never leave the system unattended when pressurized.

2.2.5 - Training

Cutting Action: Demonstrate the cutting action and potential hazard involved
through the use of audio-visual aids or actual use of the equipment. Cut through a
piece of lumber, dissect a grapefruit, etc.
Personal Protective Equipment: Explain the minimal personal protective
equipment required. Instruct when and how specific limb guards, special clothing
and other types of devices should be worn per type of work performed, locations,
etc.
System Operation: Explain the operation of the system, pointing out potential
problems and proper corrective action.
Safety Devices: Explain the reason for and operation of, safety devices. Stress the
importance of not tampering with any safety devices.
Hose: Explain the proper method of connecting hoses, including laying out without
kinks, protection from excessive wear and proper tools to use on couplings and
fittings.
General: The system shall be de-pressurized anytime the system is not in use. The
system shall be de-pressurized anytime an unauthorized person enters the
barricaded area. The system shall be de-pressurized when any replacement or
repairs are made to the system.

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2.3 - Recommended Practices

2.3.1 - Introduction

These recommended practices cover the personnel requirements, operator training,

operating procedures, and recommended equipment for the proper operation of all
types of high-pressure water jetting equipment as normally used by industries
concerned with construction, maintenance, repair, cleaning, and demolition work.
Attention is drawn to the relevant or proposed OSHA, ASTM, and ANSI standards. It
is intended that extension to this code will be produced in due course to cover
specialist applications (e.g. multiple-gun operation, pulsed jets, cutting with the use
of abrasives and high-pressure intensifiers) but in the meantime, these practices
should be used as far as practicable.
The use of high-pressure water jets for cutting and cleaning is a rapidly evolving
technology with current developments occurring. For this reason, these practices
are dated and the association shall bi-annually review these practices for any
required changes.

2.3.2 - Scope

S The recommended practices are intended to provide guidance on the proper

operation of high-pressure water jet cleaning and cutting equipment.
S In this document, the word “shall” indicates a requirement that is to be
adopted in order to comply with these recommended practices.
S The term “high-pressure water jetting” covers all water jetting, including the
use of additives or abrasives at pressures above 1000 psi (70 bar) approxi‐
mately.
S These recommended practices are also applicable at lower pressures where
there is foreseeable risk of injury. As a guideline, the recommended practices
are applicable where the product of pressure - measure in psi (bar), times
flow - measure in gallons per minute (liters per minute) exceeds 2,000 psi
times gpm (560 bar times lpm).
S Any person required to operate or maintain high-pressure water jetting
equipment shall have been trained and have demonstrated the ability and
knowledge to do so.

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2.3.3 - Definition of Terms

High-Pressure Water Jet Systems: High-pressure water jet systems are water
delivery systems which have nozzles or other openings whose function is to
increase the speed of liquids. Solid particles or additional chemicals may also be
introduced, but the exit in all cases will be a free stream. In terms of these
recommended practices, the “system” shall include the pumps (pressure producing
devices) and the hoses, lances, nozzles, valves and safety devices as well as any
heating elements or injection systems attached thereto.
High-Pressure Water Cleaning: The use of high-pressure water, with or without
the addition of other liquids or solid particles, to remove unwanted matter from
various surfaces where the pressure of the liquid jet at the orifice exceeds 1,000 psi
(69 bar).

The lower limit of 1000 psi (69 bar) does not mean that pressures below 1000
psi (69 bar) cannot cause injury or require any less attention to principles of
these recommended practices. Adequate precautions, similar to those of
these recommended practices, are required at all pressures.

High-Pressure Water Cutting: The use of high-pressure water, with or without the
addition of other liquids or solid particles, to penetrate into the surface of a material
for the purpose of cutting that material, and where the pressure of the liquid jet
exceeds 1000 psi (69 bar).
Lancing: An application whereby a lance and nozzle combination is inserted into
and retracted from the interior of a pipe or tubular object.
Dump System: An operator controlled, manually operated device or system that
rapidly reduces the pressure to a level that yields a pressure flow at the nozzle that
is considerably below the risk threshold.
Moleing: Moleing is an application whereby a hose, fitted either with a nozzle or
with a nozzle attached to a lance, is inserted into and retracted from the interior of a
tubular product. It is a system commonly intended for cleaning the internal surfaces
of pipes or drains. It can be self-propelled by its backward directed jets and is
manufactured in various shapes, sizes, and combinations of forward and backward
directed jets.

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 Nozzle: A device with one (1) or more openings where the fluid discharges from the
system. The nozzle restricts the area of flow of the liquid, accelerating the water to
the required velocity and shaping it to the required flow pattern and distributed for a
particular application. Combinations of forward and backward nozzles are often
used to balance the thrust. Such nozzles are commonly referred to as tips, jets,
orifices, etc.
Operator: A person who has been trained and has demonstrated the knowledge
and experience to perform the assigned task.
Operator Trainee: A person not qualified due to the lack of knowledge and/or
experience to perform the assigned task without supervision.
Shotgunning: An application whereby a lance and nozzle combination can be
manipulated in virtually all planes of operation.
Hose Assembly: A hose with coupling attached in accordance with manufacturer's
specifications.
Lance: A rigid metal tube used to extend the nozzle from the end of the hose.

2.3.4 - Equipment Definitions and Standards

Pressurizing High-Pressure Pump: A unit designed to deliver high-pressure

water or other fluid. This is usually based on positive displacement pistons or rubber
diaphragm/hydraulic systems and discharges water into a common manifold to
which either flexible hoses, or rigid tubing connecting to lances and nozzles are
attached. These high pressure pumps can be either mobile or permanently
mounted.
The pump should have a permanently mounted tag or tags providing the following
information:
S Product and supplier.
S Product model and serial number or year of production.
S Maximum performance in terms of flow - measured in gpm (lpm), and pres‐
sure measured in psi (bar).
S An outline of recommended safety procedures.
Relief System: The system shall be equipped with an automatic relief device on the
discharge side of the high-pressure pump.

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Automatic Pressure Relief Devices: These may Take the form of:
S Pressure Relief valve (by-pass valve) or Bursting Disc (rupture disc) in
Holder: Usually mounted on the pump discharge chamber to prevent the
pressure exceeding the rated maximum pressure of the whole system.
S Automatic Pressure Regulating Valve (unloading valve): Limits the pres‐
sure at which the high-pressure pump operates by releasing a preset propor‐
tion of the generated flow back to the pump suction chamber or to waste. It
may be used to regulate the water pressure from the pump and is individually
set for each operation. This device may be integral with the pump hydraulic
assembly. Where there is no demand for pumpage, the water pressure is
brought down to zero.
S By-Pass Valve: A device which can be adjusted to control the flow and thus
the pressure of the jet stream issuing from the nozzle by by-passing the
excess flow to another circuit.
S Pressure Gauge: The system should be equipped with a gauge indicating
the pressure being developed. Gauges shall have a a scale range of at least
50% above the maximum working pressure of the system.
S Filter or Strainer: The water system should be equipped with a filter or
strainer to prevent particles from restricting orifices in the nozzle. The filter or
strainer should be capable of removing particles smaller in size than the
smallest orifice in The nozzle and usually smaller to protect the high-pres‐
sure pumps, etc.
S Dry Shut-Off Control Valve: This operator-controlled valve, normally hand-
controlled, automatically shuts off flow to the lance and/or nozzle assembly
when released by the operator, but retains the operating pressure within the
supply line when so shut-off. This valve shall be used in systems with an
automatic pressure regulating valve. This valve may alternatively be actuated
by solenoid or pilot pressure system.

Care should be taken to release the pressure in the dry shut-off valve and line
when the pump is shut down, otherwise the valve operating lever may remain
alive.

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 S Dump System: The system should be equipped with a device which will
either shut down the unit, idle it to a safe rpm, by-pass the flow, or reduce the
discharge pressure to a low level. The dump system actuator device should
be shielded to preclude inadvertent operation. This device should immediate‐
ly shut off the high-pressure water stream if the operator loses control.
S Dump Control Valve: This operator-controlled valve, normally hand-con‐
trolled, automatically terminates significant flow to the lance and/or nozzle
assembly when released by the operator, thus relieving the operating pres‐
sure within the whole system by diverting the flow produced by the pump to
atmosphere. A valve size should be selected that will not cause generation of
or significant back pressure at the maximum possible pumping rate of the
pump. This valve may alternatively be actuated by a solenoid or pilot pres‐
sure mechanism.
S Solenoid and Electronically Operated Control Dump Systems: All electri‐
cally controlled dump systems should be of a fail safe design. Voltage of an
alternating current (AC) or direct current (DC) dump system handled by
personnel should not exceed 24 volts.
High-Pressure Hose: This is a flexible hose which connects two (2) components
and which delivers the high-pressure fluid to the gun or nozzle components. The
hose should have a burst rating of of a minimum of two and one-half (2.5) times the
intended working pressure. Operating levels below this ratio should require a
protective shielding around that hose. The hose should be marked on one (1) end
with the manufacturer's symbol, the serial number and the maximum permissible
operating pressure and test pressure. The high-pressure hose should be tested at
one and a half (1.5) times the working pressure.
End Fittings and Couplings: High-pressure hose, end fittings and couplings shall
be manufactured to be compatible with the hose and tested as a unit.
Jetting Gun Extension: This is a length or lengths of tube carrying high-pressure
fluid to the nozzle. Each shall be manufactured from suitable material for the
application. End connections shall be suitable for the application. The extension is
used in conjunction with a control valve. The extension shall have a minimum burst
strength of at least two and one-half (2.5) times the highest actual operating
pressure being used.
Nozzle: The nozzle creates the water-jet, or jets, at the required velocity, flow rate,
pressure, shape, and distribution for a particular application. Combinations of
forward and backward directed water jets are often used to balance the thrust. Such
nozzles may be referred to as tips, jets, or orifices.

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Water Jet: A jet stream of water produced from an individual outlet orifice of a
nozzle. The shape of the jet is determined by the form of the orifice while the speed
at which it travels is determined by the orifice design, orifice area and flow. The
pressure drop at the orifice is a result of an increase in velocity. The most commonly
used jet shapes are the straight-jet and fan-shaped jet.
S Straight-Jet: Concentrates the stream of water over a small area of the
work piece by minimizing the spread. A typical application is for cutting or for
general cleaning of matter with higher shear and/or bond strength.
S Fan Jet: Spreads the stream of water on one (1) plane, so giving a wide
band coverage of the work piece. A typical application is for cleaning larger
areas requiring less energy to remove unwanted matter.
Jetting Hand Manifold and Spray Bars: These are pieces of equipment into which
individual nozzles are fitted.
Foot Control Valve: The lance/gun operator's control valve may be arranged for
actuation by the operator's foot if desired, either in place of, or in addition to the
hand-control. An adequate guard should be fitted to prevent accidental operation
and the base plate area should be sufficient to ensure stability in use. If on the dump
type, the layout should ensure that the dump line, if used, is restrained from
whipping when the valve is released.
Jetting Gun: A portable combination of operator's control valve and nozzle which
resembles a gun in layout and outline. The control valve is hand-operated,
generally by a squeeze action of the hand of the operator, who should always have
control of this device and may be of the dry shut-off, or dump type, the gun being
named accordingly. The hand-control normally takes the form of a trigger or lever
which should be provided with either a guard adequate to prevent accidental
operation, or the means of being immobilized in the “OFF” position by means of a
safety catch. The gun may be fitted with a shoulder pad or hand grips to facilitate
back thrust control.
Retro Gun: A retro safety gun is fitted with forward and backward facing jets. This
reduces the thrust experienced by the operator. This type of gun is used mainly for
underwater high-pressure water jetting operations. The retro balance jet protection
tube should be sufficiently long or constructed so as to prevent the operator from
directing a retro balance jet at themselves.
Changeover Valve: An operator-controlled valve designed to properly direct
high-pressure water flow from the pump to one (1) or another items of equipment at
the operator's choice. It shall be designed to withstand the maximum pressure and
can be power operated.

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2.3.5 - Care and Maintenance of Equipment

High-Pressure Water Jetting Unit: The unit shall be maintained in accordance

with NLB's instructions. Where applicable, this should include daily checks on the
following items:
S Drive: Lubricating oil, water, hydraulic fluid and fluid levels.
S High-Pressure Pump: Lubrication oil and gearbox oil levels.
S Hydraulic Hose Reel: Lubricating oil and fluid levels.
S Condition of Guards and Shields: Wear and/or damage.
Filters and Strainers: All water filters should be checked at regular intervals,
dependant upon the supply water conditions and in accordance with NLB's
recommendations. Extreme care should be taken to filter the water source through
proper micron filtration, to prevent foreign particles from cutting changeover valves
and seating surfaces and to prevent clogging the changeover valve operating
mechanism. Such clogging can cause a loss of control, which can be dangerous to
the lance/gun operator.
Hose Assemblies: All hose assemblies shall be inspected prior to use with respect
to the following:
S Correct pressure rating and size.
S Free from external damage - e.g., exposed or broken wires.
S All end fittings and couplings are in good order and of the correct pressure
rating for the unit operating pressure.
Nozzles: All jetting nozzles shall be kept clean and the orifice shall be checked to
ensure that it is not obstructed or damaged before installation. Defective nozzles
shall not be used but should be replaced or repaired before installation. During the
start-up, prior to operation, the nozzle should be removed from the lance and the
system flushed thoroughly to remove air and foreign particles.
Jetting Guns and Lances: Jetting guns and lances shall be checked daily and the
trigger mechanism and guard given a thorough visual examination to ensure correct
operation. All high-pressure connections should be observed during operation of
the equipment at pressure. If a leak is observed, the high-pressure water jetting unit
shall be shutdown and the connection repaired or replaced before further operation.
Foot Control Valves: All foot control valves shall be checked and cleaned daily and
the foot mechanism and guard given a thorough visual examination to ensure
correct operation.

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Electrical Equipment: All electrically operated high-pressure water jetting units
shall be checked daily for external damage with special emphasis placed on
connection, junction boxes, switches, and supply cables. Care should be taken to
ensure that the electrical system is protected from the ingress of water. Correct
direction of rotation of the electric motor should be checked on initial installation and
after every re-connection.
Trailers: Mounted high-pressure water jetting units shall be checked daily
examining tires, braking systems, jacking points, towing hitch, lights, safety chains,
structural damage and general cleanliness. The units should only be towed by
vehicles fit for the purpose.
Engine Controls: All throttle cables and engine stop devices shall be checked daily
to ensure that they are functioning properly.
Maintenance Servicing and Repair: The following operations should only be
carried out by competent personnel:
S NLB's servicing requirements.
The following items should be overhauled and checked for correct functioning at
manufacturer's recommended intervals:
S Pressure relief valve (by-pass valve)
S Bursting discs (rupture discs)
S Pressure control valve
S Hand or foot operated dump control valve, shut off control valve
S Dry shut off valve or dump system
S Changeover valve
Tools: When maintaining or assembling high-pressure water jetting systems, the
correct size tools must be used. The use of adjustable tools with serrated gripping
jaws, (e.g., piping wrenches) which can damage equipment, is not recommended,
particularly on the crimped portion of a hose fitting.
Compatibility: All component parts and fittings should be checked to ensure they
are of the correct size and rating for the unit.

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2.3.6 - Protective Clothing and Personal Protection

OSHA Compliance: All applicable OSHA regulations covering personal protective

equipment shall be followed.
Head Protection: All operators shall be issued with suitable head protection which
shall be worn, where possible. This should also include a full face shield.
Eye Protection: Suitable eye protection (i.e., adequate for the purpose and of
adequate fir on the person) shall be provided to all operators of high-pressure water
jetting equipment and must be worn within the working area. Additionally, several
states have regulations governing eye protection which must be conformed with.
Where liquids liable to cause eye damage are encountered, it may be necessary to
use either a combination of visor and goggles or a full face shield.

Where liquids liable to cause eye damage are encountered, it may be neces‐
sary to use either a combination of visor and goggles or a full face shield.

Body Protection: All operators should be supplied with suitable waterproof clothing
having regard to the type of work being undertaken. Garments should provide full
cover to the operator-including the arms. Liquid or chemical resistant suits shall be
worn when there is a reasonable probability of injury that can be prevented by such
equipment.
Hand Protection: Adequate hand protection should be supplied to all operators and
shall be worn when there is a reasonable probability of injury that can be prevented
by such equipment.
Foot Protection: All operators should be supplied with waterproof boots with steel
or aluminum toe-caps. A metatarsal guard should be used by water jetting
lance/gun operators.
Hearing Protection: Most high-pressure water jetting operations produce noise
levels in excess of 90 dB (A), consequently, suitable ear protection issued in
accordance with OSHA standards must be worn and provision should be made for
its regular inspection and maintenance. All personnel and operators should receive
instruction in the correct use of ear protectors so that noise exposure lies within the
limits as specified by OSHA.

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 Respiratory Protection: A respiratory protection program shall be implemented
where there is a reasonable probability of injury that can be prevented by such a
program.
Equipment Limitations: It should be recognized that protective equipment may not
necessarily protect the operator from injury by direct high-pressure water jet impact.

2.3.7 - Pre-Operating Procedures

Planning: Each job shall be preplanned. Personnel familiar with the equipment to
be cleaned or the material to be cut and the work environment shall meet with
personnel that will be doing the work and outline potential hazards of the work area,
environmental problems, safety standards, and emergency aid procedures.
Check list: A check list shall be used to assure that the proper procedures and
proper equipment selection are followed.
Dump Valve: All systems shall incorporate at least one (1) fluid shut off or dump
device. The lance operator must always be able to shut down the water jet by
releasing pressure on the trigger, switch or foot valve pedal.
Warning Barriers: Barricades shall be erected to encompass the hazard area and
signs posted to warn personnel that they are entering a hazardous area. The
perimeter should be outside the effective range of the water jet whenever possible.
Barriers may be of rope, safety tape, barrels, etc., as long as they give an effective
warning and are highly visible.
Hook-Up:
S Hose: Hose shall be arranged so a tripping hazard does not occur. Hoses,
pipes, and fittings shall be supported to prevent excessive sway and/or wear
created by vibration or stress of the end connections when laid on the
ground, over sharp objects or vertical runs.
S Fittings: All fittings shall be cleaned and lubricated before installing in the
system. Be sure all fittings , hoses, and nozzles are fit for the purpose.
S Hose: All hoses shall be checked for evidence of damage, wear or imperfec‐
tion. The check shall be made periodically during the operation.
S Pre-Flushing: The system shall be completely flushed with sufficient water
to remove any contaminants before installing the nozzle.
S Nozzle: All orifices shall be checked in all nozzles for any stoppage, damage
or imperfections.
S Electrical Equipment: any electrical equipment in the immediate area of the
operation that presents a hazard to the operator shall be de-energized,
shielded or otherwise made safe.

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2.3.8 - Procedures
Work Area: Where practical, work pieces to be jetted should be removed from plant
areas to a high-pressure water jetting area. Where this is impractical, cutting or
cleaning in place, or adjacent to the installed position, can be done with the
necessary clearance and permission of the occupier.
S Area Limits: Area limits applicable to the cutting or cleaning operations shall
be defined and the team shall mark these limits by barriers and notices to
warn against access to other personnel. Suitable barriers shall be an ap‐
proved form of hazard warning, rope or tape, as a minimum. Alternatively, a
suitable barrier shield is acceptable at any reasonable distance. Notices
should state the following (or in other suitable wording):

“Danger Keep Clear, High-Pressure Water Jetting in Operation”

S Corrosive Materials: Where there is a possibility of encountering corrosive

or toxic materials, the occupier shall be requested to inform the person in
charge of high-pressure water water jetting of any precautions that may be
necessary, including the collection and disposal of waste materials.
S Work Surface: Operators should have good access to the work piece, a safe
working platform and secure footing. The area in which work is to proceed
shall be kept clear of loose items and debris to prevent tripping and slipping
hazards.
S Access: Access by unauthorized persons into the area where high-pressure
water jetting is taking place shall be prevented. The area shall be cordoned
off and warning notices displayed in prominent positions. The perimeter
should be outside the effective range of the water jet wherever possible.
S Approaching the Operator: The occupier shall be requested to inform all
personnel likely to require access to the area that high-pressure water jetting
is in progress. Personnel having reason to enter the water jetting area should
wait until the water jet is stopped and his presence is made known. Person‐
nel wishing to have the jet stopped shall approach a team member other than
the lance/gun operator. The lance/gun operator shall not be distracted until
the water jet has been stopped.
S Side Protection: Target and side shields shall, where feasible, be suitably
placed to safeguard personnel and equipment against contact with grit or
solids removed by water jets.
S Protective Equipment: All personnel working or entering the barricaded
area while cleaning or cutting is in progress shall wear the required protective
equipment.

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Pressurizing the System: Pressure shall be increased slowly on the system while
being inspected for leaks and/or faulty components. All leaks or faulty components
shall be repaired or replaced. System shall be de-pressurized for repairs.
Team Operations: In most water jetting operations, it is accepted practice to
employ a minimum of two (2) persons.
S Supervision: All high-pressure water jetting operations shall be controlled
by a supervisor who is trained in all aspects of the high-pressure water
jetting operation.
S Number of Operators: The operation of the high-pressure water jetting
equipment should be by two (2) or more operators according to the equip‐
ment being used and the nature of the job. These operators shall work as a
team with one (1) member in charge. The operator of the gun or lance (as
defined below) shall take the lead role while jetting is in progress.
S Lance/Gun Operator: One (1) operator from the team shall hold the lance/
gun or delivery hose with the nozzle mounted on it. His primary duty is to
direct the water jet.
S Second Operator: The second operator of the team shall attend the high-
pressure water jetting unit, keep close watch on the first operator for signs of
difficulty or fatigue and watch the surrounding area for intrusion by other
persons or unsafe situations.
S Additional Operators: Further operators are required in the following cir‐
cumstances: To assist the first operator with the handling of the lance if it is
too long or too heavy for one (1) person. To provide communication if the
lance operator is out of sight of the high-pressure water jetting unit operator.
S Job Rotation: The team members should rotate their duties during any job
to minimize fatigue to the operator holding the lance/gun.
S Team Leader: The team leader is responsible for basic equipment checks,
the preparation of the working area for safe operation and for obtaining a
permit to work where and when required.
S Code of Signals: Before starting a high-pressure water jetting operation, the
team members (one [1] of whom must be in charge) shall agree on a code of
signals to be used during the operation of the equipment.
S Fitness: The operator and other team members shall be physically and
mentally capable of performing the required operations.
Single Person Operation: Single person operation is allowed where the pressure
does not exceed 2,000 psi (137.9 bar) and the flow is less than 20 gpm (5.2 lpm).
S Single Operator Guidlines: All other recommendations pertaining to team
operations shall hold.

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Shotgunning:
S Attendance: The system shall never be left unattended when pressurized.
S Multiple Operation: When more than one (1) shotgunning operation is being
performed within the same area, a physical barrier shall be installed or ade‐
quate spacing between operators shall be maintained to prevent the possibil‐
ity of injury of high-pressure water.
S Target Holding: Objects to be cleaned shall never be held manually.
S Connection Protection: The point where the hose connects to the gun shall
be shrouded by a protective device, (e.g., heavy duty hose, shoulder guard,
etc.,) so as to prevent injury to operator should hose, pipe or fitting rupture.
S Minimum Length: Where practicable, the minimum length of the shotgun
lance extension should be four (4) feet (1.8 m) from the triggering device to
the nozzle.
S Hose Protection: Steel braided hoses should be used on air operated fail
safe systems to keep the system from being activated by someone stepping
on the hose or running over it.
Moleing or Flex Lancing:
S Control: The operator inserting the nozzle shall have direct control of the
dump system.
S Reversing: A positive method shall be used to prevent the nozzle from
reversing direction inside the item being cleaned, such as using a pipe be‐
hind the nozzle which has a length larger than the inside diameter of the item
being cleaned. This pipe nipple is known as a “stinger”.

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 S Retrojets: During manual operations, the entrance to a line or pipe shall not
be cleaned with a nozzle containing back water jets without adequate shield‐
ing.
S Clearance: The clearance between the outside diameter of the hose, lance
and nozzle assembly and the inside wall of the item being cleaned shall be
sufficient to allow adequate washout of water and debris.
S Pressurization: During manual operation, the nozzle shall be inserted into
the tube prior to pressurizing. Conversely, the system shall be de-pressur‐
ized before removal of the nozzle from the tube.
S End Identification: Hoses shall be conspicuously marked no closer than 24”
(0.6 m) from the nozzle to warn the operator of the nozzle location.
S Nozzle Support: Where the length of the nozzle and rigid coupling is less
than the inside diameter of the pipe, a length of rigid pipe (i.e., stinger) not
less than the diameter of the pipe being cleaned should be fitted directly
behind the nozzle or a suitable safety shield should be provided to protect the
operator. This is to prevent the nozzle turning around 180 degrees and doub‐
ling back towards the operator.
Rigid Lancing:
S Control: The operator inserting the nozzle shall have direct control of the
dump system.
S Clearance: The clearance between the outside diameter of the lance and
nozzle and the inside wall of the item being cleaned shall be sufficient to
allow adequate washout of water and debris.
S Pressurization: When under manual operation, the nozzle shall be inserted
into the tube prior to pressurizing. Conversely, the system shall be de-pres‐
surized before removal of the nozzle from the tube, unless proper shielding is
provided.
S Shields: When lancing tubes with a rigid lance, a guard should be installed,
where practicable, around the lance, to prevent a lance nozzle from being
inadvertently withdrawn and causing injury.
Additives: Any water additive (e.g., chemical, detergent or sold particle) shall be
used in accordance with the manufacturer's recommendations.

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Proper Operation:
S Start Up: The high-pressure water jetting unit shall not be started and
brought up to pressure unless each team member is in his designated posi‐
tion, the nozzle is held in , or directed at, the work piece and the lance/gun
securely held.
S Adjustments: Apart from operation procedures, no attempt shall be made to
adjust any nut, hose connection, fitting, etc., while the system is under pres‐
sure. The high-pressure water jet ting unit shall be stopped and any pressure
in the line discharged prior to making any such adjustments.

Care should be taken to release the pressure in the dry shut off gun and the
line when the unit is switched off.

S Equipment Malfunction: If for any reason the water flow does not shut off
when the trigger or foot pedal is released, work shall cease until the item has
been serviced, repaired or changed by properly trained personnel.
S Reaction Force: The lance/gun operator should be allowed to experience
the reaction force of the water jet progressively until the required operating
pressure is reached. The lowest pressure should be used compatible with the
work to be done. The pressure shall not be adjusted without the lance/gun
operator's awareness.
S Effect of Line Impulses: Lance/gun operators should be made aware of the
reactive effect of pressure in the line which can transmit a severe jolt to the
operator when the dump valve or dry shut-off valve operated. To minimize
this effect, total hose lengths should be kept as short as possible. Damping
devices can be introduced into the system.
S Thermo-Plastic Hoses: Thermo-plastic hose should not be used for water
jetting unless specifically designed for this purpose.
S Operator Positioning: The team members shall be safely positioned while
operating the system and if any person should encroach into the working
area, high-pressure water jetting shall be stopped.

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 S Work Stoppage: Work shall stop when the following occurs: In the event that
leaks or damage become apparent. If any person becomes aware of any
change in conditions or any hazards be introduced or exist. If plant or work
alarms are sounded. If any of the recommended practices in this document
are not followed.
S Hose Protection: All the hoses should be protected from being run over and
crushed by vehicles, fork lift trucks, etc.
S Back Thrust: The back thrust from a linearly directed jet can be calculated
from the following equation:

Back Thrust (lb.) = 0.052 Q (P) 0.5

Where: Q is the flow rate in U.S. gallons per minute
P is the jet pressure measured in psi

It is not recommended that any one (1) person be required to withstand a

back thrust of more than one-third (1/3) of their body weight for any extended
period of time.

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2.3.9 - Use of Lances and Nozzles

Lances: Lances which are rigid or semi-rigid having nozzles fitted to with any
combination of forward, backward or 90 degree angle jets shall be used with either
a dump system or dry shut-off control valve. When a flexible lance or nozzle
mounted on a hose is in use, the jet should not be operated at pressure unless the
nozzle is properly positioned inside the work piece, or the lance operator is
protected by screens or proper shielding from rear facing jets. If necessary, the
lead-in to the work piece should be cleaned by other methods.
Flexible Lances: Flexible lances used to clean pipes, where the inside diameter of
the pipe is not small enough to prevent the lance from turning back on itself, shall
have a piece of rigid straight tube, slightly longer than the diameter of the pipe, fitted
immediately behind the nozzle to prevent this from happening.
Distance Indicator: When an assembly is used which allows the nozzle to enter the
work piece with restricted visibility, the lance, hose or floor should be clearly marked
in a manner which enables the lance operator to judge how far the nozzle is in the
work piece before pressure is applied and conversely, so that pressure is released
before the apparatus is completely withdrawn from the work piece.
Lance Length: The length of a rigid lance or combination of lances shall be such
that the lance operator can maintain control at all times.
Jet Pressure: The nozzle and minimum operating pressure shall be selected by the
lance operators to allow effective and efficient high-pressure water jetting.
Improper Use: Should a lance operator enter a manhole or access port for any
purpose (preferably with the high-pressure water jetting unit turned off), the hose
shall not be used to support their weight when climbing up or down.
“T” Pieces: When using a “T” piece or nozzle carrier “T” (devices for producing two
[2] equal and opposite water jets at the end of the lance and at right angles to the
normal flow), it should be inserted into a tube, a vessel, or between two (2) surfaces
before the system is pressurized. This is necessary to ensure that should one (1)
water jet be larger then the other, or one (1) water jet become blocked or partially
blocked, the operator of the lance will not be spun out of control. When a “T” piece
is used to provide a balancing jet on a long lance to clean a single surface, it is not
always possible to check for equal thrust from both jets in the manner described
above, therefore these lances should be checked by progressive pressure
increases. This restraint shall also apply to any form of multi-jet nozzle, the jets
issuing from which having a radial component.
Confined Working: Before entry into a confined work space for high-pressure
water jetting, a certificate of clearance shall be obtained to ensure access is safe.

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2.3.10 - Operational & Training Requirements

Qualified Operators: Only trained personnel shall operate high-pressure water

jetting equipment and supervise the training of new operators.
Training: A personnel training program shall be developed by each employer and
be presented to each employee before assignment to employees first high-pressure
cleaning or cutting job. Such training shall include, as a minimum, coverage of all
items listed in in these recommended practices.
Cutting Action: The cutting action of a high-pressure water jet and the potential
hazard it poses to the human body shall be demonstrated through the use of
audio/visual aids or actual use of equipment (i.e., by cutting through a piece of
lumber, concrete block, etc.).
Personal Protective Equipment: The minimum personal protective equipment
shall be explained. Instructions shall be given as to when and how specific clothing
and other types of protective devices shall be worn according to the type of work
performed, locations, etc.
System Operation: The operation of a system shall be explained with potential
problems pointed out and proper corrective action.
Control Devices: The operation of all control devices shall be explained. The
importance of not tampering with any control devices as well as the importance of
keeping them in proper working order shall be stressed.
Equipment Maintenance: It should be pointed out that valves and seating surfaces
in pressure regulating devices encounter high wear during high-pressure water
jetting. These items require frequent inspections, maintenance and/or replacements
in order to provide operation.
Hose: The proper method of connecting hoses, including laying out without kinks,
protection from excessive wear and proper tools to use on couplings and fittings
shall be explained.
Stance: The proper stance for sound footing and how to use the various devices for
lancing, shotgunning, and moleing shall be demonstrated. The trainee, under close
supervision, shall use the various devices while the unit is slowly pressurized.
Proficiency: Personnel shall demonstrate knowledge and skill in the proper
operation of equipment through practical application.

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 General:
The system shall be de-pressurized when:
S Not in use
S An unauthorized or inadequately protected person enters the barricaded
area.
S Replacement or repairs are made to the system
S Any recommended practices are violated.
Refresher Training: Operator training shall be on an annual basis or more
frequently, if needed.

2.3.11 - Permanent Cleaning Areas

Encolsure: The areas shall be suitably enclosed and warning notices prominently
displayed at the access points and perimeters.
Access: Access by persons other than the high-pressure water jetting team shall
be strictly prohibited while work is in progress. If any unauthorized entry is made, all
work shall cease immediately.
Hazards: The working area shall be free from hazards likely to trip personnel and
be provided with adequate drainage and lighting fixtures.

2.3.12 - Freeze Precautions

Freeze Precautions: During the periods where there is a risk of freezing, follow
NLB's recommendations or take the following precautions on shutdown:
S Remove the gun or nozzle from the delivery hose
S Pump water from supply tank until level of water is just above the filter.
S Add recommended quantity of anti-freeze into the water tank.
S Place delivery hose into water tank and secure.
S Run the pump until the anti-freeze works through the system.
S Move the selector level to dump or recycle position until; the anti-freeze
shows in the water tank.
S If no supply tank is fitted, follow NLB's recommendations.

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 If a high-pressure pump or hose appears frozen, on no account shall the
pump be engaged (the engine started if there is direct drive to the pump) until
the system has been thawed out and low pressure water has been allowed to
flow through the system including the end of the lance. Make sure that the
lance does not have a restriction or nozzle during this process.

2.3.13 - Accidents

Personal Injuries: In the event that a person is injured by the impact of a

high-pressure water jet, the injury caused may appear insignificant and give little
indication of the extent of the injury beneath the skin and damage to deeper tissues.
Large quantities of water may have punctured the skin, flesh and organs through a
very small hole that may not even bleed.
Operator Identification: Immediate hospital attention is required and medical staff
must be informed of the cause of the injury. To ensure that this is not overlooked, all
lance/gun operators engaged in high-pressure water jetting should carry an
immediately accessible waterproof card which outlines the possible nature of the
injury and titled with the following text:

“Important Medical Information”

This card is found in the inside pocket of this binder. If the card is missing contact
NLB at (800) 227-7652 for a replacement.
Immediate First Aid: Where medical examination is not immediately possible in
remote situations, first aid measures should be confined to dressing the wound and
observing the patient closely until medical examination has been arranged.
Reporting: If any person or equipment is accidentally struck by the water jet, this
fact must be immediately reported to a responsible party.

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2.3.14 - Responsibility

Purpose: These recommended practices are provided to assist persons unfamiliar

with the operation of high-pressure water jetting equipment.
The responsibility of correct operation and use of the equipment is the sole
responsibility of the operator. The operator should familiarize themselves with the
identification of high-pressure water jetting metal fittings, hoses, lance/guns, and
accessories. Modification of high-pressure water jetting equipment or accessories is
not recommended without prior written approval by NLB.
Serious harm or injury may result from the misuse of high-pressure water jetting
equipment, the use of improper fittings, hoses or improper attachments.

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