M@™@ 7020519 0003436 156 mw Hot work Hoe series booklet HS(G) 5@® 7020519 0003437 052 a Health and Safety Executive Health and safety series booklet HS(G) 5 Hot work Welding and cutting on plant containing flammable materials. London: Her Majesty’s Stationery Office@™ =7020519 0003434 Teo © Crown copyright 1979 First published 1979 Second impression 1986 HS(G) series The purpose of this series is to provide guidance for those who have duties under the Health and Safety at Work etc Act 1974 and other relevant legislation. It gives guidance on the practical application of regulations made under the Act, but it should not be regarded as an authoritative interpretation of the law. Enquiries regarding this publication should be addressed to area offices of the Health and Safety Executive, or the enquiry points at: Baynards House, 1 Chepstow Place, London W2 4TF tel 01-221-0416/0870 St Hugh’s House, Stanley Precinct, Bootle, Merseyside L20 3QY tel 051-951-4381 Red Hill, Broad Lane, Sheffield S3 7HQ tel 0742-752539 ISBN 0 11 883229 8@™ 7020519 0003435 96S ml Contents Foreword 1 Introdaction 3 Hazards 5 Operations 5 General principles 5 Environment 7 Equipment 8 Methods 11 Operations in buildings 13 Limitation of operations 13 Prohibited operations 14 Welding technology 15 Control of operations 16 Procedure 18 Appendices Statutory requirements 23 Atmospheric seal plugs 24 High pressure seal plugs 32 Frozen product seal plugs 39 Bag seals for use in low pressure gas mains 45 ‘Welding operations on water-sealed gas holders 49 ‘Welding operations on waterless gas holders 50 ‘The industrial use of flammable gas detectors 52 OIAUALNH Glossary 59 iiiMi 7020519 0003440 L647 a Foreword These notes were prepared by a joint working party consisting of members of the Factory Inspectorate of the Health and Safety Executive (HSE) and organisations representing relevant sectors of industry. The Health and Safety Executive wishes to express its appreciation of their help and co-operation, and the help and co-operation of the organisations which provided information and assistance to the working party. It should be noted that the document is intended only to set out procedures by which industry may be helped to comply with the requirements of Section 31 of the Factories Act 1961* and the relevant general requirements of the Health and Safety at Work etc Act 1974, (ASW Act) when work is to be undertaken on plant which contains, or has contained flammable gases and liquids. In particular the greatest care must be taken to ensure that hot work is not carried out on vessels which contain or have contained unstable substances (e.g. organic peroxides and nitro compounds). In case of doubt, advice should be sought from the Factory Inspectorate. These notes do not cover pipelines within the meaning of the Pipelines ‘Act 1962. Any enquiries dealing with such pipelines should be addressed to the Pipelines Inspectorate of the Department of Energy. Where work is carried out on plant which is subject to licensing under the Petroleum (Consolidation) Act 1928 the conditions of licence should be checked before work commences, and, if necessary, the consent of the licensing authority should be obtained to vary the conditions. The document is not a code of practice approved by the Health and Safety Commission under Section 16 of the HSW Act, and does not have the legal status accorded to such approved codes. The Health and Safety Executive would welcome comments in due course from industry on experience in the operation of these procedures. Comments should be addressed to HSD Branch B, Health and Safety Executive, Baynards House, 1 Chepstow Place, London W2 4TF. *This and other publications referred to are available from HMSO unless otherwise stated.M@™! 7020519 0003441 513 Introduction 1 Many industrial plants in which flammable liquids and gases are processed are designed to operate continuously for long periods at high temperatures and pressures. Under normal conditions modifications and maintenance can be scheduled to coincide with periods when the plant is shut down in order to carry out the necessary work. Unexpected circumstances can and do occur which may cause the shutting down of large integrated units unless alterations can be carried out while the plant is on stream. 2. The shutting down of such large plants under emergency conditions is often not only expensive but in some instances may introduce a risk of explosion and fire from a variety of causes. 3. Alterations and repairs often require welding operations to be carried out on plant which contains flammable or other dangerous materials. Such operations, often known as ‘hot work’, while potentially very hazardous can, in certain circumstances, be carried out safely while the plant is in operation, provided that suitable precautions are taken to prevent a dangerous situation arising. Welding operations of this nature should be undertaken only as and when all other reasonably practicable alternative methods have been investigated. The operations should be planned and controlled with the utmost care and a permit to work system instituted. (See para 72). 4 Welding, cutting or similar operations involving the application of heat to plant, tanks or vessels which contain or haye contained any explosive or flammable substance is prohibited under Section 31(4) of the Factories Act 1961 until all practicable steps have been taken to remove the substance and any fumes arising from it, or until the substance and fumes have been rendered non-explosive or non- flammable. Under Section 73 of the Public Health Act 1961, control requirements exist in relation to fixed tanks or containers which have been used for storage of petroleum spirit, but are no longer used for that purpose. (See Appendix 1). 5 Some accidents involving death and injury to persons carrying out these operations have occurred in the past. The purpose of these notes is to give guidance on the precautions considered necessary in order to be able to carry out such welding operations (with certain exceptions), in a safe manner and to comply with the requirements of the Factories Act and the general requirements of the HSW Act. Previous page is blank@™@ 7020515 0003442 4ST mm 6 The precautions and safe practice set out in these notes are based on the considerable experience gained in carrying out such operations in the United Kingdom. The operations and equipment described are in common use and have been shown to provide reliable safe methods of working. It is intended that these notes should in no way be restrictive and alternative procedures and equipment may be used when it can be shown that they are equally suitable and reliable and will provide the same degree of safety. 7 A number of firms provide a specialised service in hot tapping operations but their expertise is primarily in the mechanical engineering aspects of this work. Some aspects which should be considered when planning work of the nature described in the notes are different from those met with in more normal maintenance operations and it will be necessary for the responsible person to undertake a wider consultation to ensure that all aspects which affect the safety of the work have been given proper consideration. 8 It is recognised that further research and development in technique and materials may lead to improvements in these practices and it is intended that these notes should be reviewed at intervals not exceeding five years, or at such intermediate times when the attention of the Health and Safety Executive is drawn to developments which appear to necessitate a revision of these notes.Mi 7020519 0003443 356 a Hazards 9 The principal hazards with which these notes are concerned are those of explosion and fire resulting from the application of heat; such as during welding to pipelines, or tanks and vessels which contain or have contained any flammable substance. Other hazards, including fire and electric shock, may arise from improper earthing practice during electric welding or the cutting of pipelines provided with cathodic protection systems, The possible presence of toxic or asphyxiating gases or vapours should also receive careful consideration. Scope 10 These notes are concerned with the connection of fitments to, and repairs by, welding cutting or similar operations, of pipelines, tanks and vessels which contain or have contained any flammable liquid or gas. 11 Hazards can arise to persons carrying out the welding or cutting processes from the fumes and gases evolved during the actual operations, Although these notes are not intended to deal with these hazards, suitable precautions should be taken by, for example, the provision of local exhaust ventilation and suitable protective equipment, to ensure that persons employed are protected against such hazards. Operations General principles Equipment containing flammable liquids 12 Welding can be carried out on the external surface of a tank or vessel containing a flammable liquid provided that the position of the weld is well below the level of liquid. (See also paras 21 to 22 and 53). 13 Similarly, in the case of pipelines carrying flammable liquids, welding may be carried out on the external surface provided that the line is filled completely with the liquid and that the generation of vapour or expansion of the liquid cannot give rise to abnormally high pressures. ‘The latter can usually be avoided by ensuring that there is an adequate flow of liquid along the pipe sufficient to prevent overheating but without giving rise to poor welds due to an excessive rate of cooling. Flow rates should generally not be less than 1 m/s.mm 7020515 0003444 222 a 14 Where it is not possible to maintain the minimum flow rate indicated above an alternative would be to ensure that the liquid or vapour can expand into adjacent items of plant where it will not give rise to any dangerous increase in pressure. In this connection reliance should not be placed on allowing expansion to take place via pressure relief valves designed to operate under process conditions where the relief pressure may be much higher than that at which welding could safely be carried out. 15 In all instances the thickness of metal in the area of the weld should be sufficient to preclude any possibility of penetration or failure. Additionally, the welding technique employed should be such as to avoid any risk of penetration of the metal and only competent super- visors, inspectors and welders with the necessary experience should be employed on such work. 16 The internal surfaces of the plant where welding is to take place should be free from deposits of residues which could affect the integrity of the completed weld or otherwise give rise to danger e.g. through evolution of flammable gas or exothermic chemical reaction. (See para 79(8).) 17 Even when vessels have been emptied, cleaned and purged free of vapour great care must be taken to ensure that no liquid remains trapped in any hollow constructional members. Where such members exist they should be drilled at the top and bottom to ensure complete drainage and subsequently purged with steam, air or inert gas depending on the nature of the product and capacity of the plant. 18 Metal linings or wear plates attached to the shell of a tank or vessel may trap liquid hydrocarbon behind them which subsequently leaks into the vessel through cracks or pinholes in the weld to form flammable mixtures. Before repairs to such vessels are carried out two holes diagonally opposite should be drilled in the lining plate or parent vessel as necessary to allow any liquid to drain out and the space between purged with steam, air or inert gas. Equipment containing flammable gas or vapour 19 Welding on plant containing gas or vapour is potentially more hazardous than in the case of plant containing liquids and in some cases is prohibited (see paras 56 to 63). A much reduced cooling effect is afforded by a gaseous medium and there is a corresponding increase in the risk of penetration of the metal due to overheating in the welding operation. 6W@™ 7020519 0003445 165 me 20 The temperatures and pressures inside plant to which such welding operations may be carried out are governed by the reduced strength zone during the welding operation and the measured wall thickness. These factors need to be determined in each individual case in order to ensure that at all times during the welding operation sufficient thickness of metal in the area of the weld remains unaffected so as to contain the internal pressure. Environment 21 The operations described in these notes may be carried out with safety provided that all the necessary precautions are observed. ‘Additionally there may be an clement of risk associated with the surroundings in which the plant is situated and therefore welding operations should be carried out only in an environment which is itself free from hazard. This should be verified by a competent person using appropriate methods and consideration should be given to the need for continuous monitoring of such hazards. As the power source itself may provide an ignition source, the siting of the equipment must be carefully considered when planning the work. 22 Before welding operations are carried out the following matters should be considered: (a) the provision of good access to and from the site not only for men and materials but also for emergency services; (b) the provision of adequate and suitable artificial lighting where necessary; (© the sealing of all drains (see glossary of terms) within a radius of at least 15 m of the welding operation. In certain circumstances this distance may need to be extended. Open drains and channels should be inspected and where necessary flushed with water; (d) the atmosphere up to a height of at least 2 m above ground level or above the point at which welding is to take place, whichever is the greater, and within 15 m radius at all levels up to this height, should remain free at all times from dangerous concentrations of gas or vapour. In this connection wind conditions should be taken into account; (©) all plant surfaces in the vicinity of the proposed welding operation should be free from deposits of flammable materials or such materials should be adequately protected to prevent ignition;M@@ 7020519 OO0344b OTS (f)_ the ground within 15 m of the welding operation should be free from any flammable liquids or other combustible material, e.g., material used to insulate or to protect the pipeline or tank from corrosion and which has been stripped from the plant. The latter is of particular importance when welding is carried out on under- ground pipelines in pits or excavations; {g) an excavation of adequate size with suitable shoring, ladder access and secondary means of escape should be provided when welding underground pipelines; (h) excavations, pits or other confined spaces should be provided with adequate ventilation to prevent the accumulation of dangerous concentrations of vapour; (j)_ suitable staging and scaffolding with adequate and safe means of access and escape should be provided when work is carried out at elevated positions; (k suitable non combustible, protective shields should be provided where necessary to control weld spatter; @ suitable protective clothing, including face shields and gloves, should be provided as necessary for the use of all persons employed in connection with the welding operations to protect them against burns due to any accidental leakage and ignition of flammable liquid or vapour; (a) at least one person suitably trained and equipped with fire extinguishers, including at least one of a dry powder type, should be present during the entire period of welding and any cutting operations; (n) first aid facilities including breathing and resuscitation equipment should be available, Equipment Temporary methods of isolation when cutting pipelines 23. Some of the operations described in these notes necessarily involve the cutting or disconnection of a section of pipeline which cannot be drained and purged beforehand, In some cases the nearest valves by which the section of line may be isolated will be at a considerable distance and temporary local isolation must be provided. Such means of isolation should be reliable and retain its integrity under all foreseeable operating conditions. Typical methods in current use and the@™® 7020519 0003447 731 a precautions which should be taken with them are given in succeeding paragraphs. Seal plugs 24 Operations involving the use of the different types of seal plug described below should be undertaken only when it has been shown that there is no other reasonably practicable method of doing the job. Atmospheric seal plugs (for details see Appendix 2) 25 This type of plug is inserted into the open end of a pipeline which has been isolated by other means, drained and cold cut but cannot be cleaned along its entire length and into which liquid and/or vapour or gas may leak past the isolation valve. In this way reliable sealing is obtained between the point of welding and the empty line. The sealing action of this type of plug depends on the compression of a rubber or neoprene sealing ring between two metal plates to provide a peripheral seal against the inside wall of the pipe. It is imperative therefore to ensure that not only is the plug of the correct size for the pipe under- going repair but also that the flexible sealing ring is in good condition and has not started to deteriorate in any way which might adversely affect it. Additionally, satisfactory sealing of the plug will not be achieved if the pipe is distorted in any way nor if the internal surface of the pipe is badly pitted by corrosion. In such cases the pipework should be cut back to a point where satisfactory sealing can be achieved. Plugs should be inserted far enough into the pipe, or otherwise be suitably protected, so as to remain unaffected by heat from the welding operation. If there is any doubt about the efficacy of the sealing action of such a plug when finally in position the outer periphery of the seal should be packed with wet puddle type clay or any other equally suitable material. 26 Atmospheric seal plugs cannot be relied upon to remain in position when subjected to pressure and should be provided with an opening through which any gas or vapour can be vented to a safe place at least 10 m down-wind via a suitable length of flexible hose or via an appropriate vent on the pipeline. The hose should be securely clamped to the plug vent and not be pinched nor in any way obstructed. The remote end should be suitably secured against movement from whatever cause and the concentration of any issuing gas or vapour should be checked as necessary during welding operations. Vent hoses should also be protected against damage by weld spatter. 27 As far as possible welders should work to the side of the pipeline. This is facilitated by the use of weld neck flanges or slip-on flangesWS 7020519 0003448 174 a which have been pre-welded to a stub of pipe, necessitating only a butt weld. Accidents have occurred where seal plugs have been blown out of lines under pressure due to faulty venting. 28 During the welding operation the temperature of the pipeline at the position of the plug should be checked to ensure that at no time does it become hot enough to affect the plug seal. High pressure seal plugs (for details see Appendix 3) 29 In order to isolate sections of pipeline in service stoppers or plugs able to withstand high operating pressures and temperatures without displacement or serious leakage must be inserted. The use of such plugs is also described in para 39. 30 The high pressure plug used as described relies on the differential pressure across it for its sealing action and cannot be relied upon not to allow some small leakage past the sealing element. When a pipeline fitted with such a plug is subsequently cut an atmospheric seal plug or other equally effective device should be fitted into the open end before any welding operation is attempted. If the additional plug is of a type not fitted with a vent connection, the section of pipeline between the two plugs should be drilled and fitted with a vent connection suitable for the attachment of a flexible hose. Frozen product seal plugs (for details see Appendix 4) 31 In cases where the product contained within a pipeline is of such a character that it may be frozen to form a solid plug at suitably low temperatures by the use of freezing mixtures packed around the line this method may be used to provide temporary isolation whilst repairs are carried out. If the product cannot be frozen to form a satisfactory seal an alternative procedure would be to displace the product with water and freeze the latter over a suitable length of line. 32 When considering the use of the ‘frozen plug’ method of isolating a pipeline careful consideration should be given to the possible effect of the low temperatures on the properties of the material of the pipeline. It is also highly desirable to have a bend in the pipeline between the point at which the repairs are to be carried out and that at which the pipeline is to be frozen. This will preclude the possibility of the plug being ejected under pressure in the unlikely event of it being displaced. 33. Details of this method of isolation using freezing mixtures of solid carbon dioxide and isopropanol are given in Appendix 4. 34 Freezing the product by means other than the use of solid carbon dioxide and isopropanol mixtures may also be used when it can be 10@@ 7020519 0003449 604 shown that it is safe to do so. Bag seals (for details see Appendix 5) 35 This type of seal plug is comprised of an inflatable rubber bladder with an outer cover of canvas or nylon fabric suitably treated to minimise the risk of accumulation of static electricity. 36 They are used either singly or in pairs to provide temporary isolation of lengths of pipeline containing only gases at low pressure. Alternative methods of isolation 37 The methods described above for the temporary isolation of sections of plant are not intended to be exhaustive and alternative methods may be used when it can be shown that it is safe to do so. Replacement of a length of pipeline in service 38 The replacement of a section of pipeline of welded construction may be required under service conditions when the section cannot readily be isolated by valves and drained. In these circumstances it is possible to provide temporary isolation on either side of the section to be removed by the insertion of temporary plugs or stoppers as outlined above. 39 In cases where high pressure seal plugs are to be inserted, stub connections should first be welded onto the pipeline and special valves mounted through which drilling under pressure (trepanning) can take place. With the drilling unit mounted in position but before drilling ‘commences, the integrity of the welds and fitments should be checked to ensure that they will safely withstand the full pressure of the material in the pipeline when penetration takes place. The seals on such tools are commonly tested to 140 bar (2000 psig) or more. After completion of the drilling operation the drill is withdrawn into its housing and the valve closed enabling the drilling unit to be removed and the seal plug insertion unit fitted. 40 If flow of product is to be maintained a bypass line will need to be installed through which the flow can be diverted when the isolating sea) plugs are inserted. The operations necessary for the fitting of such a bypass are similar in every respect to those described above in para 39 except that the bypass section is bolted or welded into position instead of attaching a seal plug insertion unit. uWB 7020519 0003450 Seb 41 When all the necessary connections have been made and the seal plugs inserted the isolated section of the line may then be depressurised and drained via suitable vent and purge connections welded to the line and tapped as above. After checking that the seal plug has in fact provided a satisfactory seal the section of pipeline should finally be removed only by cold cutting methods. In this connection the use of an abrasive cutting wheel cannot be considered as a cold cutting method and should not be employed. Seal plugs fitted with vents piped to a safe area should then be inserted into the open ends of the pipeline before welding on flange plates and removed only when the new section of pipeline is about to be bolted or welded into position. 42 Details of the above operations are given in Appendices 2 and 3. Replacement of a length of pipeline not in service 43 When a section of pipeline is required to be replaced it is sometimes possible to isolate the section and drain the product but not practicable to clean and purge along its entire length. In these circumstances the effectiveness of the isolation should first be proved and the line drilled to ensure that it is empty and at atmospheric pressure. The section can then be removed by cold cutting and the open ends of the line effectively sealed by plugs fitted with vents piped to a safe area before welding on flanges. These plugs should be removed only when the metal has cooled sufficiently and when the new section is about to be bolted into position. Details of the method to be adopted when the new section is to be welded into position are given in Appendix 2. Insertion of a valve or metering device in a pipeline 44 The operation of fitting a valve or metering device into a continuous length of pipeline in service is similar to those described above for the replacement of a section of pipeline. Welding on a branch connection to equipment in service 45 It sometimes is necessary to provide an additional connection to an item of equipment either to improve operational procedures or in connection with emergency repairs such as described in these notes. ‘The operations necessary to fit such a connection are similar to those described in para 40 and Appendix 3. Welding on a patch or fitment to equipment in service 46 Both internal and external corrosion of equipment and other operational requirements may necessitate repairs while the equipment remains in service. Such repairs can sometimes be effected by purely mechanical means such as the clamping of specially designed sleeves to pipework or the use of special sealing compounds but frequently 12@™ 7020519 0003451 4be a the only satisfactory solution to the problem is to weld a patch or Teak box over the affected area, If a leak box is to be fitted it should be provided with suitable connections so that it may be purged continuously with an inert gas or steam during the entire welding operation. The purge connection should subsequently either be plugged and/or sealed by welding. 47 When a leak box is being welded into position the box should be purged continuously either by steam or inert gas at a rate sufficient to render non flammable any vapour or liquid which may escape up to the point of the final closing weld. 48 The leak box or patch should be properly designed and fabricated from suitable metal plate so that after welding into position it will be able to withstand the maximum operating pressure and temperature to which it may be subjected in service. (See also paras 67 to 71). 49 These fitments are shown in Figs 11, 12 and 13 in Appendix 3 which gives details of the procedures. Operations in buildings 50 When equipment containing flammable material is located inside buildings, welding operations of the type described in these notes should be carried out with the plant in service only when it has been shown that there is no other practicable way of doing the job. The consequences resulting from equipment failure during such operations inside a building could be disastrous. Limitation of operations 51 The limitations on the temperature and pressure of products in the equipment restricting the use of the methods described in these notes are those imposed by the necessity to ensure that the metal is of sufficient thickness and strength as to preclude any possibility of failure while the welding operation is being carried out and that its strength on cooling will remain unaffected by the operation. Additionally any seal plugs used in the operation should be capable of withstanding the temperature and pressure of product for the duration of the operation. 52 Welding should not normally be carried out on equipment where the metal thickness is less than 5 mm unless after careful investigation it can be shown to be safe to do so. 13me 7020519 0003452 379 53 Welding on tanks should not normally be carried out at points less than 1 m below the level of the surface of the liquid contained therein. In this connection, attention is drawn to Appendix 7. 54 Welding should not normally be carried out on any vent line or blowdown system of equipment containing flammable liquids, gases or vapours in service unless after careful investigation it can be shown to be safe to do so. The isolation of such systems when the plant is operating should never be carried out unless adequate alternative means of venting can safely be provided. (See also para 60). 58 Welding should not be carried out on any part of plant or equipment at temperatures below 7°C unless and until it has been shown by trials to be safe to do so. Prohibited operations 56 Some materials decompose explosively at elevated temperatures whilst others react adversely with materials of which the equipment is made; careful consideration is needed before undertaking any welding operation on plant in service. 57 Welding operations should never be carried out on equipment which contains: (a) any mixture of gases or vapours within their flammable range or which may become flammable as a result of the welding operation; any substance which may undergo any reaction or decomposition leading to a dangerous increase in pressure or explosion or attack of the metal. In this connection attention is drawn to the possibility that under certain conditions of concentration, temperature and pressure acetylene, ethylene and other unsaturated hydrocarbons may decompose explosively under the initiation of a welding hot spot; (©) oxygen enriched atmospheres in the presence of hydrocarbons or other combustible materials which may be present either in the atmosphere or deposited on the interior surface of the equipment; (d) compressed air in the presence of hydrocarbons or other combustible materials which may be present either in the air or deposited on the interior surface of the equipment. 58 Welding operations should never be carried out on ferritic steel pipelines or vessels containing gaseous mixtures in which the partial pressure of hydrogen exceeds 7 bar except where evidence from tests demonstrates that it is safe to do so. (6) 14@@ 7020519 0003453 235 mm 59 Welding should not be carried out on process equipment which contains any material liable to give rise to stress corrosion cracking unless that equipment is subsequently stress relieved in such a manner as not to contravene any section of these notes. 60 Welding on pressure vessels in service should not normally be allowed in circumstances where the materials of construction are such that post-weld heat treatment is necessary nor on any vessel designed to high stress codes, e.g. British Standard BS 1515* and ASME Section 8, Division 2}. Additional connections should preferably be made through manhole covers rather than through the shell of the vessel. 61 Welding should not be carried out on any part of a flare system over which effective control cannot be exercised during all relevant operations. 62 Although oxygen is not itself flammable and therefore outside the scope of these notes it is considered desirable to draw attention to the extreme hazard associated with any attempt to weld on plant containing pure oxygen either in liquid or gaseous form. 63 At the time of writing these notes, experimental work done by a number of companies has demonstrated that it is safe to weld on plant and equipment containing high purity ethylene at pressures up to 28 bar (400 psig) and temperatures up to 150°C. If subsequently it can be shown by means of suitable tests that it is safe to exceed these limits then welding can be carried out under these conditions, Welding technology 64 This section of the notes has been written to remind engineers responsible for specifying welding procedures of the factors to be borne in mind. 65 Welding shall be carried out only by the manual electric arc Processes. 66 Successful welding is dependent upon correct welding procedure and technique with particular reference to: (a) pipe material and wall thickness including chemical composition and mechanical properties; *BS 1515 Fusion welded pressure vessels for use in the chemical, petroleum and allied industries available from British Standards Institution. tObtainable from American Society of Mechanical Engineers.@ 7020539 0003454 17) (b) fitting material and wall thickness including chemical composition and mechanical properties; (©) welding process; @) cleaning; (©) fit-up (sketch ); (£) welding electrodes (composition, size and flow rate); (g) pre-heating (temperature, method and control); (h) electrode manipulation; (j)_ are voltage and electrode polarity; (k)_ welding current () direction of welding; (m) speed and rate of deposition; (n) number, arrangement and sequence of runs; (p) post-weld cooling and/or heat treatment. Metallurgical effects of welding 67 The materials of construction of the articles to be welded together and the welding consumables should be compatible. 68 Welding should not normally be carried out on equipment where the metal thickness is less than 5 mm unless after careful investigation it can be shown to be safe to do so. 69 Welding should not normally be carried out on carbon steel unless the equipment at the point of the weld is maintained continuously at a temperature not less than 7°C which is above the transition temperature of such steels. 70 It should be noted that particularly with the higher strength steels an acceptable compromise may have to be reached between the need to keep the fusion and heat affected zones to a minimum on one hand and the need to avoid post-weld cracking on the other. 71 The welding procedure selected should be such as to ensure that not only will the strength of the equipment during welding and afterwards be adequate but that no deleterious metallurgical conditions will have been developed. Control of operations Permit to work 72 All operations to which these notes of guidance refer should be planned and controlled with the utmost care if accidents are to be 16@™ 7020519 0003455 008 mm avoided, It is the responsibility of management to ensure that the work is carried out in a safe manner and it is essential that a permit to work system is operated. In this connection it is particularly important that any outside contractor who is to take part in the operation is left in no doubt that his men may not in any circumstances begin work until the person who is to issue the permit has explained fully to the contractor or his foreman the safety precautions that must be observed. It is imperative that a written handover procedure be adopted. 73. In operating a permit to work system the following principles should be observed: (a) the information given in the permit should be clear and unambiguous; (b) it should specify precisely and in detail the item of plant on which work is to be carried out, the nature of the operations, the point at which welding is to take place and the precautions which should be taken to ensure safety of personnel; (©) the permit should specify the time at which it comes into operation, the time by which it expires and any particular conditions under which all work should cease even though the time limit for the certificate has not expired; (@) the person issuing the permit should satisfy himself, by personal inspection, that all the action specified as necessary has in fact been taken; (©) the person issuing the certificate should have the technical knowledge not only to appreciate the existence of hazards and the precautions to be taken, but also the authority to require responsible officials to make safety recommendations on matters of which they have special knowledge and to co-ordinate the duties of all concerned; (Othe permit to work procedure outlined above is for general guidance and should be adapted to suit particular needs. It does not purport to be comprehensive. Communications 74 When welding operations are to be carried out on plant which is not under the direct control of the person in charge at the site of the operation, a reliable system of communication should be established, if one does not exist already, between the site and the control centre, All concerned should be familiar with the terms of the work permit.W@™ 7020539 COO345b TH4 Ww Procedure 75 The safety of any welding operation described in these notes is dependant on the correct procedure being followed meticulously. This section has therefore been written in the form of a checklist to cover all forseeable operations and describes the procedure to be followed where appropriate only after those responsible for the operation have made an initial study and satisfied themselves that the proposed operations are safe. Although the section refers solely to pipelines, similar considerations will apply to procedures for welding on other equipment. All planning and operations should be supervised by a competent person. Initial planning of operations 76 This will require inter alia the preparation and checking of: (a) site plans of existing layout showing access routes; (b) a sketch of the proposed work showing any excavations, obstructions and any other adjacent pipelines and plant; (©) pipeline material, welding consumables and relevant specifications to ensure fitness for purpose and compatibility; (d) process conditions, ¢.g. product specifications, pressure, temperature and flow; (©) a list of services required, e.g. supervision, communications, labour, lifting equipment etc; (f) a list of fittings required; (g) a list of equipment required including welding equipment; (b) details of any statutory obligations; @__ details of company codes and procedures; (k) permits to work; (I) site notes of the operations being carried out; (m) notification to common wayleave users; (n) notification to landowners and occupiers; (p) notification to fire authority and police where the operations are to be carried on outside factory premises; (q) a review of the site conditions to establish that it is free from any hazard which may affect the safety of the operations to be carried out; (© alist and plan of emergency procedures.11 @ b) (d) © (f) a) 0) 2B @) ® © @) 9 (a) (b) © @ @® 7020519 000345? 940 a Site preparations There should be good access to and from the site; Any excavation should be of adequate size, properly shored and scaffolding should be provided where necessary. Adequate and suitable means of access into the pit and means of escape from it should be provided; Provision should be made for the adequate ventilation of any pit, excavation or other confined space; All drains within a radius of 15 m of the welding operation should be sealed; The ground and surrounding area within a radius of 15 m of the welding operation should be free, and remain free at all relevant times, from flammable liquid, gas, vapour, or other combustible material. General guidance on the industrial use of flammable gas detectors is given in Appendix 8; Adequate supports should be provided for the pipeline, fittings and any other equipment; Ground water should be removed where necessary; Adequate and safe artificial lighting should be provided where necessary; Adequate and suitable protective clothing should be provided. Standby service to be provided where appropriate First aid; Fire fighting equipment; Breathing apparatus; Resuscitation equipment. Pipeline preparation The identity and material of construction of the pipeline to be welded should be confirmed and the area to be welded either marked indelibly or an identification tag attached; Any insulation and lining should be stripped back to a point where it will not be affected by heat from welding operations; The surface of the metal to be welded should be thoroughly cleaned; The outside diameter of the pipeline and its ovality should be checked;©) ® (h) @ 80 @ © © @ 81 (a) (6) © @ @@® 7020519 0003455 617 The wall thickness of the pipeline should be measured by any acceptable method and checked that it is of sufficient thickness and strength with respect to the pressure and temperature of the contents to ensure that failure during welding and any consequent leakage does not occur; The external condition of the pipeline should be checked visually; Where necessary the internal condition of the pipeline, including any deposits of solid residues, should be checked by means of x-ray or any other acceptable method; Where there is a longitudinally welded seam, any external welds which could affect the fitting of the part to be welded to the pipeline should be ground to provide a flush fitting; Special considerations are needed before welding is carried out on spirally welded pipelines. Fitting alignment The pipeline and fitting should be adequately supported; Fittings should be positioned and aligned in accordance with the work to be carried out; The weld preparation should be checked for compliance with any relevant welding specification; All gaps should be checked for acceptable clearances. Welding procedure Welding procedures shall be determined by a competent welding engineer taking into account the recommendations set out in these notes but in any case shall be carried out only by approved welders using the electric arc welding process in approved welding procedures, Weld procedure tests and welder qualification tests should be carried out unless the welding engineer is satisfied from previous experience that they are unnecessary; Requirements for the approval testing of welders engaged in operations for which an approved welding procedure has to be applied are set out in British Standard BS 4871: Part 1*; Requirements for the approval testing of welding procedures for the fusion welding of steel, except castings, are set out in British Standard BS 4870: Part 1*; The return current cable connecting clamp for electric welding should at all times be connected to the workpiece at a point as ‘Available from British Standards Institution. 20© (f) 82 fa) (b) © @ © © 83 @ ) (a) (b) © M@! 7020539 0003459 753 mm close as possible to the actual weld. Return paths via pipe hangers, steelwork or structures are not to be permitted; The insulation of welding cables and connectors should be in sound condition at all parts; Welding cables should pass only through areas which are free from flammable liquids or gases. Action immediately prior to welding The identity of the pipeline to be welded should be checked; A check should be made that the pressure, temperature, flow rate and product specification are within the limits considered at the time of authorisation of the operation; It should be confirmed that the approved welder and his supervisor are absolutely clear concerning the agreed specified welding procedure; The temperature of the pipeline wall and the fitting should be checked; The welding current should be checked by means of an independant ammeter e.g. Tong Test type, while depositing weld metal on a piece of scrap material alongside the job, immediately before carrying out welding on the plant component; The requirements of the permit to work should be checked to ensure that they have been complied with. Action during welding Wherever possible during the welding operation the pressure, temperature and flow rate of the product should be monitored against previously agreed conditions; The surrounding atmosphere should be checked within the radius specified to ensure that there are no dangerous accumulations of gas, vapour or liquid. Integrity of the completed weld The completed weld should be able to meet any service condition to which the pipeline may be subjected after suitable heat treatment where necessary; Provision should be made for checking the integrity of the finished weld. This may involve hydraulic pressure testing, pneumatic leak testing, non-destructive testing, or other equally suitable means; The standard of acceptance applied to the results of non-destructive testing should be specified. Acceptance standards in the assessment 2@ 85 @) (b) @™ 70205159 0003460 475 of welds are given in BS 1500A*: 1960 Section 5: CSA and BS 3351*: 1971 Section 7.3.4. Similar acceptance standards are given in other relevant specifications; When pressure testing the fitment welded to the pipeline, care should be taken to ensure that the external pressure applied to the pipeline does not cause its collapse. Final completion Before dismissing the standby services the area should be checked to ensure that it is free from hazard; The completion of the operation and the safety of the site should be notified to all persons on whom notices were served and the permit to work certificate should be cancelled. "Available from British Standards Institution. 22