16.hot Work Safety PDF

Document ID No: MSSM-1-SF-001
Power & Water Utility Company for

Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010
MARAFIQ SAFETY MANUAL
16. HOT WORK SAFETY

Reference Standards: -
SASO - 336 / 1994
GS - 220 1994
OSHA – 1910.251 to 255
INTRODUCTION
Hot work presents significant risks of fire and injury. Hot work is any temporary operation involving
open flames or which produces heat/sparks. Typical operations include brazing, open flame
soldering, grinding, arc welding/cutting, oxy-fuel gas welding, hot taps, and torch applied roofing.
Risks associated with hot work are:-

 Skin and eye damage such as "welder's eye" or cataracts from welding arcs and flames which
emit intense visible, ultraviolet and infrared (IR) radiation.
 Injury to the eye or skin from flying particles which can,
 Cuts and stabs from sharp metal edges,
 Electric shock from defective equipment or unsafe electricity
 Excessive heat and burns from hot surfaces, flames, sparks, etc.,
 Fires and explosion from sparks, flames or hot metals, flashbacks or equipment failure.
 Respiratory problems from toxic welding fumes released during the welding/cutting process.
 Hearing damage due to excessive noise levels.
Care must be taken to ensure that hot work is performed safely in order to avoid any untoward
incidents as stated above.
Page 1 of 11
Rev. No.: 0
16.1 DEFINITIONS
 Hot Work: any process involving grinding, welding, thermal or oxygen cutting or heating and other
related heat producing or spark producing operations.
 Grinding: a machining process: (a) to shape components that are too hard to be machined by
conventional methods such as hardened tool steels and case or induction hardened components.
(b) To obtain a high degree of dimensional accuracy and surface finish on a component.
 Welding: a process that uses heat to join metals.
 ARC Welding: a process for joining metals with heat produced by electricity.
 Cutting: a process for breaking metals using an oxygen-acetylene gas mixture that produces a high-
temperature flame, or by other means.
 Welding Fumes: a mixture of very fine particles and gases, produced during welding process.
 High Risk Area: an area in which flammable / combustible liquids, vapors or gases, dusts or fibers,
or other flammable or explosive substances may represent a risk to plant or personnel (e.g. fuel gas
station).
Page 2 of 11
Rev. No.: 0
16.2 HOT WOTK

 Risk Assessment should be completed for hot works with significant risks
and Permit to work Certificate must be obtained
 Personnel performing hot work and using welding, cutting, grinding and
other equipment should be trained and competent.
 All required equipment should be inspected and ensured safe before use.
 First option should be to move the object to be welded or cut to a safe place
and carry out hot work.
 If the object to be welded or cut cannot readily be moved, all movable fire
hazards due to combustible or explosive material in the vicinity and below
the workplace should be taken to a safe place.
 If all the fire hazards cannot be removed, then guards such as fire proof
blankets, shields, etc should be used to confine the heat, sparks, and slag,
and protect the immovable fire hazards.
 Openings and cracks of flooring and walls should be closed,
 Suitable fire extinguishing equipment such as portable extinguishers, fire

hydrant hose should be maintained in a state of readiness for instant use
depending upon the nature and quantity of the combustible material
exposed.
 In “high risk” areas, a fire watch or a standby man with fire extinguisher, fire
blanket and charged fire water hoses should be posted.
 If the combustible materials cannot be removed from the area, cover them
with fireproof blankets or shields.
 Fixed fire protection system should be defeated where required.
Exhaust ventilation should be provided for:-
i. welding booths in workshop areas

ii. Extracting fumes while conducting welding jobs in confined spaces.
 Pipelines, tank, vessel, drums, containers, etc, should be

drained/flushed/purged/ventilated/gas tested, as required.
 Hoses, cables, and other equipment should be kept clear of passageways, ladders, and
stairs.
Page 3 of 11
Rev. No.: 0
 The work piece should be clamped and should not be held by hand.
 While carrying out hot work in confined spaces or at height or under water
all safety requirements should be taken according to risks and as stated in
Marafiq safety manual.
 Smolder should be wetted and extinguished after the completion of work
16.3 OXY-ACETYLENE GAS CUTTING

Oxy-acetylene gas cutting should be complete in all respect with:-
 pressure gauge regulators,
 flashback arrestors,
 hose check valves,
 proper connectors,
 proper hoses
 gas torch, etc.
Gas cylinders should be mounted on a purpose built trolley,

secured properly with chain and kept right:-
 away from the actual welding or cutting operation area,

 not subjected to open flame, hot metal, or other sources of
artificial heat
 outside the confined space away from access and should not
be taken inside confined space
 Free from electrical hazards where they cannot become part of
an electrical circuit.
Pressure regulators, including their related gauges, should be in proper working

condition.
Page 4 of 11
Rev. No.: 0
Appropriate flashback arrestors should be connected to pressure regulators and

hoses with arrow pointing towards gas flow in order to prevent flashback from
invading the gas supply system such as hoses, regulators and
cylinders and causing an explosion.
Flashback arrestors should be properly identified for oxygen and fuel gas cylinders
and accordingly should be connected. They should not be interchanged.
Gas hoses should be: -
 easily distinguishable from each other

 Oxygen hose – green or blue in color and
 Fuel gas hose – red or orange in color
 Inspected at the beginning of each working shift. Defective hose should

be removed from service.
 be checked for leaks with a soapy water solution.
 kept away from the working area to prevent: contact with

flames, heat, sparks or hot spatter;
 clear of sharp edges and abrasive surfaces or where vehicles

can run over them
 Replaced if any with leaks, worn spots or burns, cuts, cracks,

crazing, foreign particles embedded in it, etc.
Check Valves should be provided at the torch end to prevent reverse

flow of flame in case of backfire in hoses, regulators or cylinders
causing fire and explosion.
Gas torches should be:-
 Inspected at the beginning of each working shift for leaking shutoff valves,
hose couplings, and tip connections. Defective torches should not be
used
 Examined regularly and any blocked nozzles cleaned or

replaced after isolating and depressurizing the gas cylinders.
Page 5 of 11
Rev. No.: 0
 Lighted by friction lighters or other approved devices, and not by matches

or from hot work.
 Shut off when not in use and should not be left lighted on a
 bench or the floor.
When the job is finished:-
 Oxygen and acetylene regulator valves should be closed

 Cylinder valves should be closed
 Entrapped gas from the torch and hoses should be bled off.
Oxygen should not be used for ventilation purposes, comfort cooling,

blowing dust or dirt from clothing, or for cleaning the work area
Cylinders, cylinder caps and valves, couplings, regulators, hose, and apparatus
shall be kept free from oil or greasy substances and should not be handled with
oily hands or gloves.
Oxygen should not be directed at oily surfaces, greasy clothes, or within a fuel oil
or other storage tank or vessel
16.4 ARC WELDING Reference Standards: - SASO 336 / 1994 & GS 220
&1994- 4.2.1
Diesel engine powered welding machines should be kept away
outdoor with its panels closed to protect from adverse effects of
noise and exhaust fumes.
All power supply, welding and ground cables should be inspected

before use for worn or cracked insulation and maintained in good
condition to reduce shock hazards
The metal work piece, where welding take place, and welding
machines should be grounded
Page 6 of 11
Rev. No.: 0
Earthing lead should be connected directly to the work piece and not
to plant common ground
Electrodes should be removed from the holders when not in use and not be
struck against a cylinder to strike an arc.
Welding screen / curtains or shields are to be provided to protect

personnel other than welders from the adverse effects of welding
arc, radiations, noise, etc.
Used stubs of welding electrodes should be collected in a metal

container or bucket and should not be thrown on floor
On completion of job, power should be turned off
16.5 HOT WORK IN CONFINED SPACES

Prior to entry confined space, following safety requirements for
confined space entry should be ensured:-
 Permit to Work Certificate – obtained

 Gas testing - done
 Standby attendant – posted
 Exhaust ventilation to remove welding fumes– provided
 Forced ventilation or breathing air line respirators for
personnel working inside – provided
 Fire extinguishers – provided as required
 Emergency rescue arrangement – kept ready
 Gas cylinders – kept outside of confined space
 All flammable or combustible material - removed or protected
from ignition.
Page 7 of 11
Rev. No.: 0
All gas hoses and equipment from the confined space should be
removed immediately after use and at the end of each working day.
Those should not be left in confined spaces overnight or when not
required.
16.6 HOT WORK ON TANKS & PIPE LINES

Flammable liquids and vapors such as petrol, diesel, fuel oil, paints, solvents, glue, lacquer and cleaning
agents are found in many places of work. If a welding torch or powered cutter is used on a tank or drum
containing flammable material (solid, liquid or vapor), the tank or drum can explode violently.
People have been killed or seriously injured by such explosions. Tanks and drums that seem to be „empty‟
usually still have residues in the bottom, in seams and other crevices. Just a teaspoon of petrol in a drum
can be enough to cause an explosion, when heated and turned into vapor.
Mostly hot work on tanks and gas pipe lines should be avoided. Instead
cold cutting using shears and cold repair methods of using materials
such as epoxy resins and fiberglass to seal cracks and holes should be
used, where practicable.
If a tank is being cut, it is often advisable to try and remove all or part of
it preferably the top using cold cutting methods.
Preferably hot work on tanks and pipelines at the operational hazardous

area should be avoided. Tanks or pipelines should be disconnected
from other equipment by removing pipe sections and brought to a safe
place for carrying out hot work.
Prior to carrying out hot work on tank or pipe lines:-
Risk assessment should be completed including preparation and

accordingly identified risk control measures should be applied.
Tanks or pipe lines should be:-

Released of pressure by venting
Isolated using blinds on suction or delivery lines if possible
Emptied by pumping or draining the liquid into a suitable container. The

residues should be disposed of in line with environmental requirements
and not tipped into drains, sewers or water courses.
Page 8 of 11
Rev. No.: 0
Cleared of gas, vapors and other flammable / volatile material by

means of
 washing or jetting using water or detergent / solvent solutions
 filling the tanks with water or
 purging with an inert gas, such as nitrogen or
 Steam cleaning.
If the tank or pipe lines are purged with inert gas, then it should
be:-
 Ventilated to maintain safe working atmosphere before allowing

human entry into it by carrying out gas test
 Tested for flammable / explosive gas prior to carrying out hot

work on it. Purging should be continued till flammable/explosive
gas concentration is maintained within allowable limits 0 to 10%
LEL
Light used inside the tank or pipelines for inspection or hot work
must be ‘flameproof’, i.e. designed for use in flammable
atmospheres
16.7 GRINDING SASO 323/1994 & GS 213/1994
Definition of grinding: A machining process: - (a) to shape components that are too hard to be
machined by conventional methods such as hardened tool steels and case or induction
hardened components. (b) to obtain a high degree of dimensional accuracy and surface finish
on a component
Potential Hazard:
 Sparks, noise, eye and skin injury from flying metal

filings, grinding wheel pieces, etc.).
 Having fingers or hands caught in the grinding wheel,
resulting in amputation.
 Being struck by portable grinder
Page 9 of 11
Rev. No.: 0
 Appropriate PPE, such as face shield should be used

 Portable grinder and grinding wheel must be inspected
before use.
 Portable grinder must have a wheel guard and a

deadman‟s switch.
 A cracked wheel or one that has been dropped or has

become damaged must not be used.
 A wheel should not be forced onto the machine or the

size of the mounting hole should not be altered- if the
wheel won't fit the machine, only the correct that will fit
the machine should be used.
 Speed of the grinding wheel must not be exceeded

maximum operating speed specified for the wheel.
 Work piece should be secured firmly before grinding.
16.8 Personal Protective Equipment

Helmets or hand shields with proper dark filter lenses of different
shades for arc welding and gas cutting – welder for arc welding
or arc cutting operations,
Dark lens goggles or other suitable eye protection – for helpers

and attendants
Goggles or face shields – while grinding
Page 10 of 11
Rev. No.: 0
Flame resistant protective gauntlet gloves and aprons should be

worn during welding
Respiratory protection with suitable cartridges and exhalation

valve should be used while welding to protect from toxic fumes,
particulates and smoke of metals, flux and electrodes
Safety shoes with protected tops should be worn to protect the

operator from spark hazard
Hearing protection should be worn to protect from high noise

levels produced by grinding or cutting activities
Page 11 of 11

16.hot Work Safety PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

16.hot Work Safety PDF

Uploaded by

Copyright:

Available Formats

Document ID No: MSSM-1-SF-001

Power & Water Utility Company for

MARAFIQ SAFETY MANUAL