KHARAFI NATIONAL

HEALTH & SAFETY

SAFE OPERATING PROCEDURE SOP 008

WELDING, CUTTING & HOT WORK

1 16 Jun. 2009 H&SM QAM (P) Corp. H&SM CD (QA&C) MD

Rev Date Prepared Reviewed Reviewed Reviewed Approved

SOP 008 Rev. 1 16 Jun. 2009 Page 1 of 10

 REVISION RECORD SHEET

NOTES

i) Revisions after Rev. 0 are denoted by a vertical line in the left hand margin
2
against the revised text, with the revision number displayed next to the revision
line as shown by the example on the left.

ii) Revision numbers are A, B, C, etc. up to the issue for management approval
and implementation, which is Rev. 0. Subsequent revisions are 1, 2, 3, etc.

No. Date Description of Revision By Rev Rev Rev App

0 02 Apr. 2008 Issued for approval & implementation BK AA DB HQ SY
1 16 Jun. 2009 Reference to DMD changed to MD. Reference to BK AA DB HQ SY
OH&SM in the footer removed.

SOP 008 Rev. 1 16 Jun. 2009 Page 2 of 10

 CONTENTS

1.0 SCOPE

2.0 DEFINITIONS

3.0 INSTRUCTIONS
3.1 Objective
3.2 Responsibilities
3.3 General Procedure
3.4 Fire Prevention Measures for Welding, Cutting & Other Hot Works
3.5 Safe Welding Procedures
3.6 Safe Oxy/ Acetylene Gas Cutting Procedures
3.7 Gas for Welding and Cutting
3.8 Safe Grinding Procedure
3.9 Training

4.0 APPENDICES

5.0 REFERENCES

SOP 008 Rev. 1 16 Jun. 2009 Page 3 of 10

1.0 SCOPE
1.1 This guideline describes the general safety requirements relating to welding, cutting,
and hot work and is applicable to all the operations within Kharafi National (KN)
inclusive of subcontractors. All precautions of this program must be applied prior to
commencing any welding, cutting or hot work by KN employees and contractors.
Where applicable, this program will be used in conjunction with client’s work permit
system or safety requirements.

2.0 DEFINITION
2.1 Hot Works : Any activity which results in sparks, fire, molten slag, or
hot material which has the potential to cause fires or
explosions (e.g. cutting, welding, soldering, thawing pipes,
torch applied heating, grinding, etc.)
The hazards encountered due to welding, cutting and other
hot work at site are:
• Fires & Explosions
• Skin burns
• Welding ‘blindness’ due to UV radiation
• Respiratory hazards from fumes & smoke
• Physical hazards

3.0 INSTRUCTIONS
3.1 Objective
3.1.1 To provide a guideline for general safety and fire precautions to be taken when
performing hot works.
3.2 Responsibilities
3.2.1 The Management shall:
• Provide proper equipment that is necessary to carry out the hot work safely.
• Provide training for all employees whose task include heat, spark or flame
producing operations such as welding, brazing, or grinding.
• Develop and monitor effective hot work procedures.
• Provide adequate safety equipment to perform the hot work safely.
• Provide proper and effective PPE for all hot work.
3.2.2 The Supervisors shall:
• Monitor all hot work operations.
• Ensure all hot work equipment and PPE are in safe working order.
• Allow only trained and authorized employees to conduct hot work.
• Ensure permits are used for all hot work outside authorized areas.
3.2.3 The Employees shall:
• Follow all hot work procedures.
• Properly use appropriate PPE applicable for hot works.
• Inspect all hot work equipment before use.
• Report any defects identified/ problems encountered with the hot work equipment.
• Not use damaged hot work equipment.

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3.3 General Procedure
3.3.1 Prior to start of any hot work, all combustible materials shall be relocated at least 10
meters away from the hot work location. Where relocation is impractical,
combustibles shall be protected with flame proof covers, shielded with metal, guards,
curtains, or wetting down material to help prevent ignition of material/ contact with
hot sparks or slags.
3.3.2 Ducts, Pipes or conveyor systems that might carry sparks to distant combustibles shall
be protected or shut down.
3.3.3 Where cutting or welding or other hot work is done near walls, partitions, ceilings, or
a roof of combustible construction, fire-resistant shields or guards or wet down of
material shall be provided to prevent ignition.
3.3.4 Where there is a storage facility for flammable liquids such as petrol or diesel or fuel,
No hot work shall be conducted within 25 meters from the storage location unless
alternative safety precautions (as appropriate) are taken to carryout the hot work in a
safe manner.
3.3.5 If welding or other hot work is to be done on a metal wall, partition, ceiling, or roof,
precautions shall be taken to prevent ignition of combustibles on the other side, due to
conduction or radiation of heat.
3.3.6 Where combustibles cannot be relocated on the opposite side of the work, a fire watch
person shall be provided on the opposite side of the work.
3.3.7 Welding, cutting or other hot works shall not be attempted on a metal partition, wall,
ceiling or roof having a covering or on walls having combustible sandwich panel
construction.
3.3.8 Cutting or welding or other hot work on pipes or other metal in contact with
combustible walls, partitions, ceilings, or roofs shall not be undertaken if the work is
close enough to cause ignition by combustion.
3.3.9 Cutting, welding or other hot work shall not be permitted in the following situations:
• In areas not authorized by the project management.
• Client’s permit required area but permit not on site/ signed
• In the presence of potentially explosive atmospheres, e.g. flammable liquids
• In areas near the storage of large quantities of exposed, readily ignitable materials.
• In areas where there is excess dust accumulation within 10 meters of the area
where welding/ hot works will be conducted. All dust accumulation should be
cleaned up following the housekeeping program of the facility before welding/ hot
works are permitted.
3.3.10 Suitable extinguishers shall be provided at site of weld and maintained ready for
instant use (min. 9kg).
3.3.11 Based on the risk assessment, a fire watch person shall be provided during and for one
hour past the completion of the welding or hot work.
3.4 Fire Prevention Measures for Welding, Cutting & Other Hot Works
3.4.1 A designated welding/ hot work area shall be established to meet following
requirements:
• Floors swept and clean of combustibles within 10 meters of hot work area.
• Flammable and combustible material shall be kept at a safe distance of 10 meters
away from hot work area.
• Adequate ventilation, such as suction hood system shall be provided to the work
area.

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 • At least one 9 kg dry chemical fire extinguisher shall be at site of hot work and
one within access of the 10 meters of work area.
• Where hot work is done at high elevations or at overheads, flammable &
combustible materials shall be maintained at a safe distance of 10 meters away
from the anticipated location of hot slags/ sparks falling onto ground. Effect of
wind shall also be considered in maintaining safe distance.
• Protective dividers such as hot work curtains or non-combustible walls shall be
provided to contain sparks and slag to the combustible free area.
• Appropriate PPE’s shall be used during hot works to protect from flying particles,
UV radiation and contact with hot metals/ sparks.
3.4.2 Requirements for welding or other hot works conducted outside the designated area:
• Portable welding curtains or shields must be used to protect other workers in the
area.
• Welding/ hot work operation shall not commence unless necessary work permit
has been received from the client and permission has been obtained from the
concerned immediate KN Supervisor/ Engineer.
• Where appropriate, respiratory protection shall be worn by the operator/ user and
others passing the area.
• Plastic/ rubber materials shall be covered with welding tarps during welding
procedures.
• Fire watch shall be provided for all hot work operations.
3.5 Safe Welding Procedures
3.5.1 Electric Welding
3.5.1.1 Perform safety check on all equipment.
3.5.1.2 Ensure fire extinguisher is charged and available.
3.5.1.3 Ensure electrical cord, electrode holder and cables are free from defects (no cable
splices are allowed with in 10 feet of the electrode holder).
3.5.1.4 Ensure PPE (welding hood, gloves, rubber boots/soled shoes, aprons) are available
and have no defects.
3.5.1.5 Ensure the welding unit is properly grounded.
3.5.1.6 If any defective equipment are discovered, it must be repaired or replaced before use.
3.5.1.7 Remove flammables and combustibles.
3.5.1.8 No welding is permitted on or near containers of flammable material, combustible
material or unprotected flammable structures.
3.5.1.9 Place welding screen or suitable barricade around work area to provide a fire safety
zone and prevent injuries to passersby. Do not block emergency exits or restrict
ventilation.
3.5.1.10 Ensure adequate ventilation and lighting.
3.5.1.11 Follow Hot Work Permit procedure as per client’s requirements where applicable.
3.5.1.12 Set appropriate voltage to the type of work piece and weld metal on the welding
machine regulator.
3.5.1.13 Uncoil and spread out welding cable.

SOP 008 Rev. 1 16 Jun. 2009 Page 6 of 10

3.5.1.14 To avoid overheating, ensure proper contact of work leads and connections, remove
any metal fragments from work clamps (to avoid electric shock do not wrap welding
cables around a body part and avoid welding in wet conditions).
3.5.1.15 Fire watch must conduct a routine fire check for one hour after welding and until all
welds have cooled.
3.5.1.16 Perform final fire watch and ensure the area is clear.
3.5.2 Gas Welding
3.5.2.1 Perform Safety Check on all equipment.
3.5.2.2 Ensure tanks have gas and fittings are tight.
3.5.2.3 Flashback arrestors must be fitted.
3.5.2.4 Ensure fire extinguisher is charged and available.
3.5.2.5 Ensure hoses have no defects.
3.5.2.6 Ensure PPE (welding hood, gloves, rubber boots/ soled shoes, aprons) are available
and have no defects.
3.5.2.7 All defective equipment must be repaired or replaced before use.
3.5.2.8 Remove flammables and combustibles.
3.5.2.9 No welding is permitted on or near containers of flammable material, combustible
material or unprotected flammable structures.
3.5.2.10 Place welding screen or suitable barricade around work area to provide a fire safety
zone and prevent injuries to passersby. Do not block emergency exits or restrict
ventilation.
3.5.2.11 Ensure adequate ventilation and lighting.
3.5.2.12 Follow Hot Work Permit procedures as per client’s requirements where applicable.
3.5.2.13 Open valves on oxygen and gas tanks to desired flow.
3.5.2.14 Once the welding is completed, shut tank valves and relieve hose pressure. Store
hoses in a safe place, coiled and kept intact.
3.5.2.15 Fire watch must conduct a routine fire check for one hour after welding and until all
welds have cooled.
3.5.2.16 Perform final fire watch and ensure the area is clear.
3.6 Safe Oxy/ Acetylene Gas Cutting Procedures
3.6.1 Perform safety check on all equipment.
3.6.2 Ensure fire extinguisher is charged and available.
3.6.3 Ensure gas hoses, torches, flashback arrestors, gas regulators are in good condition
and free from any defects.
3.6.4 Ensure gas hoses, torches, flashback arrestors, gas regulators and gas cylinder are
fitted correctly and properly secured.
3.6.5 Perform safety check for possible gas leak in the entire system of oxy/ acetylene gas
cutting equipment.
3.6.6 Ensure PPE (appropriate goggles, gloves, shoes, aprons, helmet) are available and
have no defects.
3.6.7 Ensure the gas line is purged and appropriate pressure is set on the regulator.
3.6.8 If any defective equipment are discovered, it must be repaired or replaced before use.
SOP 008 Rev. 1 16 Jun. 2009 Page 7 of 10
3.6.9 Remove flammables and combustibles in and around the work area.
3.6.10 No oxy/ acetylene gas cutting is permitted on or near containers of flammable material,
combustible material or unprotected flammable structures.
3.6.11 Place suitable barricade around work area to provide a fire safety zone and prevent
injuries to passersby. Do not block emergency exits or restrict ventilation.
3.6.12 Ensure adequate ventilation and lighting.
3.6.13 Follow Hot Work Permit procedures as per client’s requirements where applicable.
3.6.14 Uncoil and spread out gas hoses.
3.6.15 Never leave the oxy/ acetylene gas cutting equipment unattended when not in use.
Make sure to close/ isolate the gas cylinder when not in use.
3.6.16 Fire watch must conduct a routine fire check for one hour after gas cutting and until
all part have cooled.
3.6.17 Perform final fire watch and check the gas cylinders are closed/ isolated.
3.6.18 Handling & Use of Compressed Gas Cylinders
• Compressed gas cylinders shall be kept upright position and secured by chain to
prevent accidental fall. Gas cylinder shall be located at a safe distance away from
where the cylinder may come in contact with any sparks or flames.
• Compressed gases contained within a cylinder are under extremely high pressure.
Therefore, whenever gas is to be withdrawn from a cylinder, pressure regulating
valves shall be used. Under no circumstances is gas to be removed from a
cylinder without the use of a pressure regulating valve.
• All cylinder connections, hoses, valves, etc., shall be inspected by the user prior to
using the compressed gas cylinder. All connections shall be tight with no leaks.
Damaged and/ or deteriorated cylinder, valves, couplings, hoses, etc., shall not be
used.
• When opening cylinder valves, gas outlets shall always be pointed away from the
user and any other facility personnel standing in the immediate usage area.
• All cylinder valves shall be opened slowly using only approved wrenches for the
cylinder as provided by the supplier.
NOTE: When using a compressed gas cylinder, the operating wrench shall remain
on the cylinder valve at all times.
• All compressed gas-cylinder valves, couplings, hoses, etc., shall not be lubricated
or allowed to come in contact with oil and/ or grease.
• Cylinders of compressed gases shall not be placed in areas where there may be oil
and/ or grease nor handled with oily and/ or greasy hands.
• After each use of a compressed gas, the cylinder valve shall be fully closed and all
gas remaining in the regulator valve shall be slowly purged. The regulator valve
shall be removed, the cylinder valve cap shall be installed, and the cylinder tank
shall be removed from the work area and returned to its proper storage location.
• If the contents of a compressed gas cylinder are depleted, the cylinder valve shall
be fully closed, and the valve protection cap shall be reinstalled. The gas cylinder
shall be appropriately marked with an ‘EMPTY TANK’, sign and the tank shall be
stored in a secured upright position.
3.6.19 Gas Hoses
• Gas hoses used for oxy/ acetylene cutting shall be maintained in good condition
and free from any defects.

SOP 008 Rev. 1 16 Jun. 2009 Page 8 of 10

 • Hose connectors and other fittings must be tightly secured to ensure any leakage
of gases.
• Hoses should not be dragged across sharp, rough, hot or corrosive surfaces. Hoses
should not be dragged across surfaces where connections may become
contaminated with grease or oil.
• Hoses used for acetylene and oxygen shall be color coded ‘Red’ and ‘Green’
respectively to identify the gases.
3.6.20 Torches, Gauges and Flash Back Arrestors
• Torches, gauges or flashback arrestors or other such fittings must not be dropped
or allowed to strike against objects.
• Torches, gauges, flashback arrestors or other such fittings should be handled and
transported with care to prevent damage or contact with oil, grease or corrosive
substance.
• Flash back arrestors shall be fitted in accordance with the manufacturer’s
instruction at every pressure regulator outlet of each gas cylinder.
• Defective torches, gauges, flashback arrestors and other fittings shall not be used
at any time.
3.7 Gas for Welding and Cutting
3.7.1 Compressed Gas Cylinder Storage
• All compressed gas cylinders shall be stored in an upright position.
• Cylinders shall be secured by a chain to ensure that they will not be accidentally
knocked over.
• Storage locations shall be well ventilated and ambient room storage temperatures
shall not be allowed to exceed 125°F.
• Cylinder storage locations shall be distinctly marked with the names of each
compressed gas maintained at the location. ‘NO SMOKING - FLAMMABLE
GAS’ signs shall be posted at all entrances to locations where flammable gases are
stored.
• Each compressed gas cylinder maintained at a storage location shall be labeled
with proper identification of its contents.
• All cylinders in storage/ being transported shall require valve protection caps at all
times except when the cylinder contents are being dispensed.
• Storage locations for oxidizing gas (e.g. oxygen) and flammable gas (e.g.
acetylene) cylinders shall be maintained at a safe distance of 10 ft to separate the
oxidizing and flammable gas cylinders.
• Cylinder storage areas containing flammable gases shall be stored to avoid contact
with a possible ignition source. Walls of the storage area shall have a fire rating
resistance of at least one hour, and doors shall be in accordance with relevant
international standards.
• Flashback arrestors are to be installed on both flammable gas cylinders and
oxygen cylinder during use to provide protection against any backfire.
• Portable fire extinguishers consisting of dry chemical or carbon dioxide shall be
available at the storage locations.
3.7.2 Transporting Compressed Gas Cylinders
• Compressed gas cylinders shall never be rolled, slid, or dragged from one location
to another.
• Trolley shall be used to transport cylinders inside the local site.

SOP 008 Rev. 1 16 Jun. 2009 Page 9 of 10

 • All pressure regulators shall be removed, and valve protection caps shall be
installed prior to moving any cylinders.
3.8 Safe Grinding Procedure
3.8.1 The Grinder shall be fitted with proper size and rated grinding wheel. The
specification of the wheel shall not exceed the rpm rating of grinder.
3.8.2 Grinders shall be fitted with safety guard and maintained at all times.
3.8.3 Employee using/ about to use the grinder shall be responsible to do the current
inspection, properly spaced work rest, guards, correct wheel rpm rating, proper
washers, condition of wheel, etc. Any defects or damages are discovered in the wheel
or the machine shall be immediately reported to their supervisor.
3.8.4 Users of grinder shall warn the personnel in the immediate area prior to grinding.
3.8.5 Power cords must not be used to lower grinder from elevation locations.
3.8.6 Loose clothing is not permitted while using grinders.
3.8.7 Appropriate PPE must be worn by the employees using the grinders, employees
working in the surrounding area and the passersby
3.8.8 Client’s Hot Work Permit procedures must be followed where applicable.
3.8.9 Never leave the grinder unattended when not in use. Make sure to isolate the power
supply when not in use.
3.8.10 Ensure fire extinguisher is charged and available.
3.8.11 The work area and its surroundings shall be checked to ensure that any flammables
and combustibles are removed prior commencing grinding.
3.8.12 Perform final fire watch and ensure the area is clear.
3.9 Training
3.9.1 Employees involved in welding, cutting and other hot works shall be trained
adequately which shall include on a minimum:
• Review of requirements listed in this program
• Use of Client’s Hot Works Permit System (as applicable)
• Supervisor responsibilities
• Fire watch responsibilities - specifically, the fire watch must know:
- That their ONLY duty is fire watch
- When they can terminate the watch
- How to use the provided fire extinguisher or other fire fighting appliance
- How to activate fire alarm if fire is beyond the incipient stage
• Employee responsibilities
• Contractors responsibilities
• Documentation requirements
• Any specific PPE usage requirements
• Fire extinguisher training

4.0 APPENDICES
4.1 None.

5.0 REFERENCES
5.1 None.

SOP 008 Rev. 1 16 Jun. 2009 Page 10 of 10