Professional Documents
Culture Documents
Approved By:
Manager, Drilling
P. N. Nicholls
Manager, HES
M. Gracas de Deus
SOP 9 Hot Work Procedures
1.0 Purpose
These guidelines are intended to establish the minimum rules that must be followed
during Hot Work operations. They do not preclude establishing additional
restrictions warranted by particular circumstances or conditions. Any variance from
this procedure shall be specified and approved on the Hot Work Permit (Appendix
1) by the Area Superintendent (or equivalent level of management).
2.0 Definitions
2.1 "Hot Work" - any work activities that introduce a potential ignition source of
any kind to the job site, including but not limited to, activities such as welding,
cutting, brazing, burning, grit-blasting, use of electrical power tools (drill,
sander, grinder, etc.), use of matches or lighters, operation of portable
internal combustion engines (that are not a properly designed and
permanently installed part of the facility), driving vehicles into an electrically
classified area, i.e., tank impounding basins, etc. See Appendix 5 for various
examples of ignition source types and minimum requirements.
Hot Work as defined herein does not include internal combustion engines
such as crane drivers, electrical generator drivers, and fire water pump
drivers that are a properly designed and permanently installed part of the
facility.
Hot Work as defined herein does not include hot-tapping, which is beyond
the scope of this SOP. Any hot-tapping activity requires preparation of a job-
specific plan and procedure, for approval by the Area Superintendent (or
equivalent level of management) in the department or section that is
responsible for the facility.
2.1.1 Burn, Weld, Grind, Arc (Open Flame Hot Work) – This type of ignition
source constitutes the highest risk of ignition in our industry. Open flames
and known incendive spark producers are usually associated with the
following activities: welding, cutting, grinding, burning, matches, lighters,
smoking, etc.
2.1.2 Non-Open Flame Ignition Sources – This ignition source type generally
involves higher levels of ignition energy associated with electrical (110V+)
powered tools and equipment. It also includes hot surfaces and tools with
rotary motors that can produce sparks. The following are some examples:
vehicles, generators, welding machines, classified electrical equipment with
the seal (enclosure) compromised, portable electrically powered tools, sand
blasting, lab analyzers, power tools with rotary motors, unclassified electrical
equipment, laptop computers, etc.
2.1.3 Handheld, Battery Powered Tools - This type of ignition source generally
involves the use of battery powered handheld tools with lower energy levels
associated with batteries. Examples of this type of ignition source can
include: cameras, electrical/electronic test equipment, non-destructive testing
and inspection equipment, vibration analyzers, VOC emissions analyzers,
boroscopes, strobe lights, calculators, etc.
2.2 "Restricted Area" - any onshore location within 100 feet of hydrocarbon
service or storage, or within a tank berm, or any offshore structure that
produces, processes, stores, utilizes, or otherwise handles hydrocarbons in
any way. Hot work, especially welding and cutting, shall be avoided in
Restricted Areas whenever feasible (i.e. by welding materials outside of
Restricted Areas and moving fabricated equipment to the installation site
where final tie-in can be completed). A daily Permit to Work and Hot Work
Permit is required and all other provisions of this SOP must be followed, as a
minimum, whenever hot work is to be performed in a Restricted Area.
General Permit to Work requirements are found in SOP 21.
2.4 "Designated Safe Welding Area" - an onshore location that does not
contain or is not within 100 feet of hydrocarbon service or storage, or a
hydrocarbon-free offshore platform designated as a "Safe Welding Area" by
the Area Superintendent (or equivalent level of management) in the
department or section that is responsible for the facility involved. Hot work in
a "Designated Safe Welding Area" does not fall under the requirements of
this SOP. However, a Designated Safe Welding Area will become a
Restricted Area if hydrocarbons are introduced into that area by any means.
For control purposes, the Area Superintendent (or equivalent level of
management) should consider requiring an annual or standing Hot Work
Permit for off-shore “Designated Safe Welding Areas.”
2.5 "Hot Work Permit" - a written authorization for safely performing Hot Work
in a Restricted Area for burn, weld, grind, arc (open flame hot work).
2.6 "Person-In-Charge (PIC)" - the person responsible for on-site direction and
supervision of the hot work. The PIC shall be named on the Hot Work
Permit, and must be knowledgeable and capable of performing all
responsibilities of this position as designated in Appendix 3. Depending on
the circumstances and the nature of the work, the PIC is typically a facility
Operations or Drilling representative. A Facilities Engineering
Representative should only be considered the PIC when the hot work is at a
remote site or platform where Operations is not present.
2.7 "Supervisor" - the immediate, first-line Supervisor (if other than the Area
Superintendent) of the PIC, and/or of the facility or job in question. The
Supervisor shall be named on the Hot Work Permit.
2.8 "Person Performing the Hot Work (PPW)" - the lead person directly
performing or inspecting the hot work.
2.9 "Fire Watch" - a person or persons assigned to a hot work job site for the
sole purpose of monitoring and observing for fire and explosion hazards, and
providing quick and effective fire protection if needed. The Fire Watch shall
3.1.1 Before hot work is authorized and started, there shall be thorough
communication between all employees and contractors involved. The
meetings will be conducted by the PIC and recorded in the job logbook. All
personnel shall be instructed on the job to be performed, General Permit and
Hot Work Permit restrictions, potential work site hazards and the need to be
on the alert for changing conditions that might increase the fire hazard.
3.1.2 Hot work is not permitted in a Restricted Area until the area is tested for
flammable gases and vapors and generally determined to be gas free (“zero”
percent LFL). However, if the gas concentration in a Restricted Area is
above 0% but not greater that 5% LFL, an exception can be granted by the
PIC if, after review of existing conditions and hydrocarbon sources, it is
deemed appropriate and safe. If concentrations are above 5% LFL but less
than 10% LFL, Supervisor approval must be obtained and documented on
the permit before work can proceed. Hot work shall not be permitted where
the gas concentration exceeds 10% LFL. If hot work is to be performed in a
confined space, the combustible gas or vapor concentration cannot exceed
300 ppm (controlled by the health hazard).
3.1.3 Hot work shall not be permitted on the same deck level as, or on any deck
levels above a vessel, tank, piping, pig-trap or other hydrocarbon-containing
equipment that is open to the atmosphere and has not been isolated,
cleaned, and/or determined to be gas-free.
A single block and/or check valve shall not be considered a positive means
of isolating equipment from the atmosphere or from connected vessels or
piping. In accordance with SOP-10, Lockout/Tagout, blind flanges, skillets or
blinds are preferred for isolation. When double block and bleed valves are
used as an alternative means of isolation, bleed lines must be carefully
checked to ensure they are not plugged and are routed so as to drain in a
safe location. If the drain is in the area of the hot work, it must be monitored
at frequent intervals (specify on the permit).
a) Continuously purging the vessel or tank with inert gas (nitrogen, steam,
etc.) to keep all oxygen displaced during the welding work, or
b) Filling the vessel or tank with water to a level at least three feet above the
weld area.
3.1.6 All combustible materials within 35 feet of the hot work area shall be
removed. If combustible materials can not be removed, they must be
protected by fire-resistant coverings or shields, or kept wetted.
3.1.7 Tanks, vessels and other equipment within 35 feet of the hot work location
(including such equipment on lower deck levels when there is no solid
decking to protect it) shall be protected by means of fire-resistant or wetted
coverings, shields, or by continuous water sprays.
3.1.8 All drains within 50 feet of the hot work area shall be plugged and filled with
water to form a seal. Vents in the vicinity of (including vents on the decks
above and below) hot work shall be routed away from the vicinity of the hot
work, or the input source to the vents shall be safely isolated.
NOTE: Pressure relief lines or vents are to be isolated only after assuring
that other positive means of pressure relief are provided and are functioning
properly. If other reliable means of pressure relief cannot be confirmed, then
such pressure relief lines or vents must not be isolated, and hot work should
not be authorized.
3.1.9 Hot work shall not be permitted while any wireline work is in progress. Refer
to SOP-14, Simultaneous Operations Guidelines, Section 7.0, Production
Wireline Activity.
3.1.10 A Hot Work Permit for a specific job is valid for only that day or that shift. If
the work is not completed, a new permit must be issued before hot work may
resume. The permit shall be approved only after the original permit
precautions plus any additional precautions are verified.
3.1.11 If work has been interrupted for more than 30 minutes for any reason, gas
testing shall be repeated before hot work resumes. If the hot work is stopped
as a precautionary measure because of hazardous (yet, normal) operating
conditions or activities, i.e., pigging, hot-oiling, generator shutdown, etc., it
may be resumed under the existing permit provided the PIC verifies that:
3.1.12 Hot work shall be permitted during night shifts only after the Area
Superintendent has approved the work by signing the space provided on the
permit. A separate Hot Work Permit is required for the night shift.
3.2.1 A General Work Permit and an initial gas test is required before a non-open
flame ignition source can be introduced into the restricted area. The PIC
may require gas testing at a greater frequency if deemed appropriate. See
SOP 21 for requirements on General Work Permits.
(see Appendix 4). In addition each portable engine shall have its own
shutdown control.
3.3.1 Handheld, battery powered tools require face to face communication with the
Production Foreman or equivalent position and receive verbal approval prior
to using the equipment in the restricted area. No hot work permit is required.
3.3.2 If handheld, battery powered tools are planned to be used as part of a non-
routine task that requires a general work permit, it should be noted on the
permit.
3.4.1 Portable communications equipment that is not intrinsically safe shall not be
operated in operational areas unless approved under a general work permit.
All hot work in a Restricted Area requires prior approval by the Area
Superintendent (or equivalent level of management), or by a supervisor who
has been given written delegation of this responsibility in the Area
Superintendent's absence, in the department or section that is responsible
for the facility in question. The person approving the work can do so by
signing the Hot Work Permit or, in lieu of signing the permit, can give verbal
authorization by issuing a unique permit control number. This number shall
be entered by the Supervisor requesting the work on the permit in the box
labeled “Control Number”. The person giving the verbal authorization shall
maintain a log of the authorizations given. Copies of verbal authorization
logs with copies of the Hot Work Permits verbally authorized shall be kept for
one year after the date of work (see Section 5.0).
4.2 Supervisor
The first-line Supervisor of the PIC, and/or of the facility or job in question, is
responsible for requesting the hot work to be done and for obtaining the Area
Superintendent's approval of the Hot Work Permit. The Supervisor, in
consultation with those involved in the work, shall identify the permit
restrictions that apply to the job. When the Supervisor is satisfied with the
permit, he/she should sign it and recommend to the Area Superintendent that
the permit be approved. The Supervisor shall sign the permit before the
permit is valid.
The PIC is responsible for completing the Hot Work Permit, for inspecting the
hot work area to ensure the conditions of the permit are fully met, and for
determining if there are any planned activities (pigging, hot oiling, etc.) that
may affect the hot work.
4.3.1 The PIC shall consult with the Supervisor to identify the permit restrictions
needed for the specific hot work to be conducted.
4.3.2 The PIC, along with the PPW, shall personally inspect the hot work area to
ensure that the permit conditions are met and the area is considered safe
from potential fire and explosion hazards. When the PIC is satisfied, he/she
should sign the Hot Work Permit approving the work (see “WORK MAY
SAFELY BEGIN” on the permit).
4.3.3 The PIC shall ensure that gas testing is performed by a qualified person who
is certified in the proper calibration and use of the gas detector before work
begins and at intervals specified on the permit (refer also to SOP-25, Gas
Detectors).
4.3.4 After the area has been determined to be safe and ready for hot work, the
PIC shall obtain the signature of the PPW and the person who conducted the
initial gas testing and give a copy of the Hot Work Permit to the PPW.
4.3.5 As long as a known ignition source is present in a Restricted Area, the PIC
shall remain in attendance or reasonably accessible until the hot work is
complete.
4.3.6 If the scope of the hot work activity is too broad for the PIC to adequately
direct and supervise, an additional qualified person(s) shall be designated to
assist the PIC.
4.4.1 Assist the PIC in inspecting the work area for potential fire and explosion
hazards prior to hot work beginning.
4.4.2 Sign the Hot Work Permit (see “WORK MAY SAFELY BEGIN”) and ensure
that the hot work is performed in accordance with the permit restrictions and
conditions.
4.4.3 Be on alert for changing conditions in the hot work area, or on decks above
or below the area, that may increase the fire hazard, and report these
changes to the PIC or shutdown the hot work if warranted.
On any burn, weld, grind, arc open flame hot work job, the PIC shall verify
the job assignment and work direction of the one or more Fire Watches, as
required by the permit. The Fire Watch shall be qualified and certified (refer
also to SOP-25, Gas Detectors) to perform the duties of a Fire Watch, and
shall have no other duties at the time of the hot work. A Fire Watch shall not
function as a welder's helper. If the hot work is being performed in a
confined space, the Fire Watch can double as Stand-By provided he/she has
been trained.
4.5.1 Be able to properly operate the fire extinguishers and other available fire
equipment if needed. Adequate fire extinguishers shall be at the hot work
site and readily accessible to the Fire Watch.
4.5.2 Have the fire pump running and one hose rolled out, pressurized, and at the
hot work site. If the facility is not equipped with a fire water system or the
facility's fire water system is inoperable, secondary protection should be
provided (i.e. dry chemical wheeled unit or foam wheeled unit). In the
instance of hot work performed on well jackets a minimum of two (2) 30 lb.
dry chemical extinguishers dedicated to the Fire Watch are required for each
hot work job. The proprietor of the facility should consider dedicating
extinguishers to be used specifically for Fire Watch duty.
4.5.3 Be qualified and certified in the calibration and use of the gas detector, and
conduct gas testing continuously or at frequent intervals during the hot work,
as directed by the PIC. Testing intervals shall be based on the type of
location and hazards involved. After interruptions of 30 or more minutes,
testing shall be done before normal work resumes.
4.5.5 Continually observe the work in progress and the areas around, above and
below the work site for fire or other hazardous conditions that may arise.
The Fire Watch shall watch for falling hot slag and sparks on areas below
and around the hot work.
4.5.6 Wear personal protective equipment as prescribed in the Fire Watch Training
Course module.
4.5.7 Monitor the worksite to ensure there are no hot /smoldering surface(s)
remaining which could start a fire after the welding or cutting operation has
interrupted or completed.
5.1 During planning of any hot work, the first-line Supervisor shall obtain the
necessary approval from the Area Superintendent (or equivalent level of
management), or from a supervisor delegated this responsibility in the Area
Superintendent's absence, for conducting hot work.
5.2 The originals of Hot Work Permits shall be retained for one year at a location
designated by the Area Superintendent or equivalent level of management.
5.3 All required records or logs shall be kept for one year from the date of the
work. If a permit was approved via verbal authorization, a copy of the Hot
Work Permit, showing the unique control number, shall be sent by the PIC to
the Area Superintendent (or equivalent level of management) upon
completion of the work so it can be filed with the log.
5.4 The PPW shall retain a copy of the permit while at the job and shall comply
with its conditions. Upon completion, stoppage, or shutdown of the work, the
PPW shall return his/her copy to the PIC.
5.5 Hot Work Permits are only valid for the date of issue. If the nature of the job
changes, the job extends to the next day, or if permit conditions can no
longer be followed, the permit shall be suspended and a new permit shall be
issued.
Periodic reviews of Hot Work Permit records shall be made during the course of
CABGOC Internal Reviews and Department Self Inspections to verify that
Operations are complying with the intent of this Hot Work Procedure.
Hot Work Permit books/pads are stocked in the Warehouse. Each pad contains 25
permits. The symbol number for ordering books is 55.9505812.
No permit
No required
PIC conducts safety meeting
Is site made
No
safe?
No
Yes Supervisor gives the permit
to the PIC
No
Person Person
Fire
Skill In Performing
Watch
Charge Work
1. Burn, Weld, Grind, Arc (Open Flame Hot Hot work permit process, including gas
Work) testing and fire watch required.