18002-HSE-MG-027-00 Hot Works Management

HOT WORKS MANAGEMENT
DOCUMENT: 18002-HSE-MG-027
405 MW dc SOLAR PV PLANT,SAKAKA- KSA
Owner / Client ACWA POWER
Owner’s Engineering
Principal contractor MAHINDRA SUSTEN
Name & Designation Signature Date Signed
Dibu. MK
Prepared by:
HSE Manager
A u t h o r i z e d b Muneer Nwairan
y: Project Director
Approved by ACWA POWER
The latest version of this document is available in electronic format for consultation and document management.
Document: 18002-HSE-MG-027-00
Rev. No. Purpose of Issue Date Issued Remark
0 Initial release for approval 23/08/2018
Table of Contents
1. Purpose and objective...........................................................................................................................4

2. SCOPE....................................................................................................................................................4
3. GENERAL INFORMATION.......................................................................................................................4
3.1 Reference and Definitions.................................................................................................................4
3.2 Related Documents:..........................................................................................................................4
4. Roles and responsibilities......................................................................................................................4
5. DEVELOPMENT......................................................................................................................................5
5.1 Authorized Staff Control....................................................................................................................5
5.2 Equipment Control with operations with risk of fire.........................................................................5
5.3 General requirements for operations with risk of fire.......................................................................5
5.3.1 General Considerations..................................................................................................................5
5.3.2 Signalling for Operations with Risk of Fire.....................................................................................5
5.3.3 Work in Confined Spaces...............................................................................................................6
5.3.4 Operations on uneven surfaces or at heights................................................................................7
5.4 Arc Welding Works............................................................................................................................8
5.5 Cutting and welding with blowtorch..................................................................................................8
5.6 Handling of pressurized gas cylinders................................................................................................9
5.6.1 Storage of cutting/welding equipment with pressurized gas.........................................................9
5.6.2 Handling and operation of valves................................................................................................10
5.6.3 Handling and operation of regulators..........................................................................................11
5.6.4 Hoses and connections................................................................................................................11
5.6.5 Leaks in welding/ cutting equipment with pressurized gasses....................................................12
5.7 Protection of Personnel:..................................................................................................................12
6. Appendixes..........................................................................................................................................13
6.1 Forms.....................................................................................................................................................13
1. PURPOSE AND OBJECTIVE
The purpose of this procedure is to establish minimum safety guidelines for the control of identified risks
in operations with risk of fire (welding, cutting etc.), where carried out outside of areas specifically
assigned or designed for work of this nature.
This procedure considers welding and cutting operations carried out in areas not specifically designed for
these activities (welding areas or maintenance workshops).
2. SCOPE
This procedure applies to all works development during the construction and commissioning to Sakaka
405 MW dc PV Project.
Apply to all companies hired to perform works and services on the Project, even when they have been
contracted by another company, as long as they are coordinated and supervised by the responsible of the
organisation unit or project.
3. GENERAL INFORMATION
3.1 REFERENCE AND DEFINITIONS
Welding and cutting: equipment generating heat have important associated risks such as the projection of
hot particles or sparks, which may generate potential fire hazards in any place close to where such work is
being performed, when conditions are not duly controlled.
3.2 RELATED DOCUMENTS:
1. 18002-HSE-MG-017-00 work permit management

2. 18002-HSE-MG-012-00 PPE Management
3. 18002-HSE-MG-015-00 Method Statement Management
4. 18002-HSE-MG-011-00 HSE Inspection
5. 18002-HSE-PL-001-00 HSE Management plan
6. 18002-HSE-PL-005-00 Fire prevention and control plan
4. ROLES AND RESPONSIBILITIES
Project Director: Provide the necessary elements and support to facilitate communication,
implementation and monitoring of that established in the project for which they are responsible.
Production Staff: Guarantee monitoring of that established in this guide for all areas under their
responsibility.
HSE Manager: The HSE Manager will be responsible for the training of relevant persons (Contractor
Supervisors and all staff), implementation and application of this guide on all project fronts and will verify
the monitoring thereof.
Subcontractors Manager: Responsible for training in the contents of this guide to all supervision staff of
the respective companies, for the purpose of ensuring that monitoring of compliance with this guide and
any other related guide at all levels of their organisation.
5. DEVELOPMENT
5.1 AUTHORIZED STAFF CONTROL
The Subcontractor's must include a copy of Authorised Personnel Welding Activities such part of his
Method Statement.
Staff performing welding work must have sufficient training and a Certificate for this training issued by
the company for which services are being provided. There must be written confirmation of this
qualification.
Operations with risk of fire must be carried out by at least two persons at all times: A welder and an
assistant (fire prevention assistant).
All Staff that perform operations with risk of fire must have the necessary personal protective equipment.
5.2 EQUIPMENT CONTROL WITH OPERATIONS WITH RISK OF FIRE
Subcontractors must include such part of his Method Statement the following information:
7. Authorised Personnel Welding Activities duly completed. All equipment to be used during the
project must be included.
8. Compressed Gases Welding Equipment List duly completed. All equipment to be used during
the project must be included.
Both forms must be updated by the Subcontractor every time necessary. Copies of updates must be
submitted to the HSE Manager.
5.3 GENERAL REQUIREMENTS FOR OPERATIONS WITH RISK OF FIRE
5.3.1 GENERAL CONSIDERATIONS
Any operation with risk of fire requires the management of the corresponding permits to work in
accordance with 18002-HSE-MG-017-00 work permit management
Equipment for use in operations with risk of fire must be inspected before initiating operation,
considering the parameter established 18002-HSE-MG-011-00 HSE Inspection
In all cases, at a minimum a 4kg ABC type fire extinguisher must be provided in the workplace.
All operations with risk of fire must be signalled and signposted in accordance with 18002-HSE-MG-013-
00 HSE Sign posting
Elements for blocking potential sparks and/or projectiles must be put in place where possible (fire-
resistant tarpaulins, screens etc.) and UV radiations from welding arcs may cause serious injury to the
eyes.
In all cases, 18002-HSE-MG-012-00 PPE Management must be used as a reference for operations with risk
of fire.
5.3.2 SIGNALLING FOR OPERATIONS WITH RISK OF FIRE
The corresponding permits to works must be placed at the site of the work. The permit to work is
considered a safety signal.
All operations with risk of fire must be barricaded, taking special care if they are performed at heights or
in confined spaces.
Operations with risk of fire at heights and/or in confined spaces must be signalled in accordance with
18002-HSE-MG-013-00 HSE Sign posting.
Protection or cables and/or hoses in operations with risk of fire.
Cables and/or hoses must not obstruct passage through passageways or transit area of persons. They
must be suspended where possible, ensuring that the lowest section of the cable or hose is at a height no
lower than 1.50 metres.
5.3.3 WORK IN CONFINED SPACES
Any operation with risk of fire performed in confined spaces must be considered for air injection (forced
ventilation) and the use of a body harness/life line.
When performing welding and cutting operations in confined spaces, adequate ventilation shall be
provided, and local exhausting ventilation systems shall be provided to extract welding and cutting
harmful fumes outside the confined space.
If natural ventilation is not provided, mechanical ventilation shall be required. Mechanical ventilation
shall be at a minimum rate of 56 cubic meter per minute (2000 cubic feet per minute) per each welding
equipment.
It is preferable that local exhaust ventilation to be used as near as practicable to the work being welded
and provided with a rate of air-flow sufficient to maintain a velocity in the direction of the hood of 30
meter per minute (100 linear feet per minute) which shall extract the welding fumes into a special filter in
(HEPA Filter – High Efficiency Particulate Air filter).
Exhaust systems shall also be efficient means to provide a rate of airflow of at least 20 air change per
hour to keep the concentration of fumes within safe allowable concentration limits.
When welding, cutting, or heating materials using toxic substances, the following precautions shall be
taken:
9. Mechanical ventilation and respiratory devices shall be provided in any confined spaces or
limited spaces.
10.Except for Beryllium, when substances specified in table (1) exist in confined spaces or indoors,
adequate mechanical ventilation, preferably local exhaust ventilation, shall be used. With
Beryllium, appropriate respirators shall be used.
Any operation inside of Confined Spaces requires the management of the corresponding permits to work
in accordance with 18002-HSE-MG-017-00 work permit management and it will be done according with
18002-HSE-MG-028-00 confined space management
5.3.4 OPERATIONS ON UNEVEN SURFACES OR AT HEIGHTS
When operations with risk of fire are performed, the staff involved should use a harness with a steel
double life line. The work platform must feature a handrail, railing and baseboard. Staff must cordon off
the smaller area and have material put in place to prevent the dispersion of sparks.
When operations are performed on uneven surfaces or at heights, the welder must notify staff of the
performance of such work and the estimated duration and place, in the lower section, fire prevention
elements (fire-resistant tarpaulins, screens, fibreglass panels etc.) to protect staff and/or equipment
located at lower levels.
In such cases, barricades must be placed at ground level to prevent persons passing under the work area.
Before initiating any operation with risk of fire, the direct supervisor of the work must complete the
following activities in the order they are listed:
11.They shall handle the corresponding permits to work in accordance with 18002-HSE-MG-017-00
work permit management. If the work is to be performed on any equipment, pipe, tank or
receptacle, etc. under the control of operations with risk of fire, it will be necessary to process
the corresponding permit to work in accordance with 18002-HSE-OP-018a-00 Control of Testing
activities
12.A meeting shall be held prior to the initiation of operations with staff who are to perform same
to communicate the responsibilities and risks identified and the emergency measures necessary.
All persons working in the vicinity of the operations to be carried out will also be informed.
13.It must be verified that all persons involved in the operation have the necessary personal
protective equipment. It must be verified that the signalling of the area is in accordance with
18002-HSE-MG-013-00 HSE Sign posting.
14.It shall be verified that work materials, equipment and tools are available in-place and in good
condition.
15.It must be verified that persons performing the tasks must have the necessary personal
protection equipment, in accordance with 18002-HSE-MG-012-00 PPE Management
The persons responsible for completion of the work must do the following:
16.Ensure processing of the corresponding permits to works at the site of the operation and be
familiar with the procedure to be followed.
17.Inspect the equipment, in accordance with 18002-HSE-MG-011-00 HSE Inspection
18.Inform persons, teams and crews working nearby of the initiation of their activities.
19.Ensure the at least one 9kg dry chemical powder fire extinguisher type ABC is in place and that
staff are familiar with its function and operation.
20.Install barriers and screens adequate to avoid accidental exposure to the arc, sparks and slag of
persons not involved in the operation (radiation or direct contact burns).
5.4 ARC WELDING WORKS
Welding machines must be grounded with adequate elements, barricaded and protected from inclement
weather. Before starting, the parameters established 18002-HSE-MG-011-00 HSE Inspection must be
inspected.
The use of the necessary personal protective equipment is obligatory. It is not permitted to improvise
ground wire using reinforcement rods and waste metal. In the event of having to tie ground wire this
must be done with adequate connections. It is prohibited to connect ground wires and electrode holders
to the welding machine with provisional methods such as wooden wedges, annealed wire etc. The welder
is responsible for connecting said wires to the machine with appropriate nuts and plugs. It is not
permitted to begin operations using used electrodes. All connection and disconnection works with
welding machines, and their conditioning for works, must be done by staff qualified for the task. Do not
leave the electrode holder with the electrode in place when setting it down in any place and/or leaving it
unattended, to avoid use by staff not involved in the activity. Place leftover electrode in an appropriate
container, NOT ON THE GROUND. Do not overcharge conductive elements to ground while handling a live
electrode.
5.5 CUTTING AND WELDING WITH BLOWTORCH
Authorisations/materials necessary:
21.Forms "Permits to Work"

22.Personal protective equipment for operations with risk of fire.
23.Portable fire prevention equipment (4.5 kg Dry Chemical Powder Fire Extinguisher type ABC)
placed a minimum of two feet from the site of the operations.
Where cutting or welding work with pressurized gas is to be undertaken, the following instructions must
be followed:
24.There should be no grease or oil on any part, component or accessory of the welding or cutting
equipment that uses pressurized gas, even if the cylinders are empty.
25.All material (cloths, tools etc.) to be used in work with pressurized gas must be clean.
26.Inspect cylinders for dents, abrasions, leaks, breaks and damage to the valve. If any of the
cylinders present any of these problems, the operation cannot proceed.
27.Inspect hoses for breaks, abrasions, or badly performed joints.
28.The corresponding colours are:
o RED: Acetylene (these hoses must not have any joints or breaks and must be one single
piece. If any imperfection on acetylene hose, however small, it must be substituted for
another).
o GREEN: Oxygen
o BLUE: Inert air or gasses.
29.Inspect gauges, ensuring that they are functional, of the adequate colours (compatible with
hoses), checking for breaks, worn connections, screws in poor condition, gaskets or O-rings that
are broken or in poor condition.
30.Inspect the blowtorch ensuring that it is functional, not obstructed and that valves and
regulators are in good condition.
31.The transport cart must be in good condition, with no breaks or faults. The wheels must be in
good condition.
32.To light the blowtorch, use only the "spark" (device). It is prohibited to use cigarettes, lighters or
matches for this operation.
33.Upon lighting the blowtorch, open the gas valve before opening the oxygen valve.
5.6 HANDLING OF PRESSURIZED GAS CYLINDERS
5.6.1 STORAGE OF CUTTING/WELDING EQUIPMENT WITH PRESSURIZED GAS
This equipment must be stored in a cool, dry, well ventilated place reserved for this purpose. It should not
be placed at a distance of less than 6 metres away from other cylinders containing inflammable gasses or
highly combustible materials. Where this is not possible, they must be separated by a brick wall or block
of at least 2 metres in height.
Empty cylinders must not be kept in areas where they are not being used. Labels and/or marks that
appear stamped by the provider must not be removed. Do not use oil or grease to operate on cutting or
welding equipment with pressurized gas. Dirty clothes or dirty or greasy tools pose a serious risk of fire
and/or explosion. Cylinders must be transported in adequate vehicles or on trolleys. They should be
transported in upright, vertical position and secured to prevent them from falling. It is prohibited to
transport any pressurized gas cylinder by any other means. It is not permitted to use pressurized gas
cylinder as rollers, even if they are empty. Cylinders must be hoisted using baskets, correctly secured and
with the cover in place. Cylinders not being used in cutting or welding operations must be in a vertical
position and secured to a fixed element to prevent them from moving. It is not permitted to take
compressed gas cylinders into confined spaces. Throughout operations with risk of fire, cutting/welding
equipment (cylinders and hoses) must be placed in such a way so that they are not exposed to sparks or
slag of the same operation or of others being performed nearby.
Arresters shall be installed in blowtorches and regulators.
LPG cylinders shall be stored away from combustible materials.
Cylinders shall be stored at ground level and be readily accessible.
Do not store close to occupied building. Store LPG cylinders in a well-ventilated shed, made up of non-
combustible material.
It should be protected from extreme weather / shelter provided.
LPG cylinders shall be stored at least 3 meters’ away from other cylinders like oxygen, chlorine, ammonia.
Always store or keep LPG cylinders in vertical position.
Storage shed shall be kept under lock and key. Key shall be readily available all the time.
Do not allow unauthorized access by providing a fence 2 meters’ high.
Open the valves of the fuel cylinders (propane, acetylene, natural gas, etc.) by just a quarter turn. Open
oxygen valves fully. The key or knob (in the case of being detachable) of the valve must be kept in place
throughout use.
Before connecting regulators to cylinders, carefully open and close the valve a little to clean the hoses of
any foreign particles. Once the regulator is connected, pace it on the side of a pressure gauge while the
cylinder valve is opened. Open the valve slowly, ensuring that the second stage of the regulator is closed
before opening the cylinder valve.
5.6.2 HANDLING AND OPERATION OF VALVES
The pressure of the acetylene on the valve, on the ratchet side, must not exceed 15 PSI (pounds per
square inch), thus it is prohibited to use gas tanks with broken or defective pressure gauges that do not
guarantee a correct reading of the pressure. Similarly, it is forbidden to use wires to secure the gas hoses
to valves and ratchets.
Non-return valves shall be installed to gas cylinders on each hose directly close to the torch for
oxyacetylene welding, cutting and heating equipment which mix oxygen and acetylene or other fuel
gases.
Flash-back arrestor valve shall be installed on the regulators of oxygen and acetylene cylinders to prevent
very fast flame back as a result of clogged torch tip. If oxygen and acetylene mixed in one of the hoses, it
shall cause gas explosion or flashback
Under no circumstances should oil or grease of any kind be used as a lubricant in valves or accessories in
oxygen cylinders. A valve on a cylinder with gas fuel should not be opened close to sparks, a naked flame
or other sources of ignition. Verify that the nuts on the regulator or union correspond with the valve
outlet and do not force connections that do not coincide. Do not use a cylinder without placing the
pressure reduction regulator in its valve, except where it is connected to a manifold, in which case the
regulator must be coupled to the manifold collector.
Upon completing the operation, the cylinder valves must be closed and the protective covers (hoods)
must be put in place if they have been removed for any reason. If an outlet valve is obstructed by ice or is
frozen, it must be thawed by slowly applying hot water. The water must not be boiling and must be
applied slowly to the valve.
NEVER THAW A VALVE USING A NAKED FLAME
The valves should open slowly. A cylinder that does not have a hand-wheel valve must be opened with a
spindle key, a special key or other tool designed specifically for this purpose.
Before making the connection to an outlet valve of the cylinder, it must be opened very gently to allow a
little gas to escape so that any particle of dust or dirt in the opening are released. Neither the valve nor
the opening of same should be directed towards the user or any other person. When cylinders are not
connected for use, they should be kept covered with their metallic hoods to protect the valves. Upon
closing the valve, inspect to ensure that there are no leaks between the cylinders and the regulator.
5.6.3 HANDLING AND OPERATION OF REGULATORS
All equipment for welding and cutting with a blowtorch must be disabled upon completion of the work.
Regulators are to be removed and hoods must be fastened by hand to the compressed gas cylinders.
They can only be used in the cylinders and for the gasses for which they have been designed.
Regulators must not be swapped around between cylinders that contain or have contained different
gasses. You must verify that all regulators used in combustible gas cylinders or oxygen have a pressure
gauge and that the pressure gauge works correctly. You must verify that high pressure gauges have
security lids and are marked "oxygen" in green. You must verify that connections for oxygen cylinder have
right hand thread and those for acetylene a left hand thread. Before removing the regulator of a cylinder
valve, you must close the cylinder valve and release the residual gas on the regulator.
NEVER PERFORM CLOSE TO A HEAT SOURCE
If a regulator has a leak or escape, it must be substituted for another as soon as possible. Where
applicable, you must follow the regulator operation procedure specified by the manufacturer.
5.6.4 HOSES AND CONNECTIONS
Oxygen and acetylene Hoses and tubes must be purged before and after use in operations with risk of
fire. Before commencing and after completing the operation, you should verify that the connections and
hoses of cutting equipment have no leaks. To repair a leak in an oxygen hose, it must be cut and a splice
applied. Acetylene hoses with leaks must be substituted with new hoses. It is prohibited to use acetylene
hoses with splice tubes or repairs of any kind. Where the hose is burned by the flame kickback, it must be
replaced with a new one. All new hoses must be handled in accordance with this procedure.
The colour code for pressurized cylinder hoses is the following:
34.GREEN: Oxygen
35.RED: Acetylene
36.BLUE: Inert air and gasses
The connections for the hoses and handles of blowtorches and regulators must bust have clamps or
handles. The use of joints in these connections is not permitted.
It is prohibited to use hoses with exterior metallic lining. Anti-kickback valves should be place between
the blowtorch lever and the hoses, both for oxygen and acetylene. No gas should be used to clean cutting
cylinders or any other kind.
5.6.5 LEAKS IN WELDING/ CUTTING EQUIPMENT WITH PRESSURIZED GASSES
Where a leak is detected in a combustible gas cylinder, follow the following instructions:
37.Immediately notify the security supervisor and direct works supervisor.

38.Close valves.
39.Purge the gas circuit with the main hose and transport the cylinder far from any source of
ignition.
40.Provisionally block, where possible, the gas leak from the cylinder.
41.Place it out of service immediately and duly mark it as such and notify the provider for its
return. If the leak occurs in the lid, fuse or other security device, follow the following steps:
42.Transport the cylinder far from any source of ignition.
43.Liberally open the cylinder valve and allow gas to escape slowly.
44.The direct works supervisor shall remain in the area until the pressure is removed from the
cylinder, to ensure there is no fire.
5.7 PROTECTION OF PERSONNEL:
45.Employees performing any type of welding or cutting and other personnel present in the
welding area shall be protected against radiation, flying sparks, glare, melting materials and
welding slag by wearing proper and adequate personal protective equipment and clothing.
46.Suitable eye and face protective wear (safety glasses, goggles, and face shields) with
appropriate filter lenses to the nature and size of welding electrode shall be used.
47.Protective flame-resistant gauntlet gloves and cotton suits with full sleeves and without pockets
shall be used. The trousers shall have no cuffs and shall extend well down to the shoes.
Appropriate safety shoes shall be used, and durable flame-resistant aprons made of leather may
be used as an additional protection over the protective clothing.
6. APPENDIXES
6.1 FORMS
48.18002-HSE-FO-027a-00 Welding Equipment Register

49.18002-HSE-FO-017b-00 work permit Register
50.18002-HSE-FO-017a-00 PTW Template
51.18002-HSE-FO-012a-00 PPE Matrix
52.18002-HSE-FO-011l-00 Inspection Compressed gas cylinders
53.18002-HSE-FO-011n-00 Inspection welding ppe

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HOT WORKS MANAGEMENT

Owner / Client ACWA POWER

Principal contractor MAHINDRA SUSTEN

Name & Designation Signature Date Signed

Approved by ACWA POWER

Rev. No. Purpose of Issue Date Issued Remark

0 Initial release for approval 23/08/2018

1. Purpose and objective...........................................................................................................................4

1. PURPOSE AND OBJECTIVE

3.1 REFERENCE AND DEFINITIONS

3.2 RELATED DOCUMENTS:

1. 18002-HSE-MG-017-00 work permit management

4. ROLES AND RESPONSIBILITIES

5.1 AUTHORIZED STAFF CONTROL

5.2 EQUIPMENT CONTROL WITH OPERATIONS WITH RISK OF FIRE

5.3 GENERAL REQUIREMENTS FOR OPERATIONS WITH RISK OF FIRE

5.3.1 GENERAL CONSIDERATIONS

5.3.2 SIGNALLING FOR OPERATIONS WITH RISK OF FIRE

5.3.3 WORK IN CONFINED SPACES

5.3.4 OPERATIONS ON UNEVEN SURFACES OR AT HEIGHTS

5.4 ARC WELDING WORKS

5.5 CUTTING AND WELDING WITH BLOWTORCH

21.Forms "Permits to Work"

5.6 HANDLING OF PRESSURIZED GAS CYLINDERS

5.6.1 STORAGE OF CUTTING/WELDING EQUIPMENT WITH PRESSURIZED GAS

Arresters shall be installed in blowtorches and regulators.

LPG cylinders shall be stored away from combustible materials.

Cylinders shall be stored at ground level and be readily accessible.

It should be protected from extreme weather / shelter provided.

Always store or keep LPG cylinders in vertical position.

Do not allow unauthorized access by providing a fence 2 meters’ high.

5.6.2 HANDLING AND OPERATION OF VALVES

NEVER THAW A VALVE USING A NAKED FLAME

5.6.3 HANDLING AND OPERATION OF REGULATORS

NEVER PERFORM CLOSE TO A HEAT SOURCE

5.6.4 HOSES AND CONNECTIONS

5.6.5 LEAKS IN WELDING/ CUTTING EQUIPMENT WITH PRESSURIZED GASSES

37.Immediately notify the security supervisor and direct works supervisor.

5.7 PROTECTION OF PERSONNEL:

48.18002-HSE-FO-027a-00 Welding Equipment Register

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