Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July, 2005
Fluor Arabia Limited Contract A2IT Page 1 of 5
28. HOT WORK
The Owner may replace this procedure during the pre-commissioning and start-up phase.
A. SCOPE
This procedure establishes the safe work practices to be used when performing Hot work in a
regulated area on the project. Hot work is to be defined as an open flame, welding arc, non-
explosion proof electrical tools or equipment and any heat source capable of causing ignition.
A properly executed HOT WORK PERMIT shall be present prior to work.
Within certain areas designated as "OPEN AREAS", a HOT WORK permit will be issued by
the Project Safety Department on a daily basis. The permit will be a blanket permit addressing
all hot work for the defined area. The permit will not address each individual job specifically,
however all hot work will be performed in compliance with provisions of the permit.
All areas not defined as "OPEN AREAS" will be classified as RESTRICTED. Hot work
performed in restricted areas will be permitted on a task specific basis by the Project Safety
Department or Owner operations personnel. The permit issuer and the respective supervisor are
responsible for inspecting the area the Hot Work is to be performed.
B. GENERAL
Only employees that have been trained in the safe operations of cutting equipment may use the
equipment. Employees that have successfully completed their craft certification test applicable
to the use of cutting and welding equipment will be deemed qualified to use cutting equipment.
Employees must be familiar with OSHA sections CFR 1910.254 and 1910.252 (a) (b) and (c).
Operators of equipment should report any equipment defect or safety hazards and discontinue
use of equipment until necessary repairs have been made. Only qualified personnel shall make
repairs.
Areas where welding or burning operation occur must be protected to prevent the ignition
source from generating a fire.
a) Remove any flammable material or liquid from the area. (No aerosol cans in
area)
b) Assign a fire watch.
c) Ensure the fire watch is trained, bear the training color coding on the ID Badge
and that he wears a red reflective vest.
d) Remove or protect combustibles from sparks and slag.
e) Contain sparks and slag with welding cloth / fire blanket.
H:\000_General\Share\501 - Construction\SITE SAFETY PROCEDURES\28-Hotwork.doc GENERAL SITE CONDITIONS AND SAFETY PROCEDURES
Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July, 2005
Fluor Arabia Limited Contract A2IT Page 2 of 5
f) Proper barriers or screens must be erected to protect others from the arc (flash
burn).
g) A twenty 10 Kg (20 pound) or larger dry chemical fire extinguisher must be
within 6 meters (20 feet) of any welding, burning or flame work.
h) Keep hoses and leads out of walkways. Inspect all leads, grounds, clamps,
welding machine hoses, gauges, torches and cylinders each day before use.
i) Avoid breathing fumes. Use exhaust systems, blowers or respirators.
j) No welding or burning is to be done on a closed vessel or tank, or any vessel or
tank that has not been decontaminated. (This includes drums, barrels, etc.)
k) All hot work equipment must be inspected by a competent inspector and must
bear the current color coded monthly inspection tag to be used.
l) A fire watch will be required when Hot Work is to be performed;
• in all locations where fire may develop;
• where combustible material stored within 11 meters (35 ft.) of Hot Work;
• combustibles are greater than 11 meters (35 ft.) away but are easily ignited;
• adjacent to wall or floor openings within a 11 meters (35 ft.) radius of
combustible material; and
• combustible materials are adjacent to the opposite side of metal partitions,
ceilings or roofs.
C. PROTECTIVE CLOTHING
Protective clothing required for welding and burning varies with the size, nature and location of
the work to be performed.
1) Only fire resistant clothing must be worn.
2) All welders shall use flameproof gloves.
3) Clothes should be free from oil and grease
4) Flameproof leather (or suitable material) aprons should be considered if long-term
exposure to radiant heat or sparks is anticipated.
H:\000_General\Share\501 - Construction\SITE SAFETY PROCEDURES\28-Hotwork.doc GENERAL SITE CONDITIONS AND SAFETY PROCEDURES
Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July, 2005
Fluor Arabia Limited Contract A2IT Page 3 of 5
C. WELDING (ELECTRIC)
1) All work must have an adequate ground.
2) Welding rods are not to be left in the electrode holder when in use. Used welding rod
stubs are to be put in metal containers.
3) All arcs must be shielded in all construction areas.
4) All machines must be turned off at the end of the shift.
5) An approved welding helmet must be worn. Equipped with no less than a no. 10 filter
plate, with safety plate on both sides of the filter plate.
6) Welders must wear a hard hat with the welding helmet.
7) Never perform electric welding from a metal ladder.
8) Welders performing gas shielded arc welding must be familiar with the American
Welding Society Standard A6-1-1966.
D. BURNING (GAS)
1) Before connecting regulators to cylinders, carefully open the cylinder valve a crack to
blow out any foreign particles. After the regulator is connected, stand to one side of
gauge while the cylinder valve is opened. Open the cylinder valve slowly. Be certain
that the second stage of the regulator is closed before opening the cylinder valve.
2) Open valves on fuel gas cylinders (propane, acetylene, natural gas) a quarter turn only.
Open oxygen cylinder valves completely. The valve wrench must be kept in place
during use.
3) Do not exceed 15 psi on the torch side of the gauge when using acetylene.
4) When lighting a torch, open the fuel gas valve on the torch before opening the oxygen
valve. Use an approved spark lighter.
5) All compressed gas cylinders should be kept in bottle-carts (trolleys) when transported
or in use.
6) All burning rigs must be broken down at the end of the shift, with regulators removed
and protective caps secured.
7) Compressed-gas cylinders must be secured by a chain in a vertical position while in
storage, transit or use.
H:\000_General\Share\501 - Construction\SITE SAFETY PROCEDURES\28-Hotwork.doc GENERAL SITE CONDITIONS AND SAFETY PROCEDURES
Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July, 2005
Fluor Arabia Limited Contract A2IT Page 4 of 5
8) Keep oil and grease away from oxygen-regulator hose and fittings. Do not store
wrenches, dies, cutters or other grease-covered tools in the same compartment with
oxygen equipment.
9) Do not use compressed gas to clean your clothing, blow out anchor holes, or otherwise
clean your work area.
10) All hoses, gauges and torches must be inspected regularly.
11) Approved burning goggles must be worn. Use at least No. 4 filter with a safety lens on
both sides of the filter.
12) Never leave a torch in a vessel, tank or other closed container because of the potential
hazard of leakage.
13) Never use oxygen in pneumatic tools to pressurize a container, to blow out lines, or as a
substitute for compressed air or other gases.
14) Place cylinders and hoses where they are not exposed to sparks and slag from a burning
operation.
15) Handle cylinders with care, as follows:
Lift to upper levels with approved cages only.
Do not strike an arc on cylinders.
Do not use cylinders as rollers.
Do not lift with slings or by the protective cap.
Anti-flashback arrestors shall be installed on the regulator end of the hoses and a
check valve at the torch en of the hoses on all fuel gas and oxygen cylinders. Some
regulators may be designed with an anti-flash arrestor built into the regulators and
may only be used upon approval of the Safety Department and Owner.
E. RESPIRATORY PROTECTION
Proper ventilation and / or respiratory protection shall provided whenever there
is the potential for the build up of hazardous fumes or vapors generated from
burning, cutting or welding of lead base metals, exotic metals such as zinc,
cadmium, mercury, beryllium or exotic paints. Hot Work involving exotic
metals and or paints to be performed inside confined space requires the
approval of the Project Manager.
H:\000_General\Share\501 - Construction\SITE SAFETY PROCEDURES\28-Hotwork.doc GENERAL SITE CONDITIONS AND SAFETY PROCEDURES
Yanbu National Petrochemical Company Site Safety Procedures Manual
Yanbu Petrochemical Complex U & O Project July, 2005
Fluor Arabia Limited Contract A2IT Page 5 of 5
ATTACHMENTS
HOTWORK PERMIT
HOTWORK CHECK LIST
H:\000_General\Share\501 - Construction\SITE SAFETY PROCEDURES\28-Hotwork.doc GENERAL SITE CONDITIONS AND SAFETY PROCEDURES
