Hot Works Procedure

SAF-PR-1034

I. PURPOSE

The purpose this procedure is to ensure the safety of all personnel and to protect the plant
from damage while conducting all forms of Hot Work.

II. SCOPE

This procedure applies to all Hot Work activities carried out by all PASAR Employees and
Contractors.

III. DETAILS

1. Actions

It shall be ensured that:

• All personnel conducting Hot Works are trained and competent.

• Hot Work activities are risk assessed by the use of Job Safety Analysis.
• A Hot Work permit is in place before any hot works commences

2. Hot Work Classifications

2.1. Non- Critical Low Risk Tasks

• No combustible and flammable materials at work site within 15-meter

radius.
• There is a presence of combustible materials but it can be moved away
from work site.

2.2. Critical Medium risk tasks

• Presence of immovable combustible materials at work site. These

materials could smolder for a time and ignite later such as:
o Electrical wires/ cables;
o Belt Conveyor;
o FRP pipes/ Poly piping and tanks;
o Rubber lined pipelines and storage tanks;
o Cooling tower fins;
o Paints;
o Plastic Materials;
• Overhead Hot works activities.

2.3. Critical High Risk Tasks

• Presence of flammable gases and materials at work site that can cause
fire and explosion such as:
o LPG;
o Fuels e.g. Diesel, Gasoline and Bunker oils;
o Oxygen and Acetylene storage facilities;
o Use of Oxygen and Acetylene;
o Oxygen enriched atmosphere;
o Hot Work on any chemical pipelines and tanks;
o Where there is potential for atmospheric changes;
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 Hot Works Procedure

SAF-PR-1034

o Any Hot Work with-in a confined space;

o Any Hot Work less than 15m radius of a fuel/ gas farm.

3. General Requirements

A person shall not commence Hot Work unless;

• a Permit to Work with an associated Hot Work Permit has been issued;

• the person/s conducting Hot Work reads, understands and signs off onto the Job
Safety Analysis and the Rescue Plans for the specific Hot Work activity;

• Where there is a risk of coming into contact with hazardous energies or live
equipment during Hot Works, Energy Isolation Procedure shall be implemented.

• Where there is a risk of falling while conducting Hot Works, Work at Heights
Procedure shall be implemented.

• Where Hot Work is to be conducted inside a confined space, Confined Space

procedure shall be implemented.

4. Hot Work Permit Requirements

Hot Work Controls

• Combustible Material

o Inspect the work area for combustible materials and remove them or have
them safeguarded/protected. The radius for removal shall be not less than
15 meters to ensure that there is no risk of a fire starting. If not removable,
cover with non-flammable material such as fire blankets, etc.
o Check for flammable gases, vapors, liquids or contaminated dirt or dust. If
flammable gases are detected, degassing shall occur to ensure zero LEL
before continuing.
o Check for electrical cables that may cause a hazard during the work. These
may not be visible if they are inside conduit or pipes.
o Ensure that an adequate supply of fire blankets is available to completely
protect areas subject to damage from the Hot Work.

• Fire Hoses and Extinguishers

o Locate the nearest fire hydrant and ensure it has enough length of hoses with
nozzle, is charged and the valve is operational.
o Provide a portable fire extinguisher suitable for extinguishing the type of fire
that may generate from the Hot Work. A suitable fire extinguisher shall be
accessible within 5m of the Hot Work being carried out as indicated in Annex
A: Types of Fire Extinguisher and Classes of Fire.
o Do not remove a fire extinguisher from a fixed location provided for
emergency purposes.

• Signage & Barricading

o Ensure adequate barricading has been positioned in the area surrounding

and below the Hot Works to protect the workers from sparks, slag etc.
o Erect safety signs to where the Hot Work is to be performed. This is to include
areas above or below the work area if appropriate.
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 Hot Works Procedure

SAF-PR-1034

o Welding screens/covers shall be erected around the work area to protect

others if welding is being conducted.

• Firewatcher

o A firewatcher shall be in attendance when Hot Work is in progress, unless

the Hot Work is to be carried out inside a designated Hot Work area i.e.
Fabrication Shop.
o Ensure that the firewatcher is trained and competent in the use of a fire
extinguisher and/or fire blanket and briefed on the nature of the Hot Work
and potential hazards.
o The firewatcher shall not be involved in any task other than keeping a fire
watch.
o The firewatcher shall be located as close as practical to the task and with a
clear view of the immediate area.
o The firewatcher shall have at hand or within a 5-meter radius a suitable fire
extinguisher for the works being carried out.
o The firewatcher shall not leave the area while Hot Work is in progress.
o A Fire Watcher must be present during and for at least two hours after
completion of the hot work. The post-work fire watch may be reduced to 30
minutes if the job can be completely cooled with water and/or a thermography
camera is used to ensure no ignition source remains.

• Escape routes shall be identified and cleared of obstacles.

• Fume extraction/ventilation shall be in place where required. (i.e. where natural

ventilation is insufficient).

• Additional Hot Work Requirements for Critical Medium Risk Task:

o Provide adequate protection to the combustible materials such as watering

down Cooling Fins, Rubber and FRP Pipelines, and Conveyor or covering
with fire resistant material. Controls shall be implemented to contain sparks,
etc., at the source (fire blanket, screens, etc.).

• Additional Hot Work Requirements for Critical High Risk Task:

o Provide adequate protection to the combustible materials such as watering

down outside fuel tanks or covering with fire resistant material. Controls shall
be implemented to contain sparks, etc., at the source (fire blanket, screens,
etc.).
o This shall only be undertaken when the equipment to be worked on cannot
be removed practicably to a less hazardous location for the Hot Work
component of the task to be completed.
o Additional precautions shall be performed:
▪ Gas testing is to be undertaken in the areas until every source and
potential source of flammable gas and flammable vapor has been
tested. Gas testing is to be conducted immediately prior to Hot Works
commencing on worksite. Results for testing shall be recorded in the
associated Hot Work Permit.
▪ Hot Work will not commence if the LEL reading is greater than zero.
▪ For Oxygen enriched atmosphere, O2 gas testing shall be conducted.
Oxygen level shall be on a normal atmospheric reading: 19.5% to
23.5 %.

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 Hot Works Procedure

SAF-PR-1034

▪ No Hot Works are allowed within the premises of O2 Plant area while
in operation.
▪ Continuous gas monitoring shall be conducted by a trained Gas
Testing Officer if there is risk of atmospheric contamination from the
Hot Work or any other source.
▪ If the Hot Work does not commence within 2 hours of gas testing, the
testing shall be done again before the work proceeds.
▪ Review MSDS sheets for any hazardous materials that maybe
present (where applicable).
▪ Fire Truck is required to station at work area when doing Hot Works
near fuel storage pipelines and facilities.
▪ Use of thermography gun before the fire watch leaves the area or wet
the surrounding work area for fuel tanks by water spraying using fire
hydrant or fire truck.

5. Emergency Response and Rescue Plan

An Emergency Response and Rescue Plan shall be developed prior to work

commencing. As a minimum, the rescue plan shall address:

• assessment of work area to deem as safe prior to commencing response;

• possible incidents and injuries that could occur whilst undertaking the task;
• emergency equipment and first aid facilities required for each potential
incident and injury;
• emergency services that may be required and how to make contact with
them;
• the role each person will play within the work group during a response;
• personal protection for personnel within the response team.
• Consideration for response plans shall be referenced in the Job Safety
Analysis (JSA) and shall be approved and signed off by the
Superintendent.

For further details, Refer to PASAR Emergency Response and Rescue Plan.

6. Work Completion

• All areas shall be thoroughly inspected for hot, smoldering or burning material
(cool down or remove prior to vacating the area).

• At the completion of the Hot Work to check for hot spots, smoldering flammable
material and other potential fire hazards, the firewatcher is required to remain in
the vicinity of the Hot Work for at least thirty minutes for low risk task, and at least
2 hours for critical high risk task. A firewatcher shall have a suitable
communications plan in place to raise the alarm if required.

• Once Hot Work has been completed:

o Fire blankets and other protective material shall be removed.
o Roll up any hoses and return fire extinguishers. If any fire extinguisher has
been discharged, ensure that an incident report has been completed
o Remove all tools and equipment.
o Remove warning signs/barricading and return to storage location.
o Wet down susceptible areas to ensure that no heat is present (in tight spots
where this cannot be detected by other means).
• Upon completion of Hot Work, the Permit Holder shall:
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 Hot Works Procedure

SAF-PR-1034

o Check the work area and ensure it is safe to close the permit.
o Demonstrate the job is complete to the satisfaction of the permit issuer.
o Sign the ‘Surrender of Permit’ section of the Permit to Work. The permit is
now closed.

7. Training and Competency

All employees working on Hot Work shall attend the Pasar two-day induction and shall
pass the assessment. At the completion of the training, attendees shall be competent
in the following:

• Hazard identification and controls for Hot Works;

• Inspection and storage of the equipment;
• The use and inspection of firefighting equipment; and
• Hot Work minimum requirements.

Fire Watcher shall undergo the Fire Watcher training and shall be retrained every 24
months for Pasar employee and 12 months for contract workers.

ANNEX

A. Types of Fire Extinguisher and Classes of Fire

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 Hot Works Procedure

SAF-PR-1034

IV. RESPONSIBILITIES

Managers, Personnel under their control are aware of, understand and
Superintendents and comply with the requirements of this procedure.
Team Leaders

Employees and Comply with the requirements of this procedure.

contractors

Fire Watcher Designated person to watch for any outbreak of fire and
ensure preparations prior to work commencing are suffice.

Be aware of the location of the nearest suitable extinguisher

and fire blankets, in addition to the one onsite.

Take immediate action to combat any outbreak of fire that

may occur.
Do not leave the job unless properly relieved by a new
Firewatcher.

Gas Testing Officer Test, record, advise and ensure atmosphere is safe from
combustible gases prior to commencing Hot Works.

V. TERMS AND DEFINITIONS

Any work using an open-flame or spark-producing

Hot Work apparatus. Hot Work includes, but is not limited to, welding,
cutting, burning, grinding, and any related heat-producing
jobs that could ignite combustible material or flammable
atmospheres.

Hot Work Permit A Permit to Work Associated Permit issued by the Permit
Issuer which authorizes specified Hot Work to commence at
a specific location and time.

VI. ASSOCIATED DOCUMENTS

DOCUMENT NAME DOCUMENT CODE

Hot Work Permit SAF-FM-1045

Permit to Work SAF-FM-1002

Confined Space Entry Procedure SAF-PR-1031

Energy Isolation Procedure SAF-PR-1002

Work at Heights Procedure x SAF-PR-1039

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 Hot Works Procedure

SAF-PR-1034

Emergency Response and Rescue Plan SAF-FM-1068

Barricading Guidelines SAF-PR-1030

VII. REVISION RECORD

Date Version Modified by Revision description

14 Dec, 2018 0 Jessel O. Tan Initial Release

28 October 2020 1 Jessel O. Tan Revision in the procedure

Change of coding, template, and
signatories
13 September 2022 2 Kirk Russel Batain Retraining period for Pasar and Contractor
fire watcher
03 May 2023 3 Kirk Russel Batain Revision in Item III. Details
• From Fire Watcher must stay in
the vicinity for 30 minutes to a Fire
Watcher must stay in the vicinity
for at least 2 hours…

VIII. Document Control

Name Position
Prepared: Kirk Russel Batain Advisor, Health and Safety
Reviewed: Michael Oliver M. Dizon Superintendent, Health and Safety

Approved: Dirk Van Jaarsveld Manager, HSSE

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