Doc. No.

: L3-020-HSE-01
AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
2 28-Jun-2015 9-Oct-2020 Page 2 of 10

Distribution List

Department/Section Recipient Department/Section Recipient

Management GM Stores All staff

Operations All staff Chemistry All staff

H.R. & Administration All staff Electrical All staff

I.T. All staff Mechanical All staff

Finance All staff Instrumentation & Control All staff

Procurement All staff Engineering All staff

H.S.E. All staff Performance All staff

Security All staff

Revision Record

Revision
Issue No. Description of Change Effective date
No.

1 0 First issue 28/06/2015

Routine review, removal of HWC

2 1 10/10/2018
as an appendix and format change
 Doc. No.: L3-020-HSE-01
AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
2 28-Jun-2015 9-Oct-2020 Page 3 of 10

Contents
1.0 PURPOSE.................................................................................................................. 4
2.0 PRINCIPLE ................................................................................................................ 4
3.0 SCOPE....................................................................................................................... 4
4.0 RESPONSIBILITY ..................................................................................................... 4
5.0 DEFINITIONS/ ABBREVIATIONS ............................................................................. 4
6.0 REFERENCES ........................................................................................................... 5
7.0 HSE AND BUSINESS RISK....................................................................................... 5
8.0 PROCEDURE ............................................................................................................ 5
8.1 Planning ..................................................................................................................... 5
8.2 Fire Fighting Equipment ........................................................................................... 5
8.3 Containment of Products (Sparks, Slag, Arcing etc.) ............................................. 6
8.4 Recognised Hazards ................................................................................................. 6
8.5 Equipment.................................................................................................................. 7
8.6 Precautions to be considered .................................................................................. 7
8.7 Work control .............................................................................................................. 8
9.0 AUDIT / REVIEWS ................................................................................................... 10
10.0 ATTACHMENTS ...................................................................................................... 10
 Doc. No.: L3-020-HSE-01
AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
2 28-Jun-2015 9-Oct-2020 Page 4 of 10

1.0 PURPOSE
Poor planning and control of burning, welding and grinding activities can increase the risk
of injury to personnel either directly to those involved in the activity or to others who may be
in the vicinity. It can also lead to an increase level of risk to personnel and property due to
fire damage. This procedure summarises the hazards and the general means of avoiding
or reducing the associated risks, and refers to any type of Hot Work, including any work
that can create heat.

Any combustible material, plant or equipment must be removed or covered before any Hot
Work is carried out nearby. Hot work in any high risk area, such as near the hydrogen
plant, gas control areas or air filter house must be properly controlled and all persons
involved be aware of the risk. A fire watch must be carried out.

2.0 PRINCIPLE
This procedure aims to give guidance on the application of controls to satisfy the relevant
requirements of the following UK legislation:
• The Provision and Use of Work Equipment Regulations (PUWER)
• The Personal Protective Equipment at Work Regulations (PPE)
• The Control of Substance Hazardous to Health Regulations (COSHH)
• The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR or
ATEX)

3.0 SCOPE
For the purposes of this document ‘Hot Work’ is defined as any construction or
maintenance process that requires the use of flames, the local application of heat or any
other process that generates, or may generate, sparks or heat, including burning, welding
and grinding.

4.0 RESPONSIBILITY
Safety Controllers are responsible for ensuring that the requirements of the
Safety Rules are considered during Hot Work that are
defined as part of the System.

Supervisors/Acceptors
are responsible for ensuring that the risks of Hot Work
are assessed, and that before the work is done there is
in place a Hot Work Certificate and Gas Free Certificate
when required, all necessary equipment as defined by
the risk assessment and/or HWC and a fire watch in
place where required by the risk assessment.

5.0 DEFINITIONS/ ABBREVIATIONS

HWC Hot Work Certificate
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AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
2 28-Jun-2015 9-Oct-2020 Page 5 of 10

6.0 REFERENCES
Hot Work Certificate Register
AZN H&S PROC 026 Compressed gases

7.0 HSE AND BUSINESS RISK

Poor planning and control of hot work can lead to high risk of fire and explosion, with
potential for serious injury and comprehensive damage to plant

8.0 PROCEDURE
8.1 Planning
Where it is reasonable to do so, welding, burning and grinding activities should only
be carried out in non-operational areas, i.e. in the designated area in the maintenance
building or in a temporary, agreed location. All work and adjacent areas should be
inspected before the commencement of work for combustible environments and any
combustible materials such as paper, wood, rags, plastic, spilt oils or lubricants and if
possible, they should be removed from the areas before the commencement of any
hot work. If it is impossible to move such equipment then consideration should be given
to protection of such items to prevent or minimise the impact that hot work can have
on such equipment. NO HOT WORK MAY BE CARRIED OUT NEAR COMBUSTIBLE
OR FLAMMABLE MATERIALS, PLANT OR EQUIPMENT WITHOUT A PERMANENT
FIRE WATCH.

Equipment to be used as part of any work must be compatible with the area in which
it is to be used, and must not create its own fire hazard; for example, use of portable
halogen lighting of any type is not allowed other than in hand torches.

Work planned to be carried out in a designated gas zone must be carried out under a
safety document. This should be after sources of explosive gases, such as methane
and propane have been isolated and the danger from these removed. Hot Work within
a live gas zone is prohibited.

Where work involving welding, burning and grinding activities within the main plant
areas is required, it should only take place after assessment by a Safety Controller
who will specify any additional precautions to be taken. Where the area could be
affected by a gradual build up or immediate release of combustible gas or vapours
then appropriate continuous gas monitoring should be considered.

For other areas such as the workshop or areas outside that are not in the vicinity of
operational plant, additional precautions should be agreed with the designated
Technical Officer for the work. A HOT WORK CERTIFICATE must be issued for any
hot work on site.

8.2 Fire Fighting Equipment

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AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
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Fixed Equipment
Any fixed firefighting equipment adjacent to the work area must be made safe during
the work process, as the heat generated may cause operation of water or gas
extinguishing systems.
Fire Extinguishers
Before work commences appropriate fire extinguishers should be placed near the work
where they will not impede egress. If any extinguishers have been relocated whilst the
work proceeds, they must be returned to their normal location at the end of the work.
Any fire equipment discharged during the work process must be reported and
recharged.

Fire Evacuation Routes

It is important to ensure unobstructed fire evacuation routes are clearly marked and
that adequate rescue plans are in place, according to the type of work and risks
involved.

Fire Resistant PPE

The PPE used during hot work processes must be checked to ensure that it does not
present a fire risk in itself. Consideration must be given to other site requirements, such
as the need to wear high visibility clothing which is often worn in addition to PPE and
this can be manufactured from nylon and/or plastic, and it may appropriate to suspend
or restrict the wearing of such clothing at the point of work whilst this work is in
progress. Protection must also be considered for others that may be helping or present
at the work location.

8.3 Containment of Products (Sparks, Slag, Arcing etc.)

All work areas must be protected to prevent hazards from the process affecting
adjacent work areas or persons. This may require the use of close boarded scaffold
and/or fire proof matting to prevent sparks, slag, debris and used rod ends from falling
onto persons working at lower or adjacent levels.

Screens must erected where required to stop sparks caused by the grinding or welding
process along with need to shield unprotected person from the ultraviolet rays caused
by the arc welding process.

Adjacent work should be considered prior to the start of the hot work process and the
risk assessment should identify any interaction that may occur, it may be necessary to
suspend one of the jobs until the other is completed.

Compressed gas cylinders should be kept at a safe distance from the hot work activity
(typically > 2.5 metres (8 ft)) and, if necessary, be shielded to prevent sparks and
splashes of molten metal acting as an ignition source for leakage from a fitting or valve.
Compressed gas cylinder hoses should be fully extended when in use to prevent
splashes of molten metal sitting in the hose and burning through.

All work should be Risk Assessed prior to starting.

8.4 Recognised Hazards

• Flammable gases.
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AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
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• Flammable liquids.
• Flammable dusts.
• Combustible solids.
• Chemicals.
• Stored gases under pressure.
• Conduction of heat /sparks.
• Noxious atmospheres.
• Halogen lighting

8.5 Equipment
All equipment must be checked before each use to ensure it is safe and serviceable
for use:

Electric Welding Equipment

(i) All cable joints made correctly and insulated.
(ii) Earth return applied correctly with shortest path between workplace and
energy source.
(iii) Welding rod ovens cable connections correctly made.

Pre and Post Weld Heat Treatment Equipment

(i) All cable joints made correctly and insulated.

Gas Heating/Welding/Burning Equipment

(i) Cylinders secured upright in an approved bottle trolley or and secured to a
suitable fixed structure.
(ii) Regulators that are fitted are suitable for the work and serviced.
(iii) Flash back arrestors are fitted and are suitable for the work.
(iv) Hoses are visually inspected before use for signs of damage, correct
clamps and fittings must be used at all times.
(v) All connections must be leak checked using and inert substance or approved
gas testing device.

Grinders
(i) Correct disk for the work being undertaken fitted.
(ii) Disk guard is fitted and remains in place at all times.
(iii) Electric Grinders - Power lead is visually inspected for damage and the correct
plug fitted.
(iv) Air Grinders – Hose is visually inspected for damage.
(v) Local certification of the equipment must be checked and the unit should not
be used if the expiry date has passed.

8.6 Precautions to be considered

An assessment of the possible hazards must be made before starting work and these
will depend on the location and other relevant factors.
The following aspects must be considered:
• The need for additional screening, warning signs and/or barriers to protect
other persons from direct exposure to bright light, contain sparks, molten metal
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AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
2 28-Jun-2015 9-Oct-2020 Page 8 of 10

or hot pieces of material or prevent access to other persons, who could be

affected. This may include a fire blanket to prevent sparks etc., falling through
gratings where necessary.
• A pre-assessment of the fire/explosion risks should be undertaken and any
combustible materials must be removed from the work place prior to the start
of work. If this is not practicable then other precautions should be taken to
prevent ignition sources setting fire to combustible materials (e.g. fire blankets
or fire resistant tarpaulins to prevent hot materials being ejected from the work
area). As a preventative measure, suitable fire extinguishers adjacent to the
work area should be provided.
• As part of the Risk Assessment, the Safety Controller and the Work Planner
must consider the requirement of a fire watch to be organized both during and
after the work is completed.
• In areas where welding, burning and grinding activities interfere with site fire
detection systems, these should only be disabled after careful consideration.
The control room must be informed and must record full details of these actions
in the station log. Re-instatement of the affected system must be instigated
immediately after the work has been completed. As a minimum, a permanent
fire watch must be maintained whilst an area is operated with its detection
system disabled.
• Access to and around the point of work for the operator and equipment must
be carefully considered. In particular, egress from the work point should not be
restricted in case of an emergency.
• Ventilation of the work area needs to be sufficient to ensure that the build-up of
fumes cannot occur. If necessary fume extraction equipment should be used
to remove welding fumes to a safe point, preferably to the outside of a building.
Where fixed local exhaust ventilation is used, the equipment must be subject
to routine testing at a frequency of not more than 14 months.
• All operatives must wear PPE as required by risk assessment and site
procedures.
• Heat should not be applied to any equipment until the effects have been
considered or eliminated e.g. red lead paint, galvanising or water and
chemicals in pipework.

8.7 Work control

Safety from the System - with isolation
Where isolation is required to provide safety from the system or safety from the system
can be achieved by limiting the work or the work area, this shall be achieved before
the commencement of any hot work; any Safety Document (Permit) and Hot Work
Certificate shall be linked.

Work in areas not requiring a Safety Document (Permit)

Where hot work is taking place in an area where no safety document (Permit) is
required then a Hot Work Risk Assessment shall be completed before the
commencement of the work and a Hot Work Certificate shall be issued.

8.8 Hot Work Certificate

Certificate Identifying Numbers
The next available number from the Hot Work Certificate Register must be used.
 Doc. No.: L3-020-HSE-01
AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
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If this certificate relates to work that will require safety from the system by isolation or
limiting the work or work area then the appropriate Safety Document (Permit) number
shall be added to the document. If no safety document (Permit) is involved, then insert
‘N/A’.

Task
This is obtained from the work order card and should include:
• Task description
• Equipment involved
• Location
• Expected duration of the work
• Intended date that work will occur

Special Considerations
• Hazards likely to be present
• Whether these have been controlled or removed
• Methods of dealing with hazards that cannot be removed
• Need for fire watch during and after the work

Validity Duration
Following the completion of the assessment and in conjunction with the intended work,
the assessor can make a judgement on the likely duration that the certificate can
remain valid. Locations should consider performing a risk assessment and re-issue of
the hot work permit after each shift in order to control hot works. For example, on jobs
of long duration, or of significant hazard, it may necessary for one or more subsequent
assessments to be carried out to maintain a safe working environment.

Issue
The Issuer of the document(s) checks that the foregoing sections have been completed
and then declares the area is safe for hot work to proceed in line with the conditions
specified in the Hot Work Certificate.
The Acceptor of the document(s) confirms in writing that he has read and understood
the certificate and the conditions attached to it and will ensure that these requirements
are complied with during the course of the work.

Completion
Following the completion of the work and any associated post work fire watch, the
Acceptor of the document(s) will make a final inspection of the hot work area and any
adjacent area thought to be at risk, thoroughly inspecting the areas for any smouldering
remnants or residual heat. He shall mention these to the Issuer of the document(s)
before cancelling the certificate. If any such areas are identified then the Issuer of the
document(s) will accompany the Acceptor of the document(s) to the work location and
may extend the time required for post work fire watching, until such time as the risk in
negligible. Only when this condition is achieved will the Acceptor of the document(s)
cancel the Hot Work Certificate.

Documentation
 Doc. No.: L3-020-HSE-01
AZN Procedure
Rev. Date: 10-Oct-2018
Issue No Issue Date Revalidation
Hot Work
2 28-Jun-2015 9-Oct-2020 Page 10 of 10

When a Hot Work Certificate is cancelled it cannot be re-used. Further work in the
same area will require a new assessment to be made as outlined above.
A register of Hot Work Certificates will be kept in an appropriate location, e.g. the
Permit Office. Cancelled Hot Work Certificates will be stored in an appropriate location,
e.g. the Permit Office, and will be attached to any safety document (Permit) that has
been identified on it.

9.0 AUDIT / REVIEWS

This document will be reviewed every 2 years or as a result of audit findings.

10.0 ATTACHMENTS
Hot Work Certificate Form No. L4-01-(L3-020-HSE-00)-01