Nasrconsortium

SOUTHPARSGASFIELDDEVELOPMENT
(EPC1PHASE12)

PetroparsLTD

POGC
ParsOilGasCompany

ONSHOREFACILITIES

DocNo.SP122Y1HSPP999012D0

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WELDING
&
CUTTING
SAFETYPROCEDURE

D0

REV.

15Aug2009
DATE

ForReview/Comment
DESCRIPTION

S.Dadmehr

B.Hossiani

PREPARED

CHECKED

M.S.Vaziri
APPROVED

Sh.Tabibzadeh
AUTHORIZED

South Pars Gas Field Development Phase 12

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NASRCONSORTIUM

SOUTHPARSGASFIELDDEVELOPMENT
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POGC
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ONSHOREFACILITIES

DocNo.SP122Y1HSPP999012D0

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Tableofcontents

Purpose

2.0 Responsibilities

3.0 Procedures

4.0 Training&qualification

1.0

13

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1. Purpose
Thepurposeofthisprocedureistoensureasafeandcontrolledworkingenvironmentandthe
protectionofpersonnel,plantandequipmentinthevicinityofweldingandburningoperations.

2. Responsibilities

21SiteManager
TheSiteManagerisresponsibleforassessingtheneedandgrantingpermissionforhotworktobe
carriedouton"live"linesandorinthevicinityofflammableliquids.

22SubcontractorShi Supervisor
TheSubcontractorShiftSupervisorisresponsibleforensuringthat:
AmainWorkPermit(Hot)israisedandissuedpriortothecommencementofwork(ifrequired).
AllappropriateprecautionsdetailedinthisprocedureareenteredontheworkPermit(Hot)and
areimplementedpriortocommencementofthetask.

23SafetyAuthority

TheSafetyAuthorityisresponsibleformonitoringthesafetyofallweldingpractices.
24TaskSupervisors
TheTaskSupervisorisresponsiblefor:
EnsuringthattherequirementsoftheWorkPermitarecarriedout.
Familiarizinghimselfandhisoperatorswiththedetailsoftheprocedures.
Ensuringthatduecareandattentionismaintainedthroughouttheoperation.

25PersonnelRaisingRequisitionorContract
Itistheresponsibilityofanypersonraisingarequisitionorcontractforanyweldingequipmentor
contractedworkrequestingweldingequipmenttobeusedtoensurethattheequipmentisin
accordancewiththerequirementofthepresentstandard,particularlyasfarastheworker
protectionagainstelectricalshocksisconcerned.

3Procedures

31GeneralRequirementApplicableToAnyWelding,BurningorCuttingOperations
311FumeHazards
Awelderinaconfinedspacemustbeaccompaniedbyapersonwhostaysoutsideandcangivethe
operatoranyassistanceasrequired.

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Ingeneralanupperexposurelimitforweldingfumesis5mg/m3.(ReferenceHSEguidancenote
EH40).Howeverforcertainelementse.g.Cadmium,whichmaybepresentinweldingfumeslower
limitsareset.Examplesofmethodsofcontrollingweldingfumesaregiveninpage12

Toxicgasesandfumes,producedinweldingoperations,createserioushazards:

Fumescanbeproducedfromtheweldingofmaterialsthataregreasy.Allsuchmaterials
mustbethoroughlydegreasedanddriedbeforewelding.
Harmfulleadfumesareproducedwhenweldingorcuttingmaterialcoatedwithleadbased
paint.
Theinhalationoffumesfromtheweldingorcuttingofzincgalvanizedmetal,mayresultin
"MetalFumeFever",whichischaracterizedbyaraisedtemperature,achingmuscles,
shiveringandsweating.Thesymptomsdevelopinafewhoursafterexposuretothefumes
andpersistforapproximately24hours.
Airlinemasks,orhighefficiencyrespiratorsshouldbeworninthosecaseswhere
galvanized,painted,leadorcadmiumcoatedmaterialsarebeingcutorwelded.
Nitrousfumesmaybeproducedonoccasionswhereanoxypropanefumesflameimpinges
onalargemassofmetalforlongperiods.Adeficiencyofairduringsuchworkmayalso
producecarbonmonoxide.
Thearcweldingofiron,orsteel,isaccompaniedbytheevolutionofconsiderablequantities
offumesconsistingofveryfineparticlesofironoxide.Theweldingofbrass,bronzeand
manganesesteelgenerateslargequantitiesofCarbonMonoxideandCarbonDioxidegases
whichrequiretheprovisionofadequateventilationorthewearingofsuitableapparatusto
giveeffectivenasal/oralprotection.
Forthepurposeofweldingfumeextraction,aventilationsystemcouldbeconsideredas
adequateifprovidingaminimumof100airchangesperhouroftheconsideredenclosed
spacevolume.
Wherehardeneddepositsarefoundontheequipment,weldingorcuttingmustnotbe
starteduntilthegeneralnatureofthedepositsareestablished.

312Fire,Explosionandelectrocutionhazards

Noweldingorcuttingwithina"live"gasplantoratthevicinityofflammableliquidsmaybedone
withoutaWorkPermit(Hot)andtheconditionslaiddownonthatpermitmustbestrictlyobserved.

Inallwelding&cuttingoperations,aportablefireextinguishermustbereadilyaccessiblenearthe
work.

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Anex nguisherdesignatedforfirewatchmustbeused(8kgdrypowderminimum).Donotuse
extinguisherswhicharepermanentlypositionedforemergencyuse.

Theworkmustbesuitablyscreenedtopreventsparksandhotmetalfromflyingoutsidethe
immediateworkarea.
Fireblanketsaretobeusedtoscreenlocalorotherareasandequipment.Theuseof
flammablesubstancesasscreenisforbidden(plasticssheets).

Weldingboothsandscreensmust:
Benoncombustible.
Haveinteriorsurfacewhichminimizethereflectionofdangerousradiation.
Allowthoroughventilation.

THEWORKPIECEMUSTBEBONDEDTOEARTHBEFORESTARTINGANYWELDINGOPERATION.
Theearthcablesshouldbefixedattheworksite,orifitthisisnotpractical,within3mofthework
site.

Weldersmustnevercoilhosesorcablesaroundtheirbodywhenburningorwelding.

MerelyclosingthevalvesontheweldingtorchisNOTADISCONNECTION,gascylindervalvesshould
alsobeclosedandhosesdisconnectedatcylindershead.

Cuttingintoanycladdingcoveringpolyurethanefoaminsulationmustbeundertakenusingacold
cuttingmethod.

IfhotcuttingisunavoidablethentheSafetySuperintendent/Authorityconsultedpriorto
commencementofoperationssothatadditionalprecautions(i.e.BreathingApparatusorAirline
Equipment)areenteredontheWorkPermit.

313PreOperationChecks

CheckifaMainWorkPermit(Hot)isrequiredandifyeshasbeenraised.

Checkthatalltanks,vesselsandequipmentonwhichwelding,cutting,burning,brazingorsoldering
workistobecarriedout,arefreefromflammablegasesandvapors,oilandsludge.IFWELDINGIS
ONONESIDEOFAVESSEL,ETC.CHECKTHATTHEREARENOFLAMMABLEGASES(ORMIXTURES)
ONTHEOTHERSIDE.

Donotunderanycircumstancesusecompressedoxygenforventilation,ortoblowthrough
propanehoses.Explosionscanoccur.

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Inspectthespacebetweendoubleplates,orweirplates,whereflammablematerialmaybefound
beforeweldingorburningoperationsbegin.

Beforecuttingthebottomplatesofanytank,drilltestholesandtakegasteststoensurethat
conditionsaresafeunderthetankfloor.

314WorkSite

Ensurethatweldingandburningequipmentisproperlymaintainedandwelllocatedwithproper
lighting.

Checkthattheworkpieceisproperlyearthed.
Checkthatventilationisadequate.
Keeptheworkareatidythroughouttheoperation.
Donotuseoldbarrels,ordrumstosupportworktheymayexplodeandare
unstable.

315Ventilation/RespiratoryProtection

Whenvesselsandtanksarebeingweldedorburnedontheoutside,thereisadangeroftoxicor
flammablegasescollectingwithin.Theheatfromoutsideatankcanigniteanexplosivemixture
insidethetank.Particularcaremustbetakentoensureadequateventilationand/orrespirator
protection.Thiswillbeespeciallyrelevantinconfinedspaces,orwheretoxicornoxiousvaporsmay
resultfromcuttingorburningpipe,etc.,whichhasspecialcoating,e.g."skotcote".

316PersonnelProtectiveEquipment

Goggles,screens,helmetsandprotectiveclothing,mustbeusedinforallwelding,cutting,chipping
andgrindingoperations.

Ensurethatanyonenearbywhomaybeexposedtotheradiationsandflashfromthistypeofwork
isalsoprotected.Useglovesorgauntletsmadeofleather,orsomeothernonignitablematerial,to
shieldthehandsandarmsfromtheradiationofthearcandfromsparks.Usesleevesofsimilar
materialinadditiontoglovesifgauntletsarenotworn.

Note:Leatherglovesandgauntletsgivelittleinsulationagainstelectricalhazards.

Thenecessityforwearingprotectiveclothing,asprotectionagainstsparksandpieces

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ofhotmetal,dependsuponthepositionofthearcwithreferencetothewelder'sbody.Forsome
weldingpostures,e.g.wherethewelderisstandingatabench,theheadscreenandgauntletsmay
wellprovidesufficientprotection.Athickapronofleather,orothersuitablematerial,maybe
neededifthewelderissittingathisworkpositionwheremoltenmetalmayfalluponhisthighsor
legs.Ifthearcisabovethelevelofhisshouldersoroverhead,completeprotectionforthehead,
armsandupperpartofthebodyisnecessary.

Acommoncauseofeyeinjuryisthechippingawayofslagwhichcoverstheweldwhencoated
electrodesareused.Inthesecircumstances,ahelmetwithadoublescreenshouldbeused;one
screenconsistsofaclearsafetyglasswindowwhiletheothercontainsaglasswhichabsorbsarc
radiations.Alternatively,clearglasssafetygogglesmaybeworninconjunctionwiththeuseofa
handscreen.

317Preheatingandheatingduringwelding

Forthickworkpieces,preheatingandheatingduringweldingmightberequiredtopreventcracks.
IFELECTRICALLYHEATEDCOILSAREUSED,THEYSHALLBESUPPLIEDTHROUGHLOWVOLTAGE
POWERSUPPLY(48VOR24VINWETATMOSPHERE).
Ifheatingisundertakenbygastorch,thetorchshallbekeptinhandbyadesignatedwelderhelper.
Alittorchshouldneverbesetdownuntilturnedoff.

32GasWeldingandBurning

321LightUpProcedure

Itisimportantthatanadequateflowoffuelgasisissuingfromthenozzleofthetorchorother
apparatusbeforelightingup.
Personnelmustusethefollowingprocedures:
Settheregulatorstotherecommendedworkingpressure.
Flashbackarrestorsmustbefi edclosetothetorchi.e.within0.5m.
Keepthetorchnozzleawayfromanysourceofignitionuntilthefuelgasisflowingfreelyfrothe
nozzle.flowingfreelyfromthenozzle.
Useasparklighterforignitingthetorch.

Ifthetorchflashesbackonlightingupitisbecausetheregulatorsarenotsettothecorrect
pressureoralighthasbeenappliedbeforetheflowoffuelgasisproperlyestablished.

Iftheflamesnapsoutwhenthetorchisinuse,itisbecause:
Regulatorpressureand/orgasflowareincorrect,eithertoohighortoolow.

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Thenozzlehasbeenobstructed.
Thenozzlehasbeenheldtooclosetothework.
Thenozzlehasbecomeoverheated.
Inthelastcase,completelyshutoffbothtorchvalves.Plungethenozzleandtorchheadintowater.
Makesurethatthenozzleistightbeforerelightingtorch.Checktheregulatorsettingandcylinder
pressuresthenrelightinaccordancewiththeaboveprocedure.

322VentilationandBreathingApparatusforGasWelding

Theapplicationofanoxypropaneflametosheetmetal,coatedwithmetalliclead,zinc,leadpaints
orotherinjurioussubstances,maygiverisetohighlytoxicvapors,particularlyincuttingworkwhere
anexcessofoxygenisrequired.Forsuchworksuitableairlinebreathingapparatus(NOTcanister
respiration)mustbeworn.

Unlessthereisgoodthroughventilation,anairlinebreathingapparatusmaskmustbewornwhen
carryingoutoxypropanecuttingorweldinginaconfinedspace.Ventilationisbettereffectedby
extractionfans/airmoversthanbyblowingfreshairintotheconfinedspace.Compressedoxygen
mustneverbeusedforventilatingpurposes,orbeblownthroughpropanepiping.

Cylindersofcompressedgasmustalwaysbekeptoutsideanyenclosedspacewhere
welding/cuttingistakingplace.

323Workinterruption

Torchesandhosesmustnotbeleftinvessels,orenclosedspaces,whentheyarenotinuse,e.g.
afteruse,duringalunchbreak,orovernight.Averysmallleakofanygas,particularlypropanefrom
atorchoversuchaperiod,canmaketheatmosphereinthevesseldangerous.Wherethiscannotbe
donetheoxygenandpropaneconnectionsMUSTBEDISCONNECTEDatthecylinderssituated
outsidethevessel(turningoffthevalvesisnotsufficient).

324RepairstoSmallContainers

Thisincludesthewelding,brazing,solderingorcuttingofdrums,orcontainers(e.g.40gallon
drums,fueltanksofvehicles)whichhavecontainedpetroleumproducts,flammableorother
combustiblematerials.

Beforeanysuchworkiscarriedout,thedrumorcontainermustbeuncappedanddrainedandthen
eitherthoroughlysteamedcleanedorsubmergedinboilingwater

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andkeptattheboilingpointforatleastonehour.

Afterthesteamingorboilingprocess,compressedairmustbeblownthroughthedrumcontainer
untilthevaporsareremoved(ensuringthattheairhasafreeexittopreventbuildupofpressure).
Beforecarryingoutthehotwork,thedrumorcontainermustbecertified"GasFree"andavalid
MainWorkPermit(Hot)mustbeissued.
Whenburningorweldingisinprogressonasmallvesselunburntgasescancollectinsideandan
explosivemixturecanbeformed.

Compressedairorsteammustbepassedthroughthevessel,carebeingtakentoensurefreeand
adequateexitfortheairorsteam.

Compressedoxygenmustnotbeusedforpurging.

ThefollowingmethodsareconsideredINADEQUATEbythemselvesforpreparingvesselsforrepair:

Washingoutwithhotorcoldwaterallowingwatertorunthrough.
Purgingwithcompressedair.
Cleaningbymeansofsolvents,suchastrichloroethylene.

Allvesselssenttotheworkshopforrepairmustbecertifiedfreeofgasandcorrosivechemicals.

33ElectricArcWeldingandBurning

331ElectricArcWeldingandBurning

Theinjuriouseffectsoftheradiation'sfromaweldingarcontheeyesandskinaresimilarwhether
DCorACcurrentisemployed.

Theeffectoflookingatanunscreenedarc,ataconsiderabledistanceandforafewsecondsonly,
cancauseatemporaryorpermanenteyeinjury,whichmaynotbecomeapparentuntilsomefourto
eighthourlater.

Weldersandanyhelpersmustprotecttheireyeswiththescreens,goggles,orspectaclesprovided.
Theworkmustalsobeeffectivelyscreenedfromotherworkersinthevicinity.

332ElectricalSupplyandConnectionsseepage11

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Allweldingsets,cables,connectorsandterminationsmustbemaintainedingoodcondition.
Electricalsupplyandearthingconnections,toweldingtransformersandgeneratorsets,mustbe
made,maintained(andcondemnedifnecessary)byacompetent
electrician.WELDINGTRANSFORMERSSHOULDBEPROVIDEDWITHAEARTHCONNECTION(casing
andneutralterminalofprimarywindings).Allsuppliesforweldingequipmentmustbemadewith
approvedcablesandapprovedplugboxesandmustbecontrolledfromacircuitwhichincludes
protectionsensitivetoearthfaultcurrents.

Wherestationarytransformersorgeneratorsetsarebeingused,asuitableswitchmustbemounted
adjacenttotheequipmenttoisolateitfromthesupplymain.

333WeldingLeads
Portabletransformersorgeneratorsetshavingtrailingleadsmustbeprovidedwithinterlocked
fusedswitchsocketsandplugs,protectingbothtrailingcableandequipment.

Allleadsmustbeproperlyterminatedandleadcablecouplersandterminationsmustbeof
adequatecurrentcarryingcapacity.

Toavoidlonglengthsofpowercables,themachinemustbesitedascloseaspossibletothepower
supplypoints.

AweldingreturnleadmustbeprovidedfromtheneutralterminalofeachphaseofanACwelding
transformerorfromthenegativeterminalofaDCgeneratortotheworkpiece.THISRETURNLEAD
ISNOTPROVIDINGANEARTHCONNECTION.

THISLEADISREQUIREDINADDITIONTOTHEEARTHBONDINGOFTHEWORKPIECE.Itshouldbe
locatedascloseaspossiblefromtheworkplace.

Theconnectionsattheworkpiecemustbemadebyboltingorclampingfirmly.

Wheremorethanoneoperatorisworkingfromthesameweldingmachine,thepolarityofeach
weldingleadandweldingreturnmustbethesame.

Wheretwoormoreleadsarebeingusedinaconfinedarea,thecorrespondingleadsmustbe
pairedand,asfaraspossible,thecrossingofpairswithoneanother,orwithanysinglelead,must
beavoided.

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Whereweldingleadstrailneartanksorsumpscontaininghydrocarbons,additionallengthsofcable
mustbeaddedtothecircuittoavoidthedangerarea.

334EarthingandBonding

ForallACweldingtransformers,thetransformerlowvoltagewindingmustNOTbeearthedbutthe
transformercasemustbeeffectivelybondedtotheearthconnectionloopoftheequipment.

ForallenginedrivenACandDCweldinggenerators,noearthconnectionmaybeappliedtoeither
poleoftheweldingoutput.

Themachineframemustbeeffectivelybondedtoearth.

THEWORKPIECEMUSTBEBONDEDTOEARTHBYMEANSOFAHEAVYSECTIONCONDUCTO
HAVINGSUITABLECLAMPEDORBOLTEDCONNECTIONS.

335StrayCurrents

Inallcaseswherebuttweldingoftwoitemshastobedoneandneitheritemispermanently
attachedtoanystructure,bothitemsmustbeconnectedtotheweldingreturnandindividually
bondedtoearth.

Bondingmaybeaffectedbytheuseofmechanicalclamps,orsecurelyattachedclips.

Thisrequirementisnecessarytopreventstrayelectricalcurrentscausingsparksatadistancefrom
theweldingpointwheretheremaybeflammableatmospheres.

335ElectrodeHolders

Electrodeholdersmustbeprovidedwithahandleoftoughinsulating,nonignitablematerialwitha
guarddiscofsimilarmaterialbetweenthehandoftheoperatorandtheweldingtool.

Anelectrodeholder,whenliveand/orcontainingarodmustbeplacedoninsulatingsupports,
whennotinuse.

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Trainingandqualification
Allemployeesassignedtoperformwelding,gascutting,brazing,metalgrindingandburningshall
bequalifiedordemandcompetentbytheirsuperiortoperformthework
Allweldershouldreceivetrainingonthesafeuseofequipmentandprocess,safeworkpractice
andemergencyprocedure.

FIG1WELDINGCIRCUITCONNECTIONS

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TABLE1METHODSOFCONTROLLINGWELDINGFUMES

Weldingprocess

Environment

Manualmetal
arc(stick)mild
steel

OpenAirWeldingshelter
WorkshopEnclosed
environmentConfined

Hazardous
Components

Fe,Fluoride
Fe,Fluoride
Fe,Fluoride
Fe,Fluoride
Fe,Fluoride

Recommendedminimum
Control

LEV
LEV
LEV+FFP
LEV+RPEorFFP

OpenAirWeldingshelter
Manualmetal
WorkshopEnclosed
arcstainlesssteel environmentConfinedspace

Cr,Ni

Cr,Ni
Cr,Ni
Cr,Ni
Cr,Ni

LEV
LEV
LEV
LEV+FFP
LEV+RPEfullface

TungstenInert
Gas(TIG)

OpenAirWeldingshelter
WorkshopEnclosed
EnvironmentConfinedspace

LEV=localexhaustventilation/fan
RPE=respiratoryprotectiveequipment
FFP=filteringfacepiecerespirator
Airline=compressedairlinebreathingapparatus.

South Pars Gas Field Development Phase 12

Weldgases

FFP
Airline+LEV

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