Jubail United Petrochemical Company (United) Site Safety Procedures Manual

United Olefins Complex Project

Jubail, Saudi Arabia April, 2001
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.

7 June, 2001 GENERAL SITE CONDITIONS AND SAFETY PROCEDURES

28-Hotwork.doc Permits – Hot Work Page 1 of 5
Jubail United Petrochemical Company (United) Site Safety Procedures Manual
United Olefins Complex Project
Jubail, Saudi Arabia April, 2001
Page 2 of 5

e) Contain sparks and slag with welding cloth / fire blanket.

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

7 June, 2001 GENERAL SITE CONDITIONS AND SAFETY PROCEDURES

28-Hotwork.doc Permits – Hot Work Page 2 of 5
Jubail United Petrochemical Company (United) Site Safety Procedures Manual
United Olefins Complex Project
Jubail, Saudi Arabia April, 2001
Page 3 of 5

4) Flameproof leather (or suitable material) aprons should be considered if long-

term exposure to radiant heat or sparks is anticipated.

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.

7 June, 2001 GENERAL SITE CONDITIONS AND SAFETY PROCEDURES

28-Hotwork.doc Permits – Hot Work Page 3 of 5
Jubail United Petrochemical Company (United) Site Safety Procedures Manual
United Olefins Complex Project
Jubail, Saudi Arabia April, 2001
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.

7 June, 2001 GENERAL SITE CONDITIONS AND SAFETY PROCEDURES

28-Hotwork.doc Permits – Hot Work Page 4 of 5
Jubail United Petrochemical Company (United) Site Safety Procedures Manual
United Olefins Complex Project
Jubail, Saudi Arabia April, 2001
Page 5 of 5

ATTACHMENTS

HOTWORK PERMIT
HOTWORK CHECK LIST

7 June, 2001 GENERAL SITE CONDITIONS AND SAFETY PROCEDURES

28-Hotwork.doc Permits – Hot Work Page 5 of 5