HOT WORK GUIDE & CHECKLIST

Why this is checklist important

This checklist assists in identifying the hazards and controls that need to be considered when preparing a Permit for people to
perform hot work in or adjacent to hazardous areas. It is not required to be attached to the permit but the hazards and controls
identified must be captured on the permit/Hot Work Certificate.

Equipment  Welding equipment

typically used  Hand tools (hot tips of hand tools, hammers, chisels, shovels, etc)
 Grinder
 Electrical & battery-operated equipment
 Drills
 Saws, cutters or chisels
 Battery powered equipment
 Abrasive blasting
 Needle gun
 Motor mowers
 Other engine driven equipment
 Exhaust systems (heat)
 Water blaster/grit blaster1
 Remote control units for construction/other equipment
 Explosive powered tools
 Vacuum loader – refer to Shell for their Vacuum Loader Checklist before using any
vacuum loader.

General Precautions
For any hot work activity the hierarchy of controls for hot work (ie., elimination, use of alternate equipment, removal of
flammable/combustible materials, use of JHA/Method Statements, PPE) is applicable.

The Lead Permit Issuer (LPI) must ensure that the following requirements are adhered to:

Before hot work is started

 A Permit is obtained and a Job Hazard Analysis is completed.
 People who operate, inspect and maintain equipment to be used for hot work in hazardous zone areas are
competent.
 Ensure equipment that is used for hot work in hazardous zone areas is inspected and maintained.
 When planning work, include a task-specific risk assessment and identify controls.
 For hot work in confined spaces, refer to the Confined Space Checklist for its requirements.
 Ensure adequate controls are in place to control the entry and use of vehicles and other mobile equipment in
hazardous areas.
 Confirm that equipment, which could contain flammable materials, is gas free and isolated in line with the
procedure for safe Isolation, lock-out and tag-out.
 For tank work, ensure that lap welds and coffer dams do not contain product or vapours. Check for
product/vapour that may be trapped under the coating on tank and pipeline.

1
Sand and water blasting can be a source of static generation so is classified as Hot Work for this reason.
  Ensure the work area is cleared of flammable materials and combustible materials.
 Visually inspect the work area and test the atmosphere.
 Establish vapour barriers, if required, according to the allowable criteria as supplied by Shell.

When hot work is carried out:

 Ensure the atmosphere is tested/monitored continuously, or at sufficient frequency, to establish that the area
remains free of flammable vapours.
 Have an authorised person carry out gas testing or use flammable-gas monitoring equipment.
 If flammable gas concentrations exceed the established set points, intervene, stop the work, and investigate the
reasons for deviation.
 Define and communicate corrective action before resuming the work.
 Maintain a fire watch when performing hot work inside a tank farm and in other hazardous areas. Maintain
communication between the fire watch and the people carrying out the hot work.

General Precautions: Welding

The Lead Permit Issuer must ensure that these controls are followed when welding is carried out:

Before welding starts

 A Permit is completed.
 A Job Hazard Analysis must be completed.
 Welding is carried out by qualified welders.
 Welding screens or blankets are checked for holes or damage
 Lab test may be required for tank/pipe paint to determine whether lead paint may be an issue and a specific plan
required.
 At least 2 x 9kg DCP fire extinguishers are checked for charge and are located within proximity of the work
area.
 Barricades and signs are erected around the work area to warn people who are passing through the area.

When welding is being carried out

 All work is completed in accordance with the conditions outlined in the Permit.
 Welders and assistants wear appropriate protective clothing, appropriate welding shields or an air hood if
required, and gloves.
 Isolation of radiation and sparks is achieved by means of welding screens and/or welding bays.
 Welding blankets are used when congested or confined areas cannot be protected by screens.
 Adequate fresh air is available and that welding fumes are extracted from the work area.
 If using an arc welder, the welder is to be insulated from workpiece to eliminate potential for electric shock.
 Welding machines are earthed if required by manufacturer.
 An earth leakage core balance unit is used.
 Pipe coating and lining is protected by welding blankets externally and blankets and/or plumbers plugs
internally.
 Flammable or combustible material in NOT located within a 15 metre radius of the welding area.

General Precautions: Grinding

The Lead Permit Issuer must ensure that these controls are followed when grinding is carried out:

Before grinding starts:

 A Permit is completed.
 A Job Hazard Analysis must be completed.
 Each person is trained in the correct use of a portable grinder.
 At least 2 x 9kg DCP fire extinguishers are checked for charge and are located within proximity of the work
area.
 A visual check of the grinder is carried out. If there are signs of damage to the disk, grinder, or lead, the unit
must be tagged and damage reported to the supervisor.
 The grinder is checked to confirm the following:
—A current test tag is attached
—The guard is the correct tightness and in the correct position
—The disk is correctly attached
—The maximum grinder size is 125 mm
—The correct disk is fitted for the task (e.g. cutting, grinding and masonry)
—The speed of the grinder must not exceed the maximum speed of the disk
 The goggles and/or face shield are adequate for use.
 The object to be cut or ground is secured.
 Flammable or combustible material is NOT located within a 15-metre radius of the work area.
 Pipe coating and lining must be protected externally by welding blankets.
 Pipe coating and lining must be protected internally by blankets and/or plumbers plugs.
 Lab test may be required for tank/pipe paint to determine whether lead paint may be an issue and a specific plan
required.
 In addition to the above, Distribution has additional specific requirements – refer to the Angle Grinder Safety
Procedure.

When grinding is being carried out:

 All work is completed in accordance with the conditions outlined in the Work Permit.
 Operators and assistants who work in close proximity of the grinding activities wear appropriate hearing
protection and a face shield and either safety goggles or glasses.
 Screens and blankets are used to protect people from sparks

General precautions: Motor mowers and other engine driven equipment

The Lead Permit Issuer must ensure that these controls are followed when using a motor mower or other engine driven
equipment in a restricted area:

General conditions:
1. A Work Permit and a Hot Work Certificate must be obtained and a job hazard analysis completed before
carrying out the above activity.
2. The work permit shall specify any special precautions, or hazardous conditions that could arise and require
activity to be stopped, that are considered to apply to the location.
3. Engine driven equipment must be visually checked by the permit issuer or supervisor prior to approval for
use.
4. Equipment fitted with batteries/electric motors or other electrical equipment must have the battery covered
with insulating material to prevent accidental shorting of the terminals. The battery terminals must be clean,
 tight and insulated covers fitted. All cables and terminals are to be in good condition with insulation intact.
Other electrical equipment must be isolated or disconnected.
5. The exhaust must be fitted with a suitable spark/flame arrestor (rated for engine/recommended by
manufacturer).
6. Areas in which engine driven equipment is to be used must be checked for signs of flammable/combustible
product especially in the drains and pits, tank compounds and interceptors. Work shall not proceed when
there is any free flammable product within the area.
7. Engine driven equipment must not enter into a tank compound when any of the following activity is taking
place:
 While receiving product from any source. A waiting period of 30 minutes must be observed after
product movements are completed and area must be rechecked by permit issuer or his nominee prior to
commencement of work.
 Having water drained from the tank bottom;
 When tank is open for gas freeing
8. Engine driven equipment must not be switched off inside a tank compound except in an emergency. In the
case of engine stopping or being stopped it must not be restarted within the compound or within 15 metres of
any potential source of flammable vapours (eg., gantry, discharge points, tank vents, drain pits, etc). If it is
not possible to move the equipment to a safe area, the area must be rechecked, by the permit issuer or his
nominee, prior to attempting to restart equipment.
9. Refuelling or repairs to equipment must not be carried out within a tank compound or within 15 metres of
any potential source of flammable vapours.
10. Use of equipment must cease immediately:
 if any vapour is detected, or if public, personnel, or vehicles are within 10 metres of operating
equipment.
 at any time, an incident occurs in the facility.
11. Equipment must not be used during still/dead calm weather conditions.
12. Equipment is to be maintained in accordance with the manufacturer’s instructions

Guidelines for extensions of tank vents adjacent to hot work

To allow hot work to be carried out in or adjacent to tank vents, it may be necessary to extend the vents of working tanks away
from the hot work area. In these circumstances, we need to calculate the size of the duct that must be used to prevent excessive
pressure or vacuum.

To calculate the diameter of the venting pipe, contact Shell Engineering.

 Vent extensions allow the working tank to breathe normally during pumping out of the tank.
 If the tank has a vent extension, do not allow receipt of product. If it is necessary to receive product into the tank,
hot work must stop, temporary vents must be removed, and all vents restored to normal conditions.

Arrangement of vent extensions

Class 3 PGI, PGII tanks with Pressure-Vacuum valves:
 One Pressure-Vacuum valve is left operative
 All other vents and dip hatches are sealed
 A vapour-tight enclosure is fitted over the operative Pressure-Vacuum valve
 The extension duct is fitted to the vapour-tight enclosure
Class 3 PGI, PGII, PGIII tanks (open vented)
 The extension duct can be connected directly to one vent outlet
 All other vents and dip hatches are sealed
 If the duct is adequately supported and all joints are vapour tight, the duct may consist of light metal tubing, PVC
 piping or light hose
 The open end of the duct must be at least 6 metres above the ground and provision must be made to collect
condensate that collects at low points in the duct.
HOT WORK CHECKLIST
 General Conditions that apply to Hot Work activities
1  All company and contractor staff must acknowledge and comply with the Company’s Fire Prevention
Regulations.
 Before company or contractor staff are allowed to enter the facility, they must complete a site safety
induction.
2  The attached site plan forms part of the Permit with the Hot Work activity area marked on the plan.
 The work area must be suitably fenced or barricaded.
3 Safety distance for tank venting:
 The following table identifies the minimum distance that the vent must be extended to for each class of
product.
 Refer to the Guidelines on extension of tank vents adjacent to Hot Work in the Checklist for Hot
Work. Such vent extensions allow the tank to breathe normally and during tank pump-outs but DO NOT
permit receipt of product into the tank. If it is necessary to receive product into the tank then all hot work
must cease and temporary vents must be removed and all vents restored to normal condition.
Product Minimum distance (horizontal)
Class 3 PG I, PG II 30 metres
Class 3 PG III 8 Metres
Class C1 5 metres
4  As appropriate, tanks subject to hot work must be gas free in accordance with Shell procedures.
 When Hot Work is in progress, freely ventilate these tanks at all times and regularly check for gas in
accordance with the requirements outlines in step 15 of this checklist.
 If using inerting or suppression technology and chemicals to inert the vapour space, refer to the
manufacturer’s instructions and gas test the vapour space regularly to confirm the LEL is within the
required limits.
5  Remove all products from the site interceptor/puraceptor and from other drain sumps in the vicinity.
 When hot work is in progress, keep the drain system free of product and vapour at all times.
 Temporarily seal drains that connect to other areas or product handling activities.
6  Before hot work commences, inspect product lines, pump glands and valves in the vicinity for leaks
and make repairs as necessary.
7  Before hot work commences, remove all flammable material that is NOT required for the execution of
hot work in the area.
8  Stop hot work during the following times
 During tanker discharge
 When transferring between tanks
 When product sampling
 When dipping tanks
 When draining water from tanks
 During electrical storms
 During earthquakes.
9  Locate welding generators, compressors, other powered equipment and oxy-acetylene bottles as shown
on the site plan.
10  Unless approved, use only diesel-operated plant and machinery within the hazardous zone. See
Checklist above for specific precautions.
11  Fit exhausts of all engines with spark arrestors.
12  All welding and electrical leads must be in good condition with insulation in good condition and
unbroken.
 Protect electrical leads, gas, oxygen and air hoses from mechanical damage.
  Oxy-acetylene equipment must be fitted with ‘flash back’ arrestors on the torch and the gas bottle
pressure regulator
15  Test gas hoses to ensure these are free of leaks
 Do NOT locate gas bottles inside a tank or confined space
 Remove hoses at the end of the working day or more frequently as specified
14  Low voltage portable equipment (eg. Lighting, drills, scanners) must be used wherever possible in
tank confined spaces
 All equipment fed with electrical supply from switchboards or generators must have the necessary
supply protection safeguards (eg. RCD’s)
15  The Permit must be validated each day by the (Lead) Permit Issuer who has initial gas-test authority
for the work. Refer to the (Lead) Permit Issuer’s summary sheet for additional information.
 The Permit Issuer must inspect the area for compliance with the conditions outlined in this attachment
and obtain safe gas test readings inside tanks, vessels, sumps and pits and any other place where gas could
accumulate, at the following times:
o Before work starts
o Continuous monitoring during the hot works
o Before starting work after each work break
 The initial check and subsequent inspections must be recorded in the gas test record.
 If vapour is detected, work must stop and hot work cannot restart until clear readings are obtained.
16  On the Permit, define the time and conditions under which Hot Work can be carried out.
17  Ensure isolated sections of pipelines have adequate thermal relief to a safe area.
18  Consider the following fire-fighting equipment as required:
 2 x 9kg Dry Chemical fire extinguishers at the Hot Work area
 Consult emergency services (Bomba) to see what other equipment would be appropriate.
19  Maintain a fire watch and maintain communication between the fire watch and the workers performing
the Hot Work.
Other conditions
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