PURPOSE:

• Ensure that all the Hot works e.g. (Welding, cutting, grinding, drilling,
digging on concrete, use of Non-IS equipment in classified areas i.e.
zone 0, 1 and 2.

• Make the person/s doing the work fully understand/s the hazards and
risks involved and the precautions to be taken.

• Ensure that the person responsible for the operation area is fully
aware of the work being done or to be done in his area.
SCOPE

• The Hot Work Permit shall be issued for all the routine, non-routine
hot jobs involving equipment or materials producing flames, sparks or
heat or classified as a source of ignition. Hot Work Permit is required
in the Process, Utilities and Oil Movement areas and all other areas of
refinery including buildings, offices etc.
PROCEDURE:
• Certain areas at each site may be classified as ‘Open Areas’ after consultation with the
HSE department.
• The following areas are eligible for classification as ‘Open Areas’:
• Welding Shop
• Machine Shop
• Electrical Shop
• Instrument Shop
• Laboratory
• Fire training area
• Any work in an ‘Open Area’ or on any equipment that has been in service with
flammable & combustible materials, or any hot work to be performed by individuals
other than area staff, must have a hot work permit issued by Area Incharge/ Supervisor.
JOBS REQUIRING HOT WORK PERMIT

• Hot Work Permit is required, when Heat is used, generated or applied and is of
such intensity as to cause ignition of any flammable or combustible materials.
• An ignition source which is introduced into a hazardous area such as;
• Internal combustion engines,
• Electrical or electronic equipment not certified as explosion proof or intrinsically
safe,
• Power operated grinders, Cutting machines and ferrous tools
• Hand operated ferrous tools in contact with dry concrete, stone or masonry,
• Grit and shot blasting equipment, Electric and gas welding torches
• Blow lamps, Primus stoves and tar boilers
• Exposed luminous material, including Pyrophoric deposits
• Cameras, vibration meters, Cassette players, Radios, match boxes, lighters and all
other battery-operated items not certified as explosion proof or intrinsically safe.
• The following activities shall be considered as hot work, requiring a hot
work permit;
• Acetylene or gas burning, welding, brazing, annealing or torch heating or cutting
lead burning.
• Electric Arc welding or gouging, soldering.
• Heating and riveting.
• Use of open flames or resistance type electric heaters or coils.
• Sand blasting, breaking of concrete, drilling, grinding, and power wire brushing.
• Use of non-explosion proof type (Non-Intrinsically safe) electric motors
or equipment, extension leads and plugs.
PREPARATION BEFORE ISSUE:
• Any precautions required must include such items as:
• Disconnecting lines, blinding and isolation.
• Freeing the equipment from product and/or gases.
• Cleaning and removal of flammable/combustible materials.
• Determining the suitable location for welding or other hot work equipment.
• The covering of sewers, ditches or drains.
• Wetting down of scaffolds, concrete floors, decks and platforms.
• Flushing/coverage of holes in the ground or cracks in pavement
• Making provision for fire protection and fire guards as necessary.
• A gas test shall be carried out by the originating authority or Area operator prior to
the issue of the Hot Work Permit.
• If hot work is not started within one hour of completion of a satisfactory gas test, or
has been discontinued for that period of time, then another test shall be carried out.
• If repeated gas monitoring is required for the job, then Originating Authority shall
mention the time intervals of gas monitoring.
ISSUANCE OF HOT WORK PERMIT:

• Originating and Accepting Authority will visit the job site and discuss the
job related hazards and residual hazards.
• Originator will fill in all the requirements on the permit for the safe
execution of job and prepare the area himself or hand over the permit to
area operator for area preparation.
• Once both the Originator and Acceptor are satisfied with the job site
conditions, the Originator will sign the permit,
• All shift supervisors will be authorized by the HSE department to
initiate hot work permit after completing their training course on
gas testing and work permits.
• The hard copy of the approved permit is hanged work site. The
original and second copy is kept in the area operator.

• If any changes in condition are to be made affecting a Hot Work

Permit that has been issued, then the Originating Authority
who signed the permit must approve the changes and the
changed conditions must be entered on all copies of the
permit, otherwise a new Hot Work Permit must be issued.

• If a contractor is hired for a job, then the hiring department will

have to assign a supervisor from their department.
WITHDRAWAL OF HOT WORK PERMIT:
• Once the permit is stopped due to unsafe act/conditions or job is not completed in
the validity period, a new permit will be issued.
SECTION-A (Action & Condition List):
• The equipment should be properly depressurized and drained to avoid any chances
of fire/spill.
• Any nearby drains or sewers in the vicinity of about 15 meters will be kept covered
during the hot work.
• For critical hot jobs, Fire man / Fire tender may be called from fire station.
• Combustible materials are not closer than 11 meter and are not easily combustible
• Fire watch shall Be trained to understand the inherent hazards of the worksite and
of the hot work.
SECTION-B (Safety Equipment & Clothing Required):

• The Originator will fill the section B. For any PPE required.

• Suitable gloves shall be worn when hazards from chemicals, cuts,abrasions,

punctures, burns, biological, and harmful temperature extremes are present.
• Leather gloves for welding cutting
• PVC gloves for the chemical handling
• Rubber gloves when live electrical wires are involved during the job.

• Hearing protection will be required if sound levels equal or above 85 db.

• Gum boots will be used if hazardous chemicals are involved

SECTION-C (Gas Testing):

• Gas testing will be done for all the hot jobs.

• Gas testing will be done by the Originator or Area Operator.
• For hot work, the Lower explosive limit should be NIL.
• The concentration of toxic gases at the work site shall not exceed TLV to
avoid the exposure to toxic environment.
• Gas Tester will write the reading on the permit and will also mention
meter no. before signing and handover to performer.
VALIDITY OF HOT WORK PERMIT:

• In general, the Hot Work permit is issued for 24 hours (0600-0600 hrs.),
with revalidation after every 8 hours or shift change.
• A time delay of maximum of 30 minutes is allowed for revalidating the
permit.
• At the start of each shift the incoming shift Supervisor/Engineer shall
visit the area, check the job conditions and then revalidate the permit.
PRECAUTIONARY STEPS:

• The Hot Work Permit will be filled by the Originating and accepting
Authority.
• All the combustible material (i.e. Cotton rags, Oils, Pyrophoric material,
Wood etc.) removed from job site.
• All nearby sewers/drains upto 15 meters will be covered to avoid any
flammable gas escaping from the closed drain.
• The area will be barricaded to keep the job site isolated.
• Fire blanket or canopy will be required during the job.
• The gas testing will be done by Originator or Area Operator.
• If any chemical is present near the job site, MSDS will be provided by
Originating Authority.
• If the work could not start within 1 (one) hour of gas testing then the
gas test will be done again on the same permit.
• In case of a false emergency alarm activation, permit will not be
withdrawn.
• Hot work should not be permitted in areas into which flammable vapors
could be blown.
• Never leave an unattended oxygen/acetylene hose attached to a torch
in a confined space as it could increase oxygen or flammable gas
concentrations as a result of leak.
• Cables with splices within 10 feet of the holder shall not be used.
• Ensure that welding machines and leads are properly grounded.
• No frayed or broken wires should be used in welding.
• Any hot job on the tank bottom shall be carried out with inertization of
the bottom or by cold cutting of the plates.
• In a vessel that is partially filled with liquid, welding may be done 3 feet
or more below the level of liquid. But, prior thickness gauging shall be
done and clearance shall be obtained from Inspection. This is not
applicable for double walled and lined vessels.
• If welding is to be done on coated pipes and coating has toxic contents,
then it shall be stripped at least 4 inches from the area of heating and
provide SCBA to performer.
• When welding is to be suspended, electrodes should be removed from
holders.
• Non-Intrinsically Safe equipment can only be used in Hazardous areas
through Hot Work permit.
• If welding or grinding is to be done at height, then precautions shall be
taken to prevent the spread of sparks.
• Used fire-resisting or flame-retarding tarpaulin and area barrication at
ground level.
• In case of plant emergencies, the permit will be cancelled.