1.0 Purpose

To ensure adequate protection to people and plant during hot work operations

2.0 Scope

All business locations under HSC control

3.0 Definitions

Hot Works Grinding, welding, flame cutting or other fire or spark-producing operation

4.0 Responsibilities

4.1 Site Manager

The Site Manager must:

Ensure that this procedure is implemented and adequate controls are in place

Ensure that cutters, welders and their Supervisors are suitably trained in the safe operation of their equipment and the safe use of the process

Advise all Sub-Contractors about flammable materials and/or hazardous conditions of which they may not be aware

4.2 Site HSE Representative

The Site HSE Representative will monitor implementation of this procedure

4.3 Supervisors

Supervisors are responsible for:

The safe handling of the cutting or welding equipment and the safe use of the hot work processes

Determining the combustible materials and hazardous areas present or likely to be present in the work location

Protecting combustibles from ignition by moving the work, moving or adequately protecting the combustibles, or seeing that cutting and welding are so scheduled that operations which might expose combustibles to ignition are not started during cutting or welding

Gaining approval for the cutting or welding operations from the designated management representative

Ensuring that the cutter or welder obtains proper verification that conditions are safe before proceeding

Ensuring that fire protection and extinguishing equipment are properly located

Ensuring Sub-Contractors are made aware of existing or potential flammables combustibles in the areas in which they work

Ensure that this procedure is implemented and adequate controls are carried out.

5.0 Process

5.1 Key Principles

All sites must implement fire prevention and protection methods specific to hot work operations as applicable such as:

Eliminating/minimizing fire hazards in the vicinity of the hot work process

Providing a fire watch when hazards cannot be adequately minimized

Completing and approving work permits and associated requirements prior to beginning the cutting or welding process

Prohibiting hot work in designated, high-hazards areas

Cutting and welding equipment care and use

Training affected personnel

5.2 General Requirements

Hot work must only be performed in areas proven by risk assessment to have fire hazards adequately controlled.

All combustibles must be relocated, where practicable, a minimum of 6m from the work site. Where relocation is impractical, combustibles must be protected with flame proof covers, guards or curtains.

Ducts and conveyor systems that could carry sparks to distant combustibles must be suitably protected or shut down.

Where hot work is done near combustible walls, partitions, ceilings or roofs, fire resistant shields or guards must be provided to prevent ignition.

If hot work is to be done on non-combustible walls, partitions, ceilings or roofs, precautions will be taken to prevent ignition of combustibles on the other side, due to conduction or radiation, preferably by relocating combustibles. Where combustibles are not relocated, a fire watch on the opposite side from the work must be provided.

Hot work must not be attempted on a metal partition, wall, ceiling or roof having a combustible covering nor on walls or partitions of combustible sandwich-type panel construction.

Cutting or welding on pipes or other metals in contact with combustible walls, partitions, ceilings or roofs must not be undertaken if the work is close enough to cause ignition by conduction.

Floors must be swept clean of combustible materials for a radius of a minimum of 6m. Combustible floors must be kept wet, covered with damp sand, or protected by fire-resistant shields. Where floors have been wet down, personnel operating arc welding or cutting equipment will be protected from possible shock e.g. insulated blankets.

5.3 Welding

No welding, cutting, or other hot work must be performed on used drums, barrels, tanks or other containers that were used for holding flammable/ combustible materials until they have been cleaned. Cleaning must remove all flammable materials present, as well as any substances such as grease, tar, acids, or other materials that might produce flammable or toxic vapors when subjected to heat.

Any pipelines or connections to the drum or vessel must be disconnected or blanked.

All hollow spaces, cavities or containers will be vented to permit the escape of air or gases before preheating, cutting or welding. Purging with inert gas is recommended.

Welding cables and oxy-acetylene lines must be clear of passageways, stairways, and ladders when practical.

All hot work equipment must be inspected before each use.

Welding cables with nicks or small cuts in the insulation must be repaired. Cuts or breaks in the insulation jacket that penetrate to the conductor must be removed from service and repaired or replaced.

Welding cables and splices within 3m of an electrode must not be used.

Portable welding machines must be thoroughly inspected and documented annually.

Welding machine terminals must be effectively guarded by the use of a dead front plate or guard that will prevent inadvertent contact with energized terminals.

When arc welding is suspended and equipment is left unattended, the equipment must be effectively shut down. Cutting torches will have the cylinder valves shut and lines bled of pressure. Torches must be removed from confined spaces if left unattended for any length of time such as over lunch or overnight.

Oxy-acetylene torches must be equipped with flashback arrestors

5.4 Handling and Use of Gas Cylinders

5.4.1 Care and Use of Oxygen Cylinders

Keep oxygen fittings and lines away from oil or grease products

Oil or grease may ignite violently in the presence of oxygen under pressure

Only use equipment rated and marked for oxygen use only iv. Never connect an oxygen regulator to a cylinder containing combustible gas

Use flashback arrestor of oxygen cylinder

5.4.2 Care and Use of Acetylene Cylinders

When storing acetylene cylinders, remember it is a fuel gas

If the valve outlet becomes iced over, thaw in warm, not hot water if needed

Never use a leaking acetylene cylinder

Do not open an acetylene cylinder valve more than 1 1/2 turns. In general, acetylene valves only need be opened one quarter to one half turn

Never use acetylene from a cylinder except through an acetylene regulator

Use acetylene only in an upright position.

Never use acetylene at pressures greater than 1 bar.

Use flashback arrestor of acetylene cylinder

5.5 Hot Work

Hot Work Permit

Before hot work may proceed, a work permit must be completed and signed.

A designated, qualified person must approve hot work operations identified on the permit. This person will inspect the area prior to granting authorization for such operations so that potential hazards and necessary precautions can be identified on the permit. All such precautions must be communicated, documented and implemented prior to work proceeding.