Hot Work Permit Procedure

Authored By: Blanchard Refining Company LLC Doc No.
: RSW- 000029-GB
Chris Lamb Galveston Bay Refinery Rev No: 3
Doc Custodian:
Safety Supervisor
PR-2 Hot Work Refinery Safe Work Procedure
Approved By:
Von Meeks
Date Approved: 3/25/2020 Next Review Date: 3/31/2025 Effective Date: 3/27/2020
TABLE OF CONTENTS
1.0 Purpose ............................................................................................................................................. 2
2.0 Scope ................................................................................................................................................ 2
3.0 Procedure .......................................................................................................................................... 2
3.1. Responsibilities ............................................................................................................................. 2
3.1.1. Owning Department 2
3.1.2. Contractors/Maintenance/Hot Work Servicing Groups 3
3.1.3. MPC Supervision/Contractor Coordinators/Contractor Management 3
3.1.4. Fire Watch 4
3.1.5. Permit Writer 4
3.2. General .......................................................................................................................................... 5
3.3. Hot Work Permitting ...................................................................................................................... 6
3.4. Other/Miscellaneous ..................................................................................................................... 9
3.5. Temporary Portable Pumps ........................................................................................................ 10
3.6. Hot Bolting/Flange Tightening ..................................................................................................... 10
3.6.1. Tightening Leaking Flanges or Connections 10
3.6.2. Loosening 11
3.7. Compressed Gas Cylinders ........................................................................................................ 12
3.8. Training ....................................................................................................................................... 12
4.0 Definitions ........................................................................................................................................ 12
5.0 References ...................................................................................................................................... 14
6.0 Attachments .................................................................................................................................... 14
7.0 Revisions History ............................................................................................................................ 14
Attachment A Flange Removal Guideline ................................................................................................... 15
Printed 3/27/2020 RSW- 000029-GB.docx Page 1 of 15
Printed copies should be used with caution. The user of this document must ensure that the current approved
version of the document is used.
Blanchard Refining Company LLC Galveston Bay Refinery
Title: PR-2 Hot Work Doc Number: RSW- 000029-GB Rev No: 3
1.0 Purpose
1.1. To verify in writing, that proper safeguards and precautions have been taken to minimize the
possibility of personnel injury and property damage during hot work.
1.2. To provide requirements for the testing, site preparation and communications required between
Owning Departments or anyone performing hot work.
2.0 Scope
2.1. This procedure applies to all Marathon Petroleum Company (MPC) LP employees performing hot
work at the Galveston Bay Refinery (GBR). It also applies to all consultant agencies, contractors,
and subcontractors performing hot work at GBR.
2.2. This procedure applies to all hot work performed at GBR.
2.3. A properly authorized safe work permit including the hot work section and authorizing signatures
is required for all cutting, burning, welding, use of non-explosion proof portable power tools or
electrical equipment at Galveston Bay Refinery (GBR). This procedure applies to all hot work
performed at GBR.
2.4. All areas on GBR property where hot work will occur will require a hot work permit.
2.4.1. More information on the Safe Work Permits can found in GBR PR-3 Safe Work Permit
Procedure.
2.5. All Work Permits must be issued in accordance with instructions contained in this procedure
before the performance of any type of work or activity in the covered areas.
3.0 Procedure
3.1. Responsibilities
3.1.1. Owning Department
3.1.1.1. Grant permission for personnel to work on equipment in their area.
3.1.1.2. Ensure the correct issue and cancellation of Safe Work Permits in the area
and/or equipment under their control. Communicate the permit conditions to
the Servicing Group representatives. Ensure the permit recipients fully
understand the requirements of the Safe Work Permit.
3.1.1.3. Ensure that hot work operations remain consistent with the terms of the Safe
Work Permit.
3.1.1.4. Prepare equipment for release to the Servicing Group following all applicable
operating and HES procedures, so it is safe for the intended work.
3.1.1.5. Identify any hazards associated with the work and the actions or required
means to safely mitigate the hazards.
3.1.1.6. Conduct joint job site visits with the Servicing Group representative(s) to
verify that all precautions are in place, all necessary PPE is available, the
area is inspected for fire and explosion hazards and that site conditions are
acceptable to proceed with the work scope.
3.1.1.7. Notify Servicing Group employees of any operating emergency or changes in
conditions that could affect the safety of the job.
3.1.1.8. When applicable and practical, require that attended hot work be done in an
area outside of process units or dike areas.
3.1.1.9. Be competent (by virtue of training or experience) in the field on calibration

and use of the instrumentation utilized to monitor atmospheric conditions,
perform required atmospheric monitoring for permitted work and advise all
applicable personnel of monitoring results.
3.1.1.10. Communicate to relief, any ongoing hot work in their area.

3.1.2. Contractors/Maintenance/Hot Work Servicing Groups
3.1.2.1. Be knowledgeable of and adhere to the provisions of this procedure.
3.1.2.2. Contact a permit writer prior to the commencement of any hot work so a Safe
Work Permit can be issued. Comply with all permit requirements (e.g.,
appropriate PPE, precautions, special requirements).
3.1.2.3. Understand the scope and impact of the identified work, and ensure the
Owning Department has a complete understanding of the job’s execution
requirements and job scope to verify proper equipment preparation.
3.1.2.4. Conduct joint job site visits with the Owning Department for the work to be
performed and convey any potential hazards that will be introduced to the job
site while performing work.
3.1.2.5. Ensure that all equipment (e.g., cords, leads, hoses, cylinders, regulators,
weld machines, electric tools, etc.) is in good working condition and
acceptable for the job to be undertaken.
3.1.2.6. Provide a dedicated, properly trained fire watch when required and
discontinue the job if conditions are unsafe or if notified by the fire watch of
an unsafe condition or problem.
3.1.2.7. Notify the Owning Department of any work scope changes.
3.1.2.8. Clean up the job site upon the completion of work.
3.1.2.9. Inform the Owning Department when the job is complete. Visit the site with
operations to view the work and job site clean up status and properly turn in
Safe Work Permit.
NOTE: Welders must be able to provide personal welder qualifications to MPC upon
request.
3.1.3. MPC Supervision/Contractor Coordinators/Contractor Management

3.1.3.1. Ensure that all work carried out by personnel under his/her control is covered
by a valid Safe Work Permit and that personnel comply with all precautions
specified on the permit and all GBR HESS rules and procedures. This must
be done while understanding all limitations and restrictions of the permit.
3.1.3.2. Ensure that all precautionary measures specified on the Safe Work Permit,
employee PPE, acceptable equipment, etc., is in place prior to work
commencing.
3.1.3.3. Those planning hot work shall ensure that the provisions of this procedure
and all other applicable HES rules and procedures are included in the scope.
3.1.3.4. Ensure that employees performing work are properly informed of GBR PR-3
Safe Work Permit Procedure and of the provisions set forth in this procedure.
3.1.3.5. Ensure that the fire watch personnel are available at the site when required
and have the proper fire suppression equipment, are knowledgeable in its
use, understand their duties and were properly trained.
3.1.3.6. Verify the qualifications of welders with the Inspection Department to ensure
that they are properly qualified.
3.1.4. Fire Watch
3.1.4.1. Be knowledgeable in all assigned responsibilities of the Fire Watch and all
conditions noted on the Safe Work Permit.
3.1.4.2. Know how to sound an alarm (air horn) and/or contact emergency personnel
in the event of a fire or changing conditions.
3.1.4.3. Be positioned such that they can have clear line of sight and can readily
respond to any potential fire hazard resulting from the hot work. Fire watch
must not be assigned any work that shall interfere with fire watch
responsibilities.
NOTE: In some case’s a Fire watch may be assigned a dual role as
Confined Space attendant
3.1.4.4. For hot work jobs at elevated heights where the fire watch is positioned at
ground level, the work crew must also have an additional 20 lb fire
extinguisher with them at the elevated job site.
NOTE: This is in addition to the 20 lb extinguisher that the fire watch is
required to have near their person.
3.1.4.5. Must be trained and knowledgeable in the use of fire extinguishers,
extinguishing small fires, the provisions set forth in this procedure and of the
hazards involved in the work scope.
3.1.4.6. Must be trained and knowledgeable in proper monitoring and response to
alarms of a combustible gas testing instrument, if applicable.
3.1.4.7. Remain in the most suspect areas for a fire to occur while the hot work is
being performed, and remain in the hot work area at all times while it is in
progress.
3.1.4.8. Stop all activities when the emergency siren is activated, when a deviation
from the provisions set forth on the Safe Work Permit is observed or when
changing conditions are observed that would adversely affect employees
and/or equipment.
3.1.4.9. Wear an orange or red vest for identification purposes.
3.1.4.10. A fire watch shall be maintained for at least a half-hour after completion of
welding or cutting operations if combustible materials are present and have
the possibility to flare up.
3.1.5. Permit Writer
3.1.5.1. Know the hazards that could be encountered during the permitted work,
including information on each potential hazard, including exposure mode
(skin contact, inhalation, etc.), exposure signs and symptoms, and the
consequences of an exposure.
3.1.5.2. Inspect the work site before the work begins and ensure the hot work
operations remain consistent with the terms of the Safe Work Permit.
3.1.5.3. Determine when testing and/or monitoring is required to demonstrate the

safety of the job site. Be competent (by virtue of training and/or experience)
in the field on calibration and use of the instrumentation utilized in testing and
monitoring.
3.1.5.4. Be able to perform required atmospheric monitoring for permitted work,
delegate this responsibility to the operator in charge of the area where work
will take place or delegate to another competent member of the Owning
Department.
3.1.5.5. Ensure that the testing/monitoring results are accurately documented on the
Safe Work Permit. Determine time intervals in which atmospheric monitoring
should occur if circumstances would necessitate that more frequent testing is
needed.
3.1.5.6. Verify that all needed entries have been made on the permit, that all tests
specified have been conducted and within acceptable limits, and that all
procedures and equipment specified are in place before signing the permit
and allowing hot work to begin.
3.1.5.7. Review compliance requirements and approve/terminate hot work.
Terminate and cancel the hot work operations if an emergency arises or
when conditions change from those under which approval was granted.
3.1.5.8. Conduct hazard discussion with the employees who will perform the hot
work. The permit writer may discuss the hazards with the servicing
representative(s) or elect to discuss with all involved employees directly.
3.1.5.9. Determine if a fire watch is required and if so, instruct and discuss the
individual’s responsibilities.
3.1.5.10. Contact the Safety Department for special testing and protective equipment
requirements if needed.
3.1.5.11. Permit writers must complete initial permit writer training and scheduled
refresher training.
3.2. General
3.2.1. All hot work must be performed in accordance with this procedure, and when practical, it
shall be done in a designated safe welding and burning area, outside of process units or
dike areas.
3.2.2. All welding and burning equipment (e.g., leads, grounds, hoses, cables, gauges,
regulators, etc.) shall be visually inspected daily, prior to hot work occurring to ensure
that it is in good working condition.
3.2.3. Pollution prevention equipment (e.g. secondary containment berms) shall be used at the
Docks to prevent spills and/or releases of fluids to the environment. Weld machines must
also be positioned such that exhaust will not negatively impact the atmosphere of
employee working areas (e.g., CO build up).
3.2.4. Welding grounds shall be grounded as close to the work as possible. When welding on
pumps, turbines or compressors to eliminate welding machine grounding through
bearings or seals the ground lead shall be adjacent to the work
3.2.5. A hot work permit issued for welding is understood to cover approval of the location of the
weld machines.
3.2.6. Consideration must be given to the positioning of other spark producing equipment (e.g.
light plants/towers, generators, compressors) outside of process and diked areas. The
positioning of such equipment must be treated as unattended hot work, included in

applicable work scopes and permitted as such.
3.2.7. The immediate area will be in satisfactory condition prior to the start of any hot work.
Walkways, stairways, ladders, tank man ways, and other approaches to the work area
must be accessible and free from obstacles which may obstruct the access/egress of
personnel in the event of an emergency.
3.2.8. Additional PPE may be required for certain hot work applications (e.g. welder PPE).
Consideration must be given to exposure to weld fumes and respiratory PPE. Welders or
employees performing hot work on any scaffold, walkway, or any other elevated area
requiring fall protection shall don and use the PPE properly.
3.2.9. Adequate natural or mechanical ventilation shall also be considered to reduce or
eliminate the hazards of exposure to weld fumes. Any accumulation of gases must be
vented to a safe location, away from the hot work.
3.2.10. Sewers within 35 feet must be protected with a catch basin or flat style drain cover. In
areas where this type of arrangement will not work or where it is not practical, wet fire
blanketing may be used to cover these areas.
3.3. Hot Work Permitting
NOTE: Every hot work job is unique and may have unique hazards. All steps and consideration
necessary to ensure a safe work environment shall be addressed prior to commencing
work.
3.3.1. Hot work permits must be issued in the proper form and properly signed and
countersigned before starting any work or activity that could produce an ignition source.
Hot work must be permitted in accordance with guidelines set forth in the GBR PR-3 Safe
Work Permit Procedure and this procedure. When a hot work permit has been issued, a
cold work permit is not required for the same craft for the same job. A group permit may
be issued when a job is known to require more than one craft and the work is under the
control of the area maintenance supervisor.
3.3.2. Cutting, burning, welding, producing sparks, etc., will require a dedicated fire watch.
3.3.2.1. Additional fire watches may be required based on the hazards of the work
being performed.
3.3.2.2. A fire watch shall be maintained for at least a half-hour after completion of
welding or cutting operations if combustible materials are present and have
the possibility to flare up. This is to detect and extinguish possible
smoldering fires.
3.3.2.3. Fire watch personnel will wear a red/orange vest for identification.
3.3.3. Adequate firefighting equipment (water hose and/or, fire extinguisher and/or, fire resistant
shield/blanket, etc.) must be maintained while the hot work is in progress. In all cases, at
least a minimum 20 lbs. fire extinguisher will be required. When making this designation,
the class of fire extinguisher should be made as well. The extinguisher shall have a
clearly labeled class designation on it. Many extinguishers cover multiple classes. For
example, some cover classes A and B, some cover class B and C, some cover A, B and
C.
3.3.3.1. Class A fires include fires that involve wood, paper, cloth, etc….
3.3.3.2. Class B fires include fires that involve combustible liquids such as gasoline.
3.3.3.3. Class C fires involve energized electrical equipment. If electrical energy has
been removed from equipment, it can be treated as class A.
3.3.3.4. Class D fires are fires that involve combustible metals (ex. Titanium).
3.3.3.5. Class K extinguishers are intended for deep fryers. They are also safe to
use on class C fires. Use of a class K extinguisher is unlikely.
3.3.4. Identification of a readily available fire extinguisher should be completed during the JJSV
and documented on the SWP and/or JSA. The work party must be well aware of the
location of the fire extinguisher to be used in an emergency.
3.3.4.1. The Servicing Group shall provide fire extinguishers for all attended hot work.
3.3.4.2. Outside of process areas (OSBL), the Servicing Group shall provide fire
extinguishers for all hot work (attended & unattended).
3.3.4.3. In process areas, it may be acceptable to use the unit operations fire
extinguishers in some cases for unattended hot work with the Owning
Departments approval. The fire extinguisher shall be left in its stored location
unless needed for a fire emergency.
3.3.5. When cutting with a torch, welding or grinding, evaluate the impacted area of hot
slag/sparks and protect sewer openings, doorways, man ways, cracks in flooring, areas
of employee foot traffic, etc., within 35’. Employees must set up the work site to achieve
100% spark containment at the welding/cutting location with the use of fire blanketing or
other fire resistant material.
3.3.5.1. Note: All fire/welding blankets shall be FM Approved.
3.3.6. The site preparation shall comply with other applicable Galveston Bay Refinery
procedures/standards (e.g., safe work permitting, energy isolation, confined space, etc.).
3.3.7. Atmospheric testing must be performed in the immediate area following the guidelines set
forth in the GBR PR-3 Safe Work Permit Procedure and recorded in the appropriated
section of the Safe Work Permit. At times, depending on the hazard and conditions,
continuous monitoring may be required. This is to be determined by the Owning
Department in conjunction with the appropriate Maintenance Coordinator.
Acceptable conditions are as follows:
3.3.7.1. Oxygen concentration between 19.5% and 23.5%

3.3.7.2. LEL concentration of 0 – 10% (Confined Space is 0%)
3.3.7.3. CO concentration of 25 ppm or less
3.3.7.4. H2S concentration of less than 10 ppm
NOTE: Other materials may have to be tested for on a case by case basis. Some gases
considered toxic (not all inclusive) are: Hydrogen Sulfide (H2S), Carbon
Monoxide (CO), Sulfur Dioxide (SO2), Ammonia (NH3), Sulfuric Acid (H2SO4),
Hydrochloric Acid (HCl). For more information, see GBR PR-1 Confined Space
Entry and GBR PPE-5 Respiratory Protection.
NOTE: Combustible dust shall be cleaned from the immediate vicinity of the hot work
operations. This includes equipment, machines, overhead structures and floors.
NOTE: Though sewers, drains and like areas are to be identified and covered with
adequate fire resistant drain covers/shielding, these points are to be included as
part of the thorough atmospheric test of the hot work area.
3.3.8. Prior to the use of any atmospheric testing equipment, users must assure themselves
that the instrument is properly calibrated and in good working condition. For more
information see GBR EQ-7 Portable Gas Testing.
3.3.9. Gas tests will be made after all blinding, disconnecting, purging, steaming and other
preparatory work has been completed and in as short a time as practical prior to the start
of work. In every instance a test must be taken within two hours prior to the start of work.
When work is not started within two hours of the time the gas tests were taken, another
test must be made with results shown and initialed by the person making the second test.
3.3.10. Continuous monitoring with a gas testing instrument may be deemed necessary to
continuously monitor the hot work site. Continuous monitoring is required if attended hot
work is performed on a live unit or within 35 feet of live process equipment.
3.3.10.1. If continuous monitoring is conducted, a minimum of one, properly located,
gas testing instrument shall be provided at the work site prior to beginning
hot work.
3.3.10.2. Continuous monitors must have capability of alerting personnel remotely, or
personnel must be assigned to observe the continuous monitor.
3.3.11. All necessary isolations and related precautions must be completed prior to the
commencement of any hot work (e.g., de-energizing, locking and tagging, disconnecting,
blinding, de-pressured, plugging, purging, ventilating, flushing, or otherwise cleaning).
This is to help ensure that no hazard will be introduced or created by subsequent work.
3.3.12. No additional work activities such as sample catching, truck unloading of combustible or
flammable liquids, breaking into pipelines or equipment that contain combustible material,
etc., shall be permitted within a 35 foot radius of hot work in progress in an operating unit.
Consideration must be given to wind direction, etc.
3.3.13. Consideration must be given for barricading the area directly below the spark producing
work and area where there is a potently of sparks/slag falling. Barricading must comply
with GBR-HESS-EQ-09 Barricades.
3.3.14. In some cases, a water hose must be charged and ready to wet areas that may be
negatively impacted, where sewer covers/fire blanketing need to be kept wet or where
there is any possibility of combustible materials igniting by the hot work, falling sparks,
slag, etc. However, every effort must be made to remove combustible material in the
area of sparks/slag before this type of work is performed.
3.3.15. Effort must be made to route leads and hoses overhead and/or out of walkways to
prevent creating tripping hazards.
3.3.16. Ensure that heat conduction and/or heat radiation cannot occur through walls, roofs,
pipes, etc. and ignite nearby flammable or combustible materials. Consideration shall be
taken to break/disconnect adjacent lines and/or materials (e.g. steel members, pipes,
etc.) where heat from the hot work could be transmitted.
3.3.17. Ensure that all flammable materials are in appropriate storage area (e.g. cabinet, cage).
3.3.18. Ensure that fixed fire suppression systems have not been impaired. If one or more of
these systems must be taken out of service to accomplish the hot work, additional
portable or fixed fire protection equipment shall be available at the site.
3.3.19. The Owning Department shall discuss the scope and duration of the planned job with the
employees performing the hot work and conduct the appropriate joint job site visit. The
joint job site visit shall include verification of but is not limited to the above listed items.
3.3.20. When welding is suspended for a substantial period of time (e.g., lunch, breaks, shift
change, etc.) all electrodes are to be removed from their holders and the machine is to be
turned off and/or disconnected from its power source. For gas welding/burning in
confined spaces, torches and hoses must be removed from the vessel and/or
disconnected at the vessels.
3.4. Other/Miscellaneous
3.4.1. Hot work requiring burning, welding or open flames on any operating lines and equipment
in-service or not established as gas free shall be carefully reviewed by the Owning
Department Supervision or designee and Permit User Supervisor or designee as to the
necessity of the work. A Job Safety Analysis should be performed with all safety
precautions determined prior to work taking place.
NOTE: All in-service welds and hot taps must follow the GBR-HESS-PR-24 In-service
Welding and Hot Tapping Procedure.
NOTE: Welding on steam lines while under pressure shall require all precautionary
measures taken for similar work on oil and gas lines (e.g. in-service welds)
3.4.2. If there is any doubt as to whether any equipment is completely empty or gas free, holes
may be drilled with approval of the Owning Department, engineering, safety,
maintenance and/or inspection departments to establish safe working conditions. Repair
of drilled holes shall be considered prior to the approval for drilling.
3.4.3. If a line cannot be made gas free, the line may be cold cut if it has been emptied and
depressurized, the end of the line on which the hot work is to be performed shall be
sealed tight with mechanical plugs (car-ber, lansas, cherne, etc…) or by other suitable
means. The open end must be made gas free and any scale, etc., must be removed
before hot work begins.
3.4.4. The affected Owning Department Supervision or designee shall counter sign all hot work
permits involving the use of burning, welding, or open flames on any lines and operating
equipment not established as gas free. The job site shall be reviewed by the Owning
Department Supervision or designee to see that all precautionary measures have been
taken prior to signing the hot work permit. Close Owning Department supervision must
be maintained at all times. The Owning Department Supervision or designee shall
designate a representative to be responsible for surveillance.
3.4.5. Burning/cutting into lines or other equipment with spark/heat creating tools not known to
be oil-free and gas free is prohibited.
3.4.6. All out-of-service equipment (e.g. piping, towers, etc.) shall be isolated for hot work by
blinding, disconnecting or other acceptable means, and must be made gas-free by
steaming, washing or other accepted procedure before approval for hot work is given.
3.4.7. Hot work permits on lines connecting different Owning Departments shall be approved by
the foreman of both departments and/or their designated representatives.
3.4.8. Atmospheric storage tanks present unique hazards when out-of-service. Special attention
should be given to the floor, shell, roof, piping and hoses. Serving group shall take
appropriate precautions to confirm tank is hydrocarbon and gas free. Ensure product
residue, wax, and scale are cleaned before hot work is performed.
3.4.9. When work on empty tanks with floating roofs is required, special precautions shall be
made to ensure that all pontoon compartments as well as the tank seals are completely
gas free before a hot work permit is issued. Personnel should be instructed to stay clear
of roof vent hatches.
3.4.10. The opening of in-service explosion-proof enclosures (e.g. opening electrical junction
boxes) requires a hot work permit.
3.4.11. Demister pads in vessels shall be removed prior to hot work if they pose a hazard due to
the work activity being performed.
3.4.12. Structured packing shall be removed prior to hot work if it poses a hazard from hot work
activity (or precautions shall be put in place to mitigate sparks or slag from contacting the
packing).
3.4.13. At times during maintenance and construction it is necessary to erect and/or establish
temporary fabrication areas. The following guidelines shall be adhered to when
considering the establishment of such an area.
3.4.13.1. MPC Facility Siting Coordinator and the Contractor Coordinator (Job Rep)
shall refer to GBR RGD-PS-000011-PS Building and Tent Siting for all
temporary fabrication areas required for work.
3.4.13.2. Standard refinery PPE must be worn in the area. Spark producing hot work
will require the use of the appropriate face shield, goggles, gloves, welders
PPE, etc.
3.4.13.3. Work in temporary fab areas is considered hot work (attended) and should
be permitted as such.
3.4.13.4. If the fab shop is an existing building, it must be well ventilated and have
exits appropriately marked with emergency exit signs. Temporary
enclosures must have adequate ventilation as well. Continuous air
monitoring may be required.
3.4.13.5. As always, the cleanliness of the area must be maintained. Housekeeping
must be addressed on every shift.
NOTE: Information regarding compressed gas cylinders, their use, storage, handling
and other requirements can be found in 3.6 – Compressed Gas Cylinders
3.5. Temporary Portable Pumps
3.5.1. The Proceduralized Management of Change (PMOC Installation of Temporary Portable
Pumps) must be completed prior to the start-up of any portable pump used to pump
hydrocarbons inside tank dikes or unit battery limits.
3.5.2. Temporary non-intrinsically safe pumps used to pump hydrocarbons that are located
inside tank dikes or unit battery limits must be manned at all times while in operation and
equipped with a remote shutdown device (e.g., lanyard, electronic shutoff, disconnect
switch, fuel shutoff valve, etc.).
3.5.3. Temporary portable pumps shall not be used for pumps in hydrofluoric acid service.
3.6. Hot Bolting/Flange Tightening
3.6.1. Tightening Leaking Flanges or Connections
3.6.1.1. If a flange is leaking but not in amounts enough to give a combustible

reading (LEL), a hot work permit will be issued. The method of hot bolting,
use brass or non-sparking tools.
3.6.1.2. If a flange or connection is leaking enough hydrocarbon liquid or vapor and
combustible readings are detected, again, a hot work permit is necessary but
with stipulations on method used, such as:
3.6.1.2.1. Lower the LEL in the immediate work area to acceptable limits.
3.6.1.2.2. Use steam, inert gas, ventilation, etc., whatever acceptable
means is necessary.
3.6.1.2.3. Fire watch with continuous monitoring, steam hose, fire
extinguisher, etc., on hand.
3.6.1.2.4. Area barricaded and secured against non-essential traffic.
3.6.1.2.5. Sewers covered in case of possible ignition.
3.6.1.3. If a flange or connection is leaking and in a unit or process area where gas
has escaped from some other source, but not enough to create an explosive
or ignitable atmosphere, then a hot work permit is necessary and again, all
conditions listed under 3.5.1.2 must be followed.
3.6.1.4. If a hazardous but non-combustible leak develops, such as steam, acid,
caustic, amine, chemical injection, etc., other special precautions are
required, such as, but not limited to, acid suits, gloves, face shields, goggles,
rubber boots and possibly breathing air.
NOTE: Some leaks may be too excessive and may not be able to be handled under
these hot bolting guidelines. Some cases may require unit shut down or isolation
of the leaking equipment or flange.
3.6.2. Loosening
3.6.2.1. If a unit is shut down, it may be necessary to hot bolt flanges for blinding and
man ways on towers for opening. In cases where units are totally
hydrocarbon free and, depressurized a cold work permit may be issued for
the above-described work. In this case, hammers and wrenches may be
used. If impact wrenches are necessary, a hot work permit must be issued.
Owning Department supervision will notify Maintenance personnel as to
when hot bolting may be performed. Maintenance and Owning Department
supervision shall determine how many bolts may be removed safely.
3.6.2.2. If the unit is shut down, but not totally hydrocarbon free, a hot work permit will
be necessary for any hot bolting or loosening of flanges. The hot work permit
must stipulate what tools (brass or non-sparking etc.) are allowed to be used
and any other special safety precautions that must be followed. Bolts shall
not be removed in a pattern that allows the gasket to fall out or become
dislodged when draining lines by flange separation. Attachment A Flange
Bolt Removal Guideline shall be followed when removing bolts on live
equipment.
3.6.2.3. If no hydrocarbon is detected at the work site but the vessel or flange
contains hydrocarbon, a hot work permit will be necessary due to area
conditions. Impact wrenches and/or hammer wrenches can be utilized for
four bolting. When removing the last four bolts, or the number of bolts
specified by Maintenance and Owning Department supervision, other
methods of unbolting that do not create sparks will be necessary.
3.6.2.4. If it is unknown whether the vessel or piping is gas free, the conditions
specified in 3.5.2.3 must be followed, and perhaps others upon discussion
with appropriate Owning Department supervision and maintenance
representatives.
3.6.3. See SP-50-16 Bolted Joints in Piping and Fixed Equipment, Appendix B of ASME PCC-1
and ASME PCC-2 for further guidance.
3.7. Compressed Gas Cylinders
Compressed gas cylinders shall be used, handled, transported and stored in accordance with
HESS Practice EQ-1 Compressed Gas Cylinders
3.8. Training
3.8.1. Training must be provided initially and periodically for all employees, whose assignment
may involve hot work. The training must instruct employees in the procedures to be
followed to minimize potential hazards.
3.8.2. Supervisors are responsible for ensuring that all employees have had the proper training
prior to any assignment as a permit issuer, supervisor, fire watch, and any other specific
training relevant to that specific aspect of hot work.
4.0 Definitions
4.1. Blinding – The absolute closure of a pipe, line or duct by installing a slip blind (spade), plug or
cap which completely covers the opening, which extends at least to the outer edge of a flange’s
mating surfaces, and which is capable of withstanding the maximum upstream system pressure.
A blank, slip blind, blind flange, cap, and/or physical disconnect are all considered to be blinds.
4.2. Bonding – The joining of metallic parts with an adequately sized conductor to form an electrically
conductive path which will ensure electrical continuity and the capacity to safely conduct any
current likely to be imposed.
4.3. Electrical Area Classifications – Class I locations are those in which flammable gases or
vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable
mixtures. Class I locations shall include those specified below.
4.3.1. Class I, Division I – A location in which ignitable concentrations of flammable gases or
vapors can exist under normal operating conditions, or in which ignitable concentrations
of such gases or vapors may exist frequently because of repair or maintenance
operations, because of leakage, or in which breakdown or faulty operation of equipment
or processes might release ignitable concentrations of flammable gases or vapors, and
might also cause simultaneous failure of electric equipment.
4.3.2. Class I, Division II – A location in which volatile flammable liquids or flammable gases are
handled, processed or used, but in which the liquids, vapors, or gases will normally be
confined within closed containers or closed systems from which they can escape only in
case of accidental rupture or breakdown of such containers or systems, or in case of
abnormal operation of equipment.
A location in which ignitable concentrations of gases or vapors are normally prevented by
positive mechanical ventilation, and which might become hazardous through failure or
abnormal operation of the ventilating equipment.
A location that is adjacent to a Class I, Division I location, and to which ignitable

concentrations of gases or vapors might occasionally be communicated unless such
communication is prevented by adequate positive pressure ventilation from a source of
clean air, and effective safeguards against ventilation failure are provided.
4.4. Half Bolting – The removal of every other bolt (so the flange is left with half the number of bolts)
during plant depressurization, usually when the system is close to atmospheric pressure. Note
that half bolting is also referred to as odd-bolting or skip-bolting. See SP-50-16 Bolted Joints in
Piping and Fixed Equipment,, Appendix B of ASME PCC-1 and see ASME PCC-2 for further
guidance. (Consult with engineering support if any questions cannot be answered by the
Maintenance and Operations team planning, permitting, and performing the work.) A variance
shall be required if half bolting outside the maximum pressure allowances in Attachment A Flange
Bolt Removal Guideline.
4.5. Hot Bolting – The sequential removal and replacement of bolts on flanged joints while the unit is
under REDUCED operating pressure. The procedure generally consists of removing one bolt at a
time in a predetermined cross pattern sequence, relubricating it, reinstalling it (or a new bolt), and
retightening it to a specified torque before the next one is removed. See SP-50-16 Bolted Joints in
Piping and Fixed Equipment, Appendix B of ASME PCC-1 and ASME PCC-2 for further guidance.
A variance shall be required if hot bolting outside the maximum pressure allowances in Attachment
A Flange Bolt Removal Guideline.
4.6. Hot Work – is repair, maintenance or construction activity, which requires the use of spark-
producing equipment or open flame. All work requires a gas test and the presence of a fire
extinguisher. However, some forms of hot work require a dedicated fire watch (attended) while
other forms do not (not attended). Examples of those that require a fire watch (attended) include:
• Acetylene burning, welding and brazing.
• Electric arc welding.
• Annealing / Stress relieving ~ electric or gas.
• Use of open flames.
• Use of propane or gas fired heaters or boilers.
• Chipping, ripping, breaking, or sawing concrete or refractory.
• Cutting and grinding using a Metabo, Tiger wheel, or similar tool.
• Electric soldering.
Hot work examples that do not require a fire watch or dedicated fire extinguisher (not
attended) includes:
• Vehicle entry.
• Use of non-explosion-proof electric equipment/ Non-Intrinsically Safe
Electric and Battery powered tools
• Use of air-powered impact wrenches.
• Use of Powder Actuated tools.
• Use of gasoline- or diesel-powered engines (compressors, pumps, generators, power
washers, etc.).
• Opening of in-service explosion-proof enclosures.
• Abrasive blasting using sand and other media.
• Grass cutting inside diked areas.
• Breaking or Sawing concrete (wet method)
NOTE: Hot tapping and welding on lines or equipment under pressure or not gas-free requires a
special permit following the requirements of the GBR-HESS-PR-24 In-service Welding
and Hot Tapping Procedure.
4.7. Inerting – The displacement of the atmosphere in a permit space, or other equipment, by a
noncombustible gas (such as nitrogen) to such an extent that the resulting atmosphere will not
support combustion.
5.0 References
5.1. OSHA 29 CFR 1910.252(a) – General Requirements for Welding, Cutting, and Brazing
5.2. GBR PR-3 Safe Work Permit Practice
5.3. GBR PR14 Energy Isolation
5.4. GBR PR-15 Blinding/Line Breaking Requirements
5.5. GBR EQ-7 Portable Gas Testing
5.6. GBR PPE-5 Respiratory Protection
5.7. GBR-HESS-PR-24 In-service Welding and Hot Tapping Procedure
5.8. GBR RGD-PS-000011-PS Building and Tent Siting
5.9. PMOC Installation of Temporary Portable Pumps
6.0 Attachments
6.1. Attachment A – Flange Bolt Removal Guideline
7.0 Revisions History
Revision Revision Effective

Description of Change Written by Approved by
Number Date Date
Original Issue. Consolidated site procedure

0 that replaces GBR-HESS-PR-02 and K. M. McBride D. C. Staats 6/1/2018 11/26/2018
RSW-0067-TC under MOC 51281.
Technical Revision: Updated 3.6.2.2,

1 Attachment A, 4.4, and 4.5 per C. T. Lamb V. J. Meeks 2/20/219 2/20/2019
R20181256-005 INC-166362.
Updated to align with GBR RGD-PS-

2 B. Huerta V. J. Meeks 11/13/2019 12/17/2019
000011-PS (integrated under MOC 33609).
Updated to align with in-service bolting

3 activity requirements with SP-50-16 per C. T. Lamb V. J. Meeks 3/26/2020 3/27/2020
PSA 19-03.
Attachment A Flange Removal Guideline
Notes:
(1) Bolts shall not be removed in a pattern that allows the gasket to fall out or become dislodged when draining lines by flange separation.
(2) See SP-50-16 Bolted Joints in Piping and Fixed Equipment, Appendix B of ASME PCC-1 and see ASME PCC-2 for further guidance. (Consult with engineering support if any questions cannot be answered by the
Maintenance and Operations team planning, permitting, and performing the work.)
(3) > 50% MAWP shall require an engineering and risk analysis per PCC-2
(4) A variance shall be required in order to do half bolting or hot bolting outside the maximum pressure allowances in Attachment A Flange Bolt Removal Guideline.
Flange Bolt Removal Guideline

Applicable to 8-Bolt Flanges or Greater
Joint Integrity Must
Be Maintained
Normal Operating
Temperature & Pressure Joint Integrity
Pressure SHALL NOT exceed 50% of flange MAWP. May be Lost
(Note 3)
Pressure Temperature
Max Pressure (psig)

Temp
By Flange Rating
(oF)
150# 300# 600#
100 143 370 740
200 130 338 675
115# Steaming, Water Washing,
300 115 328 658 PR-14 SIRP in Progress.
Chemical Flushing, Etc
Process Fluids Isolated
400 100 318 635
and Locked Out
500 85 300 600
>500 Flange Bolt Stress Calculation Max Pressure = 50 psig or 25%
of MAWP whichever is lower
Process
Process Residual
Fluid
Fluid Process Fluid
Remove / Replace Flange Bolt Every other Bolt All But Four Bolts
One Bolt At A Time Stress Calculation May Be Removed May Be Removed
Printed copies should be used with caution. The user of this document must ensure that the current approved version of the document is used.

Hot Work Permit Procedure

Uploaded by

Copyright:

Available Formats

Hot Work Permit Procedure

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hot Work Permit Procedure

Uploaded by

Copyright:

Available Formats

Authored By: Blanchard Refining Company LLC Doc No.

Printed 3/27/2020 RSW- 000029-GB.docx Page 1 of 15

3.1.1.9. Be competent (by virtue of training or experience) in the field on calibration

3.1.1.10. Communicate to relief, any ongoing hot work in their area.

3.1.3. MPC Supervision/Contractor Coordinators/Contractor Management

Printed 3/27/2020 RSW- 000029-GB.docx Page 3 of 15

Printed 3/27/2020 RSW- 000029-GB.docx Page 4 of 15

3.1.5.3. Determine when testing and/or monitoring is required to demonstrate the

Printed 3/27/2020 RSW- 000029-GB.docx Page 5 of 15

positioning of such equipment must be treated as unattended hot work, included in

Printed 3/27/2020 RSW- 000029-GB.docx Page 6 of 15

3.3.7.1. Oxygen concentration between 19.5% and 23.5%

Printed 3/27/2020 RSW- 000029-GB.docx Page 7 of 15

Printed 3/27/2020 RSW- 000029-GB.docx Page 8 of 15

Printed 3/27/2020 RSW- 000029-GB.docx Page 9 of 15

Printed 3/27/2020 RSW- 000029-GB.docx Page 10 of 15

3.6.1.1. If a flange is leaking but not in amounts enough to give a combustible

Printed 3/27/2020 RSW- 000029-GB.docx Page 11 of 15

A location that is adjacent to a Class I, Division I location, and to which ignitable

Printed 3/27/2020 RSW- 000029-GB.docx Page 12 of 15

Printed 3/27/2020 RSW- 000029-GB.docx Page 13 of 15

7.0 Revisions History

Revision Revision Effective

Original Issue. Consolidated site procedure

Technical Revision: Updated 3.6.2.2,

Updated to align with GBR RGD-PS-

Updated to align with in-service bolting

Printed 3/27/2020 RSW- 000029-GB.docx Page 14 of 15

Attachment A Flange Removal Guideline

Flange Bolt Removal Guideline

Max Pressure (psig)

Printed 3/27/2020 RSW- 000029-GB.docx Page 15 of 15

You might also like