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KHANBOOLI ELECTROMECHANICAL
CONTRACTING LLC

Hot Work
Procedure

Role Name Designation Date Rev

Prepared By Jawad Ali HSE ENIGINEER 01-08-2023
Reviewed By Shankara GENERAL 04-08-2023
Narayanan MANAGER
Approved BY H. Parkar EXECUTIVE 06-08-2023
DRIECTOR
Approved By Engr. Fadhil MANAGING 06-08-2023
DIRECTOR
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TABLE OF CONTENTS
Contents
1 Acronyms/Abbreviations andDefinitions ................................................................ 4
1.1 Abbreviations................................................................................................ 4
1.2 Definitions .................................................................................................... 4
2. Purpose .............................................................................................................. 6
5.1 ProjectDirector ............................................................................................... 6
5.2 HSE Manager ...................................................................................................... 6
5.3 Site Manager/Engineer/Supervisor ........................................................................... 7
5.4 Employees.......................................................................................................... 7
5.5 Welders ............................................................................................................. 8
5.6 Fire Watchers ...................................................................................................... 8
6.1 General Requirements ..................................................................................... 8
6.2 Fire Prevention Measures ................................................................................. 10
6.3 Site Preparation .............................................................................................. 10
6.4 Ventilation ..................................................................................................... 11
6.5 Personal Protective Equipment:.......................................................................... 11
6.6 Fire Watch Requirements.................................................................................. 13
6.7 First Aid Equipment ......................................................................................... 13
7. Hot Work in Confined Space ............................................................................... 15
7.1 Fire Protection .............................................................................................. 16
7.2 Fumes, Gases and Dust.................................................................................... 16
8.1 OxygenFuelGas Welding andCutting .................................................................. 18
Start-Up ................................................................................................................ 18
ShutDown ............................................................................................................. 19
9.1 InertGas MetalArc Welding .............................................................................. 20
2 Electric Arc Welding and Cutting ......................................................................... 25
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3 Gas Cylinders ...................................................................................................... 26

Appendix A: Hot Work Permit

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1 Acronyms/Abbreviations and
Definitions
1.1 Abbreviations
LOTO Lock Out Tag Out

PTW Permit to Work

RP Responsible Person

IA Issuing Authority

JP Job Performer

PR Permit Receiver

AA Area Authority

CEMP Construction Environment Management Plan

1.2 Definitions
Employer
Project

Contractor khanbooli Electromechanical Contracting LLC (KEMCO)

Directorate Project Director, Manager Planning & Controls and the
Construction DirectorSteering Committee Board of JV Companies Representatives

Vendor/ Supplier Supplier of materials, equipment, services suppliers’ subject to a Purchase

Order.
Sub-Contractor In the scope of the present procedure, the terms indicate some
portion/ segmentof the project works to be carried out by Sub-
Contractors as per Subcontract agreement in between Contractor and
the Sub-Contractor/ Sub-Consultant.

Hot Works Any work that produces open flames, hot slag or sparks. Hot works shall define
as cutting, welding, brazing, soldering, grinding, and or any other similar
situation.
Combustible A material capable of sustained burning when ignited and in the presence of air.
Flammable A liquid having a flashpoint below 37oC.
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Fire Watch A person who has been trained to monitor the work area for unwanted fires
during and for 30 minutes after the completion of hot work, and to prevent any
such fires should they occur.
Ignition Source A source of energy sufficient to ignite a flammable atmosphere. Such sources
include, but are not limited to, flames, incandescent material, electrical spark,
hot surfaces and mechanical sparks.
Hot work permit A hot work permit is a written document that entitles to perform hot work at a
temporary hot work site. Granting a hot work permit requires that risks have
been identified and assessed, and necessary safety precautions defined.
Designated Hot Are places such as in workshops where flammable and combustible materials
Work Areas have been removed, compressed gas cylinders are secured and located at least
15 feet away from the actual hot work, ventilation considerations have been
made, fire extinguishing equipment is available, welding screens, where
applicable, are in place to protect other workers in the area, and the area has
been posted as a hot works area by KEMCO management
Flash Point The temperature at which a particular organic compound gives off sufficient
vapors to ignite in air.

Local Exhaust A ventilation system that captures and removes the contaminants at the point
Ventilation they are being produced before they escape into the worksite.
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2. Purpose
Hot work operation procedure establishes the minimum safe working guidelines for the operation
cutting, welding, brazing, grinding and soldering or any other similar operation (Hot Work)
throughout the KEMCO project. It also covers the control of ignition sources such as spark-
producing tools and devices in hazardous areas. The program meets the basic requirements of the
local regulations.

3. Scope
This procedure is applicable to KEMCO employees including all Sub-contractor, or any other party
engaged by the KEMCO on project.

4. Reference Documents
OSHAD-SF-CoP-28.0 Hot works operations (e.g. welding and cutting).

Project HSE Plan

Emergency Response Plan

Permit to work

5. Responsibilities
5.1 Project Director
KEMCO Project Director shall responsible to:
6. Provide the required sources to implement the hot work procedure across the project.
7. Ensuring that there are arrangements for identifying, evaluating and managing risk associated
with hot work;
8. To provide, as far as is practical, a safe working environment for hot work employees;
9. Ensuring that there are arrangements for monitoring incidents linked to hot working and that
the trust regularly reviews the effectiveness of this procedure.

5.2 HSE Manager

KEMCO HSE manger is responsible to implement and monitor the procedure across the project
and shall monitor the effectiveness of this procedure.
• Putting procedures and safe systems of work into practice which are designed to eliminate or
reduce the risks associated with hot work operations;
• Ensuring that staff groups and individuals identified as being at risk are given appropriate
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information, instruction and training;

• Ensuring that the hot work risk assessment is communicated to all staff members involved in
the activities and keeping signed documentary evidence that those employees have read and
understood the risk assessment and will comply with the control measures put in place for
their safety;

5.3 Site Manager/Engineer/Supervisor

KEMCO site and HSE management shall coordinate with management to implement the
procedure across the project.
Managers, Engineers and Supervisors shall ensure that:
• Determine if property is safe for welding and cutting/hot work operations;
• Welding/cutting/hot work operations are performed in designated areas by trained and
authorized personnel only;
• Risk assessment has been conducted prior to start the hot work at site;
• All hot work are planned and supervised properly;
• Provide training for all employees whose task includes heat, spark or flame producing
operations such as welding, brazing, or grinding;
• Develop and monitor effective hot work procedures;
• Provide safe equipment for hot work;
• Provide the correct and effective PPE for all hot work;
• Monitor all hot work operations;
• All hot work equipment and PPE are in safe working order;
• Allow only trained and authorized employees to conduct hot work and conduct inspections
of the hot work area before operations begin;
• Permits are used for all hot work;
• Designate approved welding/cutting/hot work areas on their project;
• Advise sub-contractors about flammable materials or hazardous conditions of which the sub-
contractors may not be aware, and select cutting/welding/hot work workers with
appropriately trained personnel who understand the risks involved;
• This procedure is adhered to during all hot work, welding and cutting operations;
• Maintain hot work permit records on site;
• All record shall be maintained by KEMCO plant dept. for the equipment’s and plant for audit
purpose.

5.4 Employees
All employees shall cooperate with KEMCO management and other persons in complying with
the safety legislation and guidelines, and shall not do anything to endanger themselves and other
persons.
Employees Involve in Hot Work
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• Follow all hot work procedures;

• Use correct hot work PPE;
• Inspect all hot work equipment before use;
• Report any equipment problems or unsafe conditions immediately.

5.5 Welders
• Perform hot work, welding and cutting operations in designated areas only;
• Obtain an approved hot work permit prior to performing welding or cutting operations;
• Required PPE shall be worn all the time at site;
• Report any injury, including suspected flash burns, to KEMCO supervisor immediately;
• Report any equipment problems or unsafe conditions immediately.

5.6 Fire Watchers

• Will be trained and competent in the use of fire extinguishing equipment
• Will be aware of alarm locations in the event of a fire
• Watch for fires in all exposed areas, and extinguish them within the capacity of equipment
available and report incident to KEMCO supervisors/management
• Maintain continuous fire watch for at least 1 hour after completion of hot works, welding or
cutting operations
• Report any injury, including suspected flash burns, to KEMCO supervisor immediately
• Report any equipment problems or unsafe conditions immediately

6. Hot Work Procedure & Requirements

6.1 General Requirements
• Supervisors and workers performing hot works shall be trained in hazard recognition,
evaluation, and control, fire protection, and safe work practices, and shall adhere to
requirements in this procedure;
• Hot work should be performed in areas that are isolated and designated for such uses;
• Whenever hot works operations are interrupted for a substantial period of time (e.g., lunch
or overnight) or completed, "hot" metal areas must be identified, and the equipment must
be shut off with any valves closed;
• “Hot metal areas: shall be barricaded and safety signage shall be displayed to warn the
personal working around concerning hazards.
• All hot work areas shall be barricaded and safety signage shall be displayed to prevent the
unauthorized entry especially operation interrupted period (e.g. lunch or overnight).
• Personnel are required to use the hot works equipment according to the manufacturer’s
instructions. Such equipment shall be maintained in safe working order at all times. Personnel
shall report any equipment defect or safety hazard to a supervisor, and the use of such
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equipment must be discontinued until it is repaired by qualified personnel;

• Prior to beginning welding or cutting operations, operatives must adhere to the procedure
outlined below;
– Cutting or welding operations must be performed in areas with adequate ventilation to
keep fumes and gases out from the task area;
– Provided personal protective equipment (PPE) must be worn by all employees
performing or assisting in welding and/or cutting operations.
– Electrical equipment and plant shall be approved by KEMCO plant and electrical dept.
prior to use;
– Only KEMCO competent person (electrician/mechanic) is authorized carry out the
quarterly inspection of the equipment/plant and shall issue the inspection tag;
– KEMCO colour code system shall be applied to identify the equipment/plant is safe for
use or not;
– A record of the inspection of the equipment will be made in the hot works permit for
the period between the quarterly inspections.
In addition:
• Before cutting or welding is permitted, the area shall be inspected by a supervisor responsible
and only allow the hot works to proceed once satisfied that the necessary control measures
are in place;
• No welding or cutting operations commence until a hot work permit has been approved and
issued for the specific work; refer to KEMCO permit to work procedure
• Where practicable all combustibles shall be relocated at least 35 feet from the work site.
Where relocation is impractical, combustibles shall be protected with flameproof covers,
shielded with metal, guards, curtains, or wet down the material to help prevent ignition of
material and fire watcher shall be provided to monitor the task and after task shall take care
for 1 hour.
• Ducts, conveyor systems, and augers that might carry sparks to distant combustibles must be
protected or shut down;
• Where cutting or welding is done near walls, partitions, ceilings, or openings in the floor
(grating, manholes, etc.), fire-resistant shields or guards must be provided to prevent ignition;
• If welding is to be done on a metal wall, partition, ceiling, or solid decking/flooring,
precautions shall be taken to prevent ignition of combustibles on the other side, due to
conduction or radiation of heat. Where combustibles cannot be relocated on the opposite
side of the work, a fire watch person shall be provided on the opposite side of the work;
• Welding must not be attempted on a metal partition, wall, and ceiling or decking/flooring
constructed of combustible sandwich panels;
• Cutting or welding on pipes or other metal in contact with combustible walls, partitions, floors,
ceilings, or roofs must not be undertaken if the work is close enough to cause ignition by
combustion.
Hot works shall not be permitted in the following situations:
• In areas not authorized by management;
• In sprinkled buildings while such protection is impaired;
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• In the presence of potentially explosive atmospheres;

• In areas near the storage of large quantities of exposed, readily ignitable materials;
• In areas where there is dust accumulation of greater than 1/16 inch within 35 feet of the
area where welding/hot work will be conducted;

6.2 Fire Prevention Measures

• Portable welding curtains or shields must be used to protect other workers in the welding area;
• A hot-work permit must be completed and adhered to prior to initiating welding operations
refer to Appendix A;
• Flammable and combustible liquids and material will be kept 35 feet from hot work area;
• Respiratory protection must be provided if an adequate monitored airflow away from
the welder cannot be achieved;
• Plastic materials must be covered with welding tarps during welding operations;
• Once welding operations are completed, the welder shall mark the hot metal or provide
some other means of warning other workers.
• Suitable fire protection equipment must be maintained ready for use at all times that hot
work, welding or cutting operations are being performed;
• Suitable fire extinguishers shall be provided and maintained ready for instant use;
• A fire watch must be established whenever welding or cutting is performed in locations
where other than a minor fire might develop.
• A continuous fire watch shall be provided during and for a minimum of 1 hour past the
completion of the welding project;
• The fire watch shall be trained in the use of fire extinguishers and the projects alarm system;
• During this time the fire watch will have appropriate fire extinguishers readily available;
• When performing welding or cutting operations on coated surfaces that are highly flammable
(determined by a flammability test), the coating must be stripped from the area to prevent
ignition before any welding or cutting operation is commenced.

6.3 Site Preparation

Prior to beginning welding or cutting operations, workers must:
• Check the work area (35' radius) to ensure that no fire hazards including oily or greasy
materials are present;
• Remove all combustible materials within 35’ not necessary for the operation. Any combustible
material
that cannot be removed, such as wood platforms, should be covered with a flame-resistant material;
• Check that all equipment is in good working condition;
• Suitable curtains/shields shall be provided to cover the combustible present nearby;
• Fire extinguishers shall be provided near the task to use in case of fire;
• The metal surface shall be free of all chlorinated solvents during any welding or cutting operations.
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6.4 Ventilation
Cutting or welding operations must be performed in areas with adequate ventilation to keep
fumes and gases out from the task area. A gas monitor will be used to monitor the area where a
risk of fume/gas build up is identified.
• Local exhaust ventilation must be used when potentially hazardous materials are being
worked on. (Examples of potentially hazardous materials include, but are not limited to,
chromium, fluorides, zinc, beryllium, cadmium, lead, and mercury);
• Adequate exhaust ventilation must be used when using inert-gas welding, plasma-arc cutting
or carbon-arc cutting;

6.5 Personal Protective

Equipment:
Provided personal protective equipment (PPE) shall be worn by all employees performing or
assisting in welding and/or cutting operations.
• Examples of PPE include eye protection, helmets and hand shields, flame resistant gloves,
limb/body protection, apron and respiratory protection;
• While performing overhead or vertical welding, personnel must wear leather personal
protective equipment (shoulder, head, and ear covers);
• All welders must wear flame-resistant aprons, coveralls, gauntlet gloves and shirts with
sleeves of sufficient length and construction to protect the arms from heat, UV radiation, and
sparks;
• Wool and leather clothing are preferred because they are more resistant to deterioration and
flame than cotton or synthetics. Synthetic fibre clothing should not be worn unless it is
specifically manufactured to be fire retardant;
• Clothing must be kept reasonably free of oil or grease;
• Front pockets and upturned sleeves or cuffs are prohibited. Sleeves and collars should be
kept buttoned and high boots should be worn under pant legs (or leggings worn) to prevent
hot metal slag or sparks from contacting the shin;
• Personnel must wear respiratory protection when ventilation is not sufficient to prevent
exposure above permissible limits. (When performing cutting or welding operations involving
coatings which generate toxic substances upon heating, or working with materials that
contain beryllium, cadmium, lead, or mercury, personnel must wear supplied-air respirators);
• Workers welding on metal alloys should wear work uniforms, coveralls, or similar full-body
coverings that are laundered each day. Lockers or other closed areas should be provided to
store work and street clothing separately;
• Other personnel in welding/cutting areas not protected by non-combustible or flameproof
screens or shields must wear appropriate goggles;
• Lenses shall bear some permanent distinctive marking which may readily identify the source and
shade.
The following is a guide for the selection of the proper shade numbers. These recommendations
may be varied to suit the individual's needs.
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Table 1: Face Shield Lens Shade Numbers of Different Hot Work

Welding Operation Shade Number

Shielded metal — arc welding 1/16, 3/32, 1/8-5/32 inch electrodes 10

Gas-shielded arc welding (nonferrous) 1/16, 3/32, 5/32 inch electrodes 11

Gas-shielded arc welding (ferrous) 1/16, 3/32, 1/8, 5/32 electrodes 12

7/32,1/4 inch electrodes 12

Shielded metal arc welding: 3/16
5/16, 3/8-inch electrodes 14

Atomic hydrogen welding 10 – 14

Carbon arc welding 14

Soldering 2

Torch brazing 3 or 4

Light cutting, hp to 1 inch 3 or 4

Medium cutting, 1 inch to 6 inches 4 or 5

Healy cutting, 6 inches or over 5 or 6

Gas welding (light) up to 1/8 inch 4 or 5

Gas welding (medium) 1/8 - 1/2 inch 5 or 6

Gas welding (heavy) 1/2 inch or over 6 or 8

Welding Gloves EN 12477

This standard describes how the gloves are designed to provide protection for both hand and wrist
while welding or similar work, this is a combination from testing EN 388 and EN 407. Welding gloves
shall provide resistance to small splashes of molten metal, short exposure to convective heat, to
radiant heat and to contact heat. The welding gloves shall give protection from mechanical risks
as well.
Type A refers to gloves that shall provide a higher protection against heat.
Type B refers to gloves that provide a lower protection against heat but they are more flexible and
pliable.
EN 470-1:1995

Protective clothing for use in welding and allied processes. General

requirements Superseded by EN ISO 11611:2007.

ISO 11611:2007 specifies two classes with specific performance requirements, i.e. Class 1 being
the lower level and Class 2 the higher level.
• Class 1 is protection against less hazardous welding techniques and situations, causing lower
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levels of spatter and radiant heat.

• Class 2 is protection against more hazardous welding techniques and situations, causing
higher levels of spatter and radiant heat.
Note:
In gas welding or oxygen cutting where the torch produces a high yellow light, KEMCO will provide
to use a filter or lens that absorbs the yellow or sodium line in the visible light of the operation.
All filter lenses and plates shall meet the test for transmission of radiant energy prescribed by ANSI
Z87.1. Where the work permits the welder to be enclosed in an individual booth painted with a
finish of low reflectivity such as zinc oxide (an important factor for absorbing ultraviolet radiation)
and lamp black, or shall be enclosed with non-combustible screens similarly painted. Booths and
screens shall permit circulation of air at floor level. Workers or other persons adjacent to the
welding areas shall be protected from the rays by non-combustible or flameproof screens or
shields or shall be required to wear appropriate goggles.

6.6 Fire Watch Requirements

KEMCO fire watch will be under these conditions as a minimum:
• At all Locations where other than a minor fire might develop;
• Fire protection equipment must be maintained ready for use at all times that welding
or cutting operations are being performed;
• Where Combustible materials are closer than 35 feet to the point of operation;
• Where Combustibles that are 35 feet or more away but are easily ignited;
• Where Wall or floor openings within a 35 feet radius of exposed combustible materials;
• Where Combustible materials are adjacent to the opposite side of metal partitions, ceilings or
roofs;
• Fire watch personnel MUST be maintained at least an hour after welding or cutting
operations have been completed.

6.7 First Aid Equipment

First aid equipment shall be available at all times at all KEMCO work sites. All injuries shall be
reported as soon as possible for medical attention. First aid shall be rendered until medical
attention can be provided.
First Degree Burn: - Involved upper layer of skin
• keep the affected area in cold water or running water for 10-15 minutes
• Apply burn spray
Second Degree Burn: - Blisters present affected the second layer of skin

• Do not break the blister, dip in cold water for 10-15 minutes, apply Burnol ointment
• Dressing with burn dressing or sterile gauze pad
Third Degree Burn: - Affecting the muscles and inner layers
of skin Call 999 for further help.
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• HOT WORK FLOW CHART

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7. Hot Work in Confined Space

A Confined space is not only a space which is small and difficult to enter, exit or work in; due to
hot work activities also large areas can become confined spaces. See KEMCO Confined Space
Procedure.
Proper precautions must be taken by KEMCO supervisor who require for hot work to be performed
in a confined space or an area that could become one. Refer to the Confined Space Pre Entry
Procedure, and contact the Entry Supervisor prior to performing hot work, welding or cutting
operations in a confined space.
Prior to welding tanks, cylinders, or other containers, KEMCO supervisory personnel must
complete a hot work permit and shall verify that such containers do not contain, or have not
contained, any flammable, toxic, or explosive materials. If containers have contained flammable,
toxic, or explosive materials, they must be emptied, flushed, or otherwise purged and sampled
prior to welding.
Refer to KEMCO Confined Space Procedure before commencing any hot work operations in an
area meeting the requirements of a confined space.
• Ventilation is a prerequisite to work in confined spaces.
• The atmosphere will be initially tested by supervisor/HSS dept. with a gas detector to
identify when it is safe to access;
• A gas detector will provide continuous monitoring while people are inside of the confined
space. And everybody must evacuate immediately if the alarm is activated.
• Do not store the gas cylinder in confined space;
• Gas cylinders are to be kept outside of the confined space unless it is not possible to avoid it.
• If gas cylinders or equipment are required inside, the user must check for leaks on valves,
connections and hoses suitable protection must be provided (upright position, chained,
secured in trolley, fire protection etc.);
• Gas cylinder shall be kept in designated trolley and all gas equipment (including hoses and
torches) shall be removed to the surface if task is suspended or completed;
• Confined space permit and log sheet also comply prior to enter in confined space;
• When welding or cutting is being performed in any confined spaces, the gas cylinders and
welding equipment must be left on the outside. Before operations are started, heavy portable
equipment mounted on wheels must be securely blocked to prevent accidental movement.
• When a welder enters a confined space through a manhole or other small opening, means
must be provided for quickly removing him in case of an emergency.
• When safety belts and lifelines are used for this purpose, they shall be so attached to the
welder's body that it cannot be jammed in a small exit opening;
• An attendant with a pre-planned rescue procedure shall be stationed outside to observe the
welder at all times and be capable of putting rescue operations into effect immediately.
• When arc welding is to be suspended for any substantial period of time, such as during lunch
or overnight, all electrodes shall be removed from the holders and the holders carefully
located so that accidental contact cannot occur and the equipment shall be disconnected
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from the power source.

• When welding shall be performed in a space entirely screened on all sides, the screens shall
be so arranged that no serious restriction of ventilation exists. It is desirable to have the
screens mounted that they are about 2 feet (0.61 m) above the floor unless the work is
performed at a low level, that the screen must be extended nearer to the floor to protect
nearby workers from the glare of welding. This protection shall be provided to all welding
works performed in tunnel either surface;
• A fixed enclosure shall have top and not less than two sides which surround the welding or
cutting operations, and a rate of airflow sufficient to maintain a velocity away from the welder
of not less than 100 linear feet (30m) per minute.
• All welding and cutting operations carried on in confined spaces shall be adequately
ventilated to prevent the accumulation of toxic materials or possible oxygen deficiency. This
applies not only to the welder, but also to operatives assisting in the task and other personnel
in the immediate vicinity. All air withdrawn will be replaced with air that is clean.
• In circumstances for which it is impossible to provide such ventilation, airline respirators or
hose masks approved for this purpose must be provided. In areas immediately hazardous to
life, a full-face respirator mask, positive pressure, self-contained breathing apparatus or a
combination of full-face respirator mask, positive pressure supplied-air respirator with an
auxiliary, self-contained air supply.
• Where welding operations are carried out in confined spaces and where welders and
operatives assisting in the task are provided with hose masks, hose masks with blowers or
self-contained breathing equipment, an operatives must be stationed on the outside of such
confined spaces to monitor and ensure the safety of those working within the confined space

7.1 Fire Protection

Fire protection equipment must be maintained ready for use at all times that hot work, welding or
cutting operations are being performed in tunnels or surface.
• Welding/cutting operations must be equipped with firefighting and fire protection
equipment, including a fire extinguisher of at least A: B: C rating. CO₂ extinguishers are not to
be used in confined spaces.
• If welding is to be performed in areas where a fire hazard may exist, fire watch practices must
be established and implemented before any welding or cutting operations begin.

7.2 Fumes, Gases and Dust

Fumes produced by some welding processes can be toxic and may require source extraction in
tunnels or on surface. An assessment of the work to be performed must be completed before each
work task is undertaken. Fumes generally contain particles from the material being welded.
Welding fumes can have an acute effect on the respiratory system.
• Any welding, cutting or burning of lead base metals, zinc, cadmium, mercury, beryllium or
exotic metals or paints that could produce dangerous fumes must have proper ventilation or
respiratory protection in place before work task is undertaken.
• Welders and operatives assisting in the work task will confirm with the CSCEC-SK E&C JV
health and safety department to determine the correct respiratory protection to be used
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during welding operations.

• All welding and cutting operations shall be adequately ventilated to prevent the accumulation
of toxic materials. This applies not only to the welders, but also to operatives’ assisting with
the task and other personnel in the immediate vicinity.

8. Gas Cylinder
Compressed gas cylinders shall be approved and legibly marked near the shoulder of the cylinder for
the purpose of identifying the gas content with either the chemical or trade name of the gas.
• All compressed gas cylinder connections must comply with ANSI B57. 1-1965 Standards
• Compressed gas cylinders shall be secured in an upright position at all times.
• All cylinders shall be kept away from sources of heat and from radiators and piping systems
that may be used for grounding purposes. Cylinders and cylinder valves including couplings
and regulators shall be kept free from oily or greasy substances and must not be handled with
gloves or rags in the same condition.
• Stored oxygen cylinders shall be kept at least 20 feet from the fuel gas cylinders or
combustible materials, especially oil or grease, or separated by a non-combustible barrier at
least 5 feet high with a fire rating of at least one-half hour. All empty cylinders shall have closed
valves. Valve protection caps must always be in place and hand-tight except when cylinders
are in use or connected for use. Valve protection devices must not be used for lifting cylinders.
• Cylinders shall not be kept in unventilated enclosures such as lockers and cupboards.
• Fuel gas cylinders stored inside buildings shall be limited to a total capacity of 2000 cubic feet
(300 pounds) of liquefied petroleum gas, except for those in actual use or attached ready for
use. Inside storage areas must be well-protected, well-ventilated, and in a dry location at least
20 feet from highly combustible materials.
• Outside storage areas must be protected from direct sunlight, external heat sources, electric
arcs, or high temperatures.
• Cylinders must be prevented from tipping, falling, or rolling.
• All empty cylinders will be handled and stored as if they were still pressurized.
• Empty and full cylinders should be stored separately.
• If cylinders are found to have leaky valves or fittings which cannot be stopped by closing the
valve, the cylinders shall be taken outdoors, away from sources of ignition, and slowly
emptied. If the leak is large, no attempt must be made to move the cylinder, evacuate all
personnel from the area and ISG JV management immediately.
• All acetylene cylinders shall be stored valve-end up.
• Assigned storage spaces shall be located where cylinders cannot be knocked over or damaged
by falling objects or subject to tampering by unauthorized persons.
• Back flow protection shall be provided by an approved device that will prevent oxygen from
flowing into the fuel-gas system or fuel from flowing into the oxygen system;
• An approved device that will prevent flame from passing into the fuel-gas system shall
provide flashback protection;
• An approved pressure-relief device set at the appropriate pressure shall provide
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backpressure protection.
• Special care must be taken when transporting gas cylinders:
• Cylinders must be secured with valve cap installed;
• Cylinders shall not be lifted by the valve protection caps, the regulators must be removed and
cylinders shall not be dropped or permitted to strike each other;
• Removed regulators must be carried in the cab of the vehicle;
• Cylinders must not be tampered with nor should any attempt be made to repair them;
• They shall be handled carefully - rough handling, knocks, or falls are liable to damage the
cylinder, valve or safety device and cause leakage;
• Safety devices must not be tampered with.

8.1 Oxygen Fuel Gas Welding and Cutting

Only approved apparatuses such as torches, regulators or pressure-reducing valves, setting generators
and manifolds will be used:
• Mixtures of fuel gases and air or oxygen may be explosive and must be guarded against;
• All hoses and hose connections must comply with the Manufacturer’s instructions and
applicable
standards;
• Workers in charge of the oxygen or fuel-gas equipment, including generators, must be
trained, qualified and judged competent by the KEMCO before being in charge of operation;
• Prior to beginning welding or cutting operations, ISG JV operatives must check that the
cylinders, regulators, backflow prevention device, flame arrestors, hoses, clamps, and torches
have been maintained and are in good working condition;
• Oil or grease must not come into contact with oxygen cylinders, valves, regulators or other
fittings. Do not handle oxygen cylinders or apparatus with oily hands or gloves, or greasy
materials. Do not let oxygen contact oily or greasy surfaces or clothes, or enter a fuel oil or
other storage tank;

• Fuel gas and oxidizers must pass through a pressure-reducing regulator prior to being used.
Pressure reducing regulators must only be used at or below the rated pressures and must be
specific to the type of gas being used. Prior to connecting a pressure regulator, cylinder valves
should be "cracked" to clear the dust or dirt that might otherwise enter the regulator. This
procedure shall be performed away from other welding work or sparks;

• Prior to removing a regulator from a cylinder, KEMCO personnel must close all cylinder valves,
and release the gas from the regulator;
• KEMCO Personnel must follow the manufacturer's operating procedures for lighting the torch.
Generally accepted practices for start-up and shut down follow.

Start- Up
• Open the oxygen valve on the torch handle and adjust the oxygen regulator to the desired
delivery range;
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• Close the torch handle oxygen valve;

• Open the fuel valve on the torch handle and adjust the fuel regulator to the required delivery
range;
• Close the torch fuel control valve;
• Hold the torch in one hand and the spark lighter in the other. Open the torch fuel valve
approximately one-half turn and ignite the gas;
• Point the torch away from people and combustible materials;
• Keep opening the fuel valve until the flame stops smoking and bring the flame back to the tip;
• Open the torch oxygen valve until a bright neutral flame is reached.

Shut Down
• When shutting down the system, first shut off the oxygen, then the fuel gas;
• Drain the gas pressures from the system.
Cylinders must be kept far enough away from the actual welding or cutting operation so that
sparks, hot slag, or flame will not reach them, or fire-resistant shields must be provided.

9. Electrical Arc Cutting & Welding

All personnel operating, installing, and maintaining welding equipment shall be qualified,
competent and trained to operate and maintain such equipment.
1. Prior to beginning welding or cutting operations, operatives must:
– Check that the equipment, all electrode holders and cables are capable of carrying the
maximum current, are properly insulated and grounded, and have been maintained in
good working condition;
– Check that any cable splices have been performed with insulating quality equal to that of
the cable, and that there are no splices within 10 feet of the electrode;
– The area must be free of chlorinated solvent vapours within 50 feet of the exposed arc;
surfaces prepared with chlorinated solvents must be thoroughly dry before welding is
performed on them.
2. When arc welding is performed in wet or high humidity conditions, personnel must use
additional protection against electric shock (e.g., rubber pads or boots);
3. To protect workers or other personnel from the arc rays, non-combustible or flameproof
screens or shields shall be used, or personnel in the area shall wear appropriate goggles;
4. Manual electrode holders must be specific to welding and cutting, and capable of handling
the maximum current required for the operation. All current carrying parts gripped by the
user must be insulated against the maximum voltage to ground;
5. Arc welding and cutting cables must be insulated, flexible and capable of handling the
maximum current required by the operation, taking into account the duty cycles, and
must not have bare or worn conductors. Cables must be free of repair or splice from 10'
of the electrode holder unless insulated connectors or splices with insulating quality
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equal to that of the cable are provided. Exposed metal parts must be insulated;
6. Ground return cables must have current carrying capacity equal to or exceeding the total
maximum output capacities of the welding or cutting unit. Do not use electrical conduits
or structures or pipelines containing gas or flammable liquids as part of the grounding
circuit system;
7. Arc welding and cutting machine frames must be grounded, either through a third wire in
the cable containing the circuit conductor or through a separate wire at the source of the
current. Grounding circuit resistance must be low enough to permit sufficient current to
flow to cause the fuse or circuit breaker to interrupt the current;
8. When machines are not in use, the power supply switch must be shut off and the electrodes
removed and the holders placed to prevent employee injury.
A disconnecting switch or controller shall be provided at or near each welding machine along with
over current protection.
All direct current equipment shall be connected with the same polarity and all alternating current
equipment connected to the same phase of the supply circuit and with the same polarity.
• To prevent electrical contact with personnel, all electrode holders shall be placed where
they do not make contact with persons, conducting objects or the fuel of compressed gas
tanks;
• All cables with splices within 10 feet of the holder shall not be used
• If the object to be welded or cut cannot readily be moved, all moveable fire hazards should be
removed.
• If an object to be welded or cut cannot be moved and if all the fire hazards cannot be
removed, then guards shall be used to confine the heat sparks and slag and to protect the
immovable fire hazards.

9.1 Inert Gas Metal Arc Welding

When performing inert-gas metal-arc welding, extreme caution must be used; inert gases can
easily displace oxygen. The following safeguards must be followed.
• The area must be free of chlorinated solvent vapours within 50 feet of exposed arc; surfaces
prepared with chlorinated solvents shall be thoroughly dry before welding is performed on
them;
• Employees exposed to radiation must have their skin completely covered;
• If welding on stainless steel, personnel must be protected by local exhaust ventilation or by
wearing supplied-air respirators.

10. Resistance Welding

All personnel operating, installing, and maintaining welding equipment must be qualified, competent
and trained to operate and maintain such equipment.
• Voltage, interlocks, guarding, grounding and shields shall be in accordance with
manufacturer recommendations;
• Precautions such as flash guarding, ventilation and shields shall be provided to control
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flashes, toxic elements and metal fumes;

• All equipment guards are in position and in safe working condition;
• Emergency stop button(s) are working;
• Resistance welding equipment must be periodically inspected by qualified personnel, and a
certification record maintained. The record shall include the date of the inspection, the
signature of the person who performed the inspection, and the serial number or other
equipment identification;
• If the object to be welded or cut cannot readily be moved, all moveable fire hazards should be
removed.

11. Care of Compressed Gas Cylinder

Compressed gas cylinders shall be legibly marked identifying the contents.
Compressed gas cylinders shall be stored and transported in the following
manner:

• Valve end must be up;

• Outside storage areas must be protected from direct sunlight, external heat sources, electric
arcs, or high temperatures;
• Inside storage areas must be well-protected, well-ventilated, and in a dry location at least 20
feet from highly combustible materials;
• Cylinders containing flammable gases will be stored at least 20 feet from oxygen cylinders;
• Cylinders shall not be kept in unventilated enclosures such as lockers and cupboards, or inside
the cabs or passenger areas of vehicles;
• Valve protection devices must be in place when cylinders are not in use, and during
storage and transport. Valve protection devices must not be used for lifting cylinders;
• Cylinders must be prevented from tipping, falling, or rolling;
• All empty cylinders will be handled and stored as if they were still pressurized;
• If cylinders are found to have leaky valves or fittings which cannot be stopped by closing the
valve, the cylinders shall be taken outdoors, away from sources of ignition, and slowly
emptied. Never put other workers at risk. If the leak is large, do not attempt to move the
cylinder, evacuate all personnel from the area and notify KEMCO supervisor/management
immediately;
• Pressurized cylinders must not be taken into confined spaces.

12. HOT WORK PERMIT

Prior to performing welding/cutting operations a hot work permit must be completed and approved by
the appropriate KEMCO Manager/Engineer/Supervisor.
Task supervisors are authorized to request the hot work permit and site engineer or station managers
are authorized to approve the hot work permit
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• On all KEMCO project locations that have not been designated as welding locations;
• In confined spaces;
• Welding or cutting tanks, cylinders, or other containers;
• In areas where a fire hazard may exist (example: weeds, wood products, fabrics);
• In areas where combustibles are closer than 35' to the point of operation;
• In areas where combustible materials are adjacent to the opposite side of metal walls,
partitions, ceilings, or roofs and areas likely to be ignited by conduction or radiation;
• One hot work permit shall be issued for one location, each individual operation must have
its own specific hot work permit;
• Hot works permit shall be issued for one shift, new hot work permit will be issued for
following/next shift and must be in place before welding or cutting operations commence.
Copies of open permits must be maintained at the work task site and in the supervisor’s/ site
management
office. Upon job completion, closed permits should be maintained and be available for
inspection. Refer to appendix A.
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Appendix A - Hot Work Permit

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2 Electric Arc Welding and Cutting

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3 Gas Cylinders
• Removed regulators must be carried in the cab of the vehicle;