Date: 07/01/14 Revision No.

: 00
Issued by: VS Page No.: Page 1 of 6
Work Instruction HOT Work Ref No.: GPL/SAF/WI-09/HTW/R0

Work Instruction on Hot Work

1.0 Purpose:
This work instruction is to ensure all hot work operations carried out within GPL site are
controlled to prevent fire incident occurrence which may lead to personal injury and/or
damage to GPL property and Environment.

2.0 Scope:
This work instruction covers all GPL site workplaces that involve hot work operation which is
to be carried out by any engaged contractor. These include but not limited to hot work
operation related to:
 Building construction or maintenance related works;
 Addition or alteration on any works of engineering construction, e.g. welding, or gas-cutting,
grinding of any MS members (e.g. steel, plates, ISMB, ISMC, etc…) system; and
 Maintenance or repair works on machinery/equipment, construction activity etc…

3.0 Roles & Responsibility:

GPL Project Head is responsible for adherence to the work instructions through PMC &
responsible contractors. And the respective Contractor is responsible to transmit this work
instruction to their sub-contractors and ensure that the contents are clearly understood by them.
In case of not adherence to work instructions and non-performance by Contractor, the GPL
Project Head has the right to get this done by other contractor and back charge the same to
defaulting contractors.

4.0 Definitions/Abbreviations:
Hot work operation: - Means any activity that generate heat, flame and/or sparks that could
potential cause a fire incident. Such may include welding, grinding, gas-cutting, pipe brazing,
etc…
Hot Work Permit Approver:-Hot work permit Approver is the appointed person by GPL /
PMC / Contractor to check and approve the permit before commencement of hot work
operation. The area manager execution is usually the Approver.
Hot work permit Requestor is the person that request to carry out the hot work (can be a
staff or contractor).
5.0 Legal:
Gas Cylinder Rule-2004
The Building & Other Construction Workers (Regulation of Emp& Conditions of Service) Act,
1996
The Building & Other Construction Workers (Regulation of Emp& Conditions of Service)
Central Rules, 1998.
Chapter VI, Rule 35- Fire Protection.
Chapter VI, Rule 47- Electrical Hazards
Chapter XIII, Rule 163 Welding Sets.

6.0 Procedure: Hot Work

6.1 Guideline (Welding & Gas Cutting)
 Welding and gas cutting operations should be done only by qualified and authorized
persons and as per IS Specifications and code of Practice.

Prepared by: RM Reviewed by: VS Approved by: JP

 Date: 07/01/14 Revision No.: 00
Issued by: VS Page No.: Page 2 of 6
Work Instruction HOT Work Ref No.: GPL/SAF/WI-09/HTW/R0

 Welding and gas cutting should not be carried out in places where flammable or
combustible materials are kept and where there is danger of explosion due to presence of
gaseous mixtures.
 Welding and gas cutting equipment including hoses and cables shall be maintained in good
condition.
 Barriers shall be erected to protect other persons from harmful rays from the work. When
welding or gas cutting is done in elevated positions, precautions shall be taken to prevent
sparks or hot metal falling on persons or flammable materials.
 Suitable type of protective clothing consisting of fire resistant gloves, leggings, boots and
aprons shall be provided to workers as protection from heat and hot metal splashes.
Welding shields with filter glasses of appropriate shade shall be worn as face protection.
 Adequate ventilation shall be provided while welding in confined space or while brazing,
cutting or welding zinc, brass, bronze, galvanized or lead coated materials.
 Welding and gas cutting shall not be done on drums, barrels, tanks or other containers
unless they have been emptied, cleaned thoroughly and it is made certain that no
flammable material is present.
 Fire extinguisher shall be available near the location of welding operations. Fire safety
permit shall be obtained for working at vulnerable areas and operating areas before flame
cutting/welding is taken up.
 For electric (Arc) welding the following additional safety precautions shall be taken:
I) when electrical welding is undertaken near pipe lines carrying flammables, such pipe
lines shall not be used as part of earth conductor but a separate earth conductor shall be
connected to the machine directly from the job.
II) Personnel contact with the electrode or other live parts of electric welding equipment
shall be avoided.
III) Extreme caution shall be exercised to prevent accidental contact of electrodes with
ground.
IV) The welding cables shall not be allowed to get entangled with power cables. It shall be
ensured that the cables are not damaged by movement of materials.

 Grinding
 All portable grinders should be used only with their wheel guards in position to reduce the
danger from flying fragments should the wheel break during the use.
 Grinding wheels of specified diameter only should be used on a grinder portable or
pedestal-in order not to exceed the prescribed peripheral speed.
 Face shield (clear)/ Goggles should be used during grinding operation.
 Use tight clothing while doing grinding work.
 Use leather apron and sleeves for better protection

6.2 General Requirement :

 Gas cylinders in use shall be kept upright on a custom-built stand or trolley fitted with a
bracket to accommodate the hoses and equipment or otherwise secured. The metal cap
shall be kept in place to protect the valve when the cylinder is not connected for use.
 Hose clamp or clip shall be used to connect hoses firmly in both sides of cylinders and
torches.
 All gas cylinders shall be fixed with pressure regulator and dial gauges
 Non-return valve and Flashback arrester shall be fixed at both end of cylinder and torch.
 Domestic LPG cylinders shall not be used for Gas welding and cutting purpose.
 DCP or CO2 type Fire Extinguisher not less than 5 kg shall be fixed at or near to welding
process zone in an easily accessible location. Fire Extinguisher should confirm to IS 2190:
1992.

Prepared by: RM Reviewed by: VS Approved by: JP

 Date: 07/01/14 Revision No.: 00
Issued by: VS Page No.: Page 3 of 6
Work Instruction HOT Work Ref No.: GPL/SAF/WI-09/HTW/R0

 Use firewatchers if there is a possibility of ignition unobserved by the operator (e.g. on the
other side of bulkheads).
 Oxygen cylinders and flammable gas cylinders shall be stored separately, at least 6.6
meters (20 feet) apart or separated by a fire proof, 1.5 meters (5 feet) high partition.
 Flammable substances shall not be stored within 15 meters of cylinder storage areas.
 Transformer used for electrical arc welding shall be fixed with Ammeter and Voltmeter and
also fixed with separate main power switch.
 Welding grounds and returns should be securely attached to the work by cable lugs, by
clamps in the case of stranded conductors, or by bolts for strip conductors. The ground
cable will not be attached to equipment or existing installations or apparatus.
 Use a low voltage open circuit relay device if welding with alternating current in constricted
or damp places.
 Take precautions against the risk of increased fume hazards when welding with chrome
containing fluxed consumables or high current metal inert gas (MIG) or tungsten inert gas
(TIG) processes.
 Avoid being in contact with water or wet floors when welding. Use duckboards or rubber
protection.
 All electrical installations shall meet the IS: 5571: 1997 and Gas cylinder rule – 2004 for gas
cylinder storage area and other hazardous areas.
 The current for Electric arc welding shall not exceed 300 A on a hand welding operation.

6.3 Welding and Gas Cutting Work:

Welding and cutting operations present a serious of hazardous situation with potential
exposure to burns, eye damage, electrical shock, crushed toes and fingers, and the
inhalation of vapors and fumes. Many welding and cutting incident in industry result from:
 Inadequate trained personnel.
 Poor housekeeping practices.
 Poor shop layout.
 Inadequate lighting and ventilation.
 Improper storage and movement of compressed gas cylinders.
 Exposure of oxygen cylinders and fittings to oil and grease creating a fire or explosion
hazards.
 Pointing welding or cutting torches at a concrete surface causing spattering and flying
fragments of concrete.
 Electrical shock when motors, generators, and other electric welding equipment are not
grounded.
 Inhalation of toxic fumes or vapors from welding metals or alloys.
Fire, explosions, and injuries can occur resulting from:
 The proximity of combustible solids, liquids, or dusts.
 The presence or development of possible explosive mixtures of flammable gases and air.
 The presence or nature of an oxygen – enriched atmosphere in locations where hot work is
performed.
 Cutter and welder and other exposed personnel, are also susceptible to eye injury from
infrared light and ultraviolet radiation.

6.3.1 Operating Precautions:

The following provides minimum guidance on operating precautions and procedures.
 Provide ventilation in rooms / shops where work is to be performed but avoid strong drafts
directed at the welding work.

Prepared by: RM Reviewed by: VS Approved by: JP

 Date: 07/01/14 Revision No.: 00
Issued by: VS Page No.: Page 4 of 6
Work Instruction HOT Work Ref No.: GPL/SAF/WI-09/HTW/R0

 Do not place work to be welded or heated on a concrete floor. Concrete when heated, may
splatter and fly exposing the welder to possible burns and also throwing hot particles a
considerable distance.
 Provide appropriate protection for welders and helpers when working on elevated surface.
Welding area shall be kept neat, clean and free from tripping hazards.
 Provide approved personnel protective equipment for welders who must entered confined
space, manholes or other space restricted areas. Also, provide a means to ensure their
quick removal in case of an emergency.
 Do not perform welding operation in sprinklered buildings when the sprinkler system is
inoperable; In explosive atmospheres or where explosive atmospheres may develop; or,
within 50 feet of storage of large quantities of exposed, readily ignitable material.
 Shielding should be provided to protect personnel from heat, sparks, light and radiation.
 A fire watch will be maintained for at least 30 minutes after completion of welding
operations to detect and extinguish possible smoldering fires.

6.3.2 Arc Welding:

 Arc welding equipment shall conform to the design and installation criteria of proper
standards for welding. The frame or case of the welding machine should be grounded
under the conditions and according to Indian Electricity Rule – 1956.
 Before starting operation all connection to the welding machine should be checked. The
work lead should be firmly attached to the work: contact surface of the magnetic work
clamps shall be free of metal splatter particles. Coiled welding cable should be spread out
before use to avoid serious overheating and damage to insulation. Work and electrode lead
cable shall be inspected for the damage and wear before use. Cable with damage
insulation or exposed conductors shall be replaced. Electrode cables shall be joined and
insulated in accordance with approved method.
 Grounding of welding machine should be checked, special attention should be given to the
ground connection of the portable machine.
 Electrode holders, when not in used should be placed where they cannot make electrical
contact with persons, conducting objects, fuel, or compressed gas cylinders.
 When it is necessary to splice cables to extend their length, only certified electricians
should make the splices. Cables with splices within 10 feet of the electrode holder should
not be used. The welder should not coil or loop welding electrode cable around parts of
their body.
 Welders should not place welding cable and other equipment where it will obstruct
passageways, stairways, landings, ladders.
 When welders are working close to one another on one structure where they may touch the
exposed parts of more than one electrode holder simultaneously, the machine should be
connected to minimize shock hazards as follows:
a. All direct current machines should be connected with the same polarity.
b. All alternating current machines should be connected to the same phase of the supply
circuit and with the same instantaneous polarity.

6.3.3 Welding in confined Spaces:

 All welding operation carried out in confined space should be adequately ventilated to
prevent the accumulation of toxic materials, possible oxygen deficiency or explosive
atmosphere.
 This applies not only to the welder but also to helpers and other personnel in the immediate
vicinity.
 All fresh air drawn shall be clean and repairable. Oxygen should never be used as makeup
air.

Prepared by: RM Reviewed by: VS Approved by: JP

 Date: 07/01/14 Revision No.: 00
Issued by: VS Page No.: Page 5 of 6
Work Instruction HOT Work Ref No.: GPL/SAF/WI-09/HTW/R0

 In such circumstances where it impossible to provide such ventilation, appropriate

respirators mask should be used. In areas immediate hazardous to life, respirator hose
mask with blower or self-contained breathing apparatus should be used.
 Where welding operations are carried out on in confined space, a gate watcher should be
stationed on the outside of the confined space to ensure the safety of those working within.
 When welding being performed in any confined space, welding machine should be left on
the outside. Before operation started heavy portable equipment mounted on wheel should
be securely blocked to prevent accidental movement.
 Where a welder entre a confined space through a manhole or other small openings, a
means should be provided for quick removal of the worker in case of emergency. When
safety belt and lifeline are used for this purpose, they should be attached to the welder
body in a way that ensures his body cannot be jammed in a small exit opening.
 When welding work is stopped during lunch or tea break, overnight, all electrodes should
be removed from the holders and the holder should be carefully located so accidental
contact cannot occur. The machine shall be disconnected from the power source.
 All confined spaces should be monitored for oxygen content, combustible vapors, and toxic
material prior to entry and periodically throughout the operation. Periodic testing should be
done and record should be maintained.

6.4 Gas Cutting Work:

 Before lighting the torch for the first time each day, allow enough of each gas to flow
through its respective hose to purge any flammable gas mixture. Purge hoses in open
spaces and away from the ignition sources. Light the torch with friction lighter. Point the
torch away from persons or combustible materials when lighting. Do not attempt to light a
torch from hot metal.
 When working in confined space, the fuel gas and oxygen supply shall be located outside
the confined space. The torch and hose should be removed from confined space when not
in use.
 Fuel gas and oxygen torch valves should be closed and the fuel gas and oxygen supply to
torch should be shut off during lunch or tea break periods, when not in use for extended
periods and when unattended.
 Cutting torch hoses must be protected from damage by contact with hot metal, open flame,
corrosive agent or sharp edges. Pressure on the hoses will be released at the end of each
workday.
 Hose must be visually inspected for damage at the beginning of each shift. Hose showing
leaks, cuts, burns, worn spots or other evidence of deterioration must be repaired or
replaced prior to use.
 Replacement hoses or fitting must be approved from IS 818-1968 for use with acetylene
equipment.
 Shielding should be provided to protect personnel from heat, sparks, light and hot spatters
etc…
 Cylinder of compressed gas must have pressure reducing regulators installed.
 Cylinders in use or in a transport must be stored in an upright position and secured to
prevent them from falling.
 Pressure hoses should be secured to prevent whipping.
 Oxygen cylinders and fittings must be kept free from grease and oil at all time.
 Cylinders should be kept away from external source of heat at all times.
 Cylinder should not be dropped or handled roughly, use trolley with wheel for transporting
cylinder at site and other places.

6.5 Fire prevention and Protection:

Prepared by: RM Reviewed by: VS Approved by: JP
 Date: 07/01/14 Revision No.: 00
Issued by: VS Page No.: Page 6 of 6
Work Instruction HOT Work Ref No.: GPL/SAF/WI-09/HTW/R0

 The welding operation environment should be free of flammable liquids and vapors.
Combustible materials within a radius of 30 feet of the operation will be protected from
activity residue flame, heat, sparks, slags etc…)
 Fire watcher procedure should be implemented whenever welding activities are conducted
within 35 feet of combustible materials, regardless of protection provided. A qualified fire
watcher should be engaged for the job.
 Whenever there are cracks or other floor openings within 35 feet of the welding or cutting
that cannot be closed or covered, precaution should be taken to remove or otherwise
protect combustible materials on the floor below that may be exposed to sparks.
 Fire extinguishing equipment should be maintained, ready for use, while welding or cutting
operations are being performed. Equipment may consist of buckets of water, buckets of
sand, hose or portable extinguishers depending upon the nature and quantity of the
combustible material exposed.
 Use fire blanket to control the spatters emitting form the welding and cutting work , due to
wind, in case of height , near to gas line etc…
7. Emergency Procedures and Details of Site Features:
i. A pre start job meeting shall be arranged for informing about proper communication
method.
ii. Safety engineer (PMC/GPL) is responsible to train the site people for the use and
implementation of SOP’s at site. Conduct training as required as per the site
requirement or progress of work.
iii. Arrangement of first aid facilities and emergency vehicles shall be ensured.
iv. Contractor should inform to PMC/ GPL for commencement of work.
v. In condition as where work affecting by natural calamities like heavy rain, dusty
environment, thunderstorm, etc PMC/ GPL guidelines shall be followed.

8. Risk Assessment
Before commencing this activity the Safety Engineer of Contractor should evaluate the
foreseeable risk by conducting independent risk assessment in consultation with site
execution team as per site condition & topography to ensure that appropriate control
measures are established and incorporated. GPL /PMC site head & Safety Engineer
are responsible to review & approve the same.

Use SOP on HIRA and standard HIRA record template available with HO-Safety.

9. Checklist:
The GPL Site Head & associates like PMC is responsible to prepare a suitable “HOT
WORK Checklists” based on the above procedure and HIRA conducted at site and also
keeping in view the site location topography.

10. References:
i. Contract Document
ii. GPL HSE Guideline
iii. Site EHS Plan
iv. BOCW Act & Rules.
v. Gas cylinder Rule -2004
vi. Indian Electricity Rule-1956
vii. OSHA

Appendix – 1: Hot Work Checklist

Prepared by: RM Reviewed by: VS Approved by: JP