API 2009 : 2002

SAFE WELDING, CUTTING, AND HOT WORK PRACTICES IN THE PETROLEUM AND PETROCHEMICAL INDUSTRIES

American Petroleum Institute

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1 INTRODUCTION
   1.1 Purpose
   1.2 Scope
   1.3 Retroactivity
   1.4 Concept of Hazard vs Risk
   1.5 General Hot Work Process
2 REFERENCED PUBLICATIONS
3 DEFINITIONS
4 JOB ANALYSIS
   4.1 Job Analysis
   4.2 Review by Qualified Persons
5 HAZARD EVALUATION AND RISK REDUCTION
   5.1 General
   5.2 Physical Hazards
   5.3 Potential Acute Health Hazards and Risk Reduction
   5.4 Potential Chronic Health Hazards and Risk Reduction
   5.5 Flammable Liquids, Vapors, Solids, or Dusts
   5.6 Combustible Materials
   5.7 Ignition Sources
   5.8 Water
   5.9 Wind
   5.10 Equipment with Liners, Blisters, or Patch Plates
   5.11 Electrical Hazards to Personnel
   5.12 Noise
6 IMPLEMENTATION OF SAFEGUARDS
   6.1 General Concepts of Safeguards and Risk Reduction
   6.2 Equipment Purging and Ventilation
   6.3 Protection of Personnel
   6.4 Safeguards Against Ignition Hazards
   6.5 Fire Watch Personnel
7 TESTING FOR HAZARDS
   7.1 Flammability Testing
   7.2 Oxygen Testing
   7.3 Monitoring for Toxic Substances
   7.4 Frequency of Monitoring the Atmosphere
8 HOT WORK PERMITS
   8.1 General
   8.2 Permit Requirements
   8.3 Issuing and Closing-out the Permit
   8.4 Interrupted Work
   8.5 Extending the Permit
9 HOT WORK IN CONFINED SPACES
   9.1 Confined Space Entry
   9.2 Oxygen Content in Confined Spaces
   9.3 Flammable Vapor Concentration
   9.4 Confined Space Ventilation
   9.5 Frequency of Monitoring in Confined Spaces
   9.6 Pyrophoric Iron Precautions
10 WORK INSIDE VESSELS, EXCHANGERS, AND TANKS
   10.1 Preparations
   10.2 Maintaining a Safe Work Environment
   10.3 Inspection of Internals
11 WORK ON THE EXTERIOR OF VESSELS, EXCHANGERS,
   AND TANKS NOT IN SERVICE
12 WORK ON EQUIPMENT IN SERVICE
   12.1 Decision Process for Work on Equipment in Service
   12.2 Hot Work With Hydrocarbons Present
   12.3 Work on the Exterior of Atmospheric Pressure In-service
        Vessels
   12.4 Hot Work on Equipment under Vacuum
   12.5 Leak Repair
13 WORK IN BUILDINGS AND PITS
14 WORK ON PIPING
   14.1 General Considerations for Work on Piping
   14.2 Piping Isolation
   14.3 Venting of Piping
   14.4 Piping Contamination and Coating
   14.5 Hot Tapping
APPENDIX A - BIBLIOGRAPHY
APPENDIX B - INERTING VESSELS

Abstract

Gives guidelines for safely conducting welding, cutting or other hot work activities in refineries, gas plants, petrochemical plants and other facilities in the petroleum and petrochemical industries.