Welding, Burning and Hot Work Safe Practices Plan

Transcription

1 Purpose Welding, Burning and Hot To establish procedures for safely conducting welding, burning, cutting and other hot work activities in accordance with BSEE regulations (30 CFR ). Scope This policy establishes requirements for burning, welding, and hot work activities at all Fieldwood Energy BSEE regulated facilities. Responsibilities The Person in Charge (PIC) and/or Project Supervisor is responsible for: Fieldwood Energy s designated person-in-charge of welding/burning operations as required in 30 CFR shall be the Person in Charge (PIC) or Project Supervisor. o In the case of SIMOPS, the person-in-charge of welding/burning operations shall be the person who has Ultimate Work Authority (UWA) per the Ultimate Work Authority Agreement Form for Simultaneous Operations. Evaluating the safety aspect of these activities as an integral part of pre-planning a job, (i.e. Job Safety Analysis). Ensuring all employees involved in these activities are properly trained and understand the requirements of this procedure and the hazards and safeguards involved. Issuing and following the Hot Work Permit to include: o Inspecting the work area o Filling out the permit form o Reviewing the permit conditions with employees involved o Monitoring the work for compliance o Revoking the permit if conditions change that may create hazards o Inspecting the work area when the work is completed and closing out the permit NOTE: A copy of the completed Hot Work Permit and associated JSA must be available at the work site at all times and kept on file. A separate permit is required for each job and/or shift change not to exceed 12 hours. The provisions of the permit must stay in place for the duration of the permitted time, including all breaks. (i.e. A designated fire watch must remain on post at all times including breaks for the duration of the permit when welding, burning and spark producing activities are being conducted.) General All offshore welding/burning shall be minimized by onshore fabrication when feasible. This Welding and Burning Safe Practices and Procedures Plan will be used in performing welding/burning activities on a platform, structure, artificial island, or other installation during any drilling, well completion, well workover, production operation or

2 other installation which contains a well open to a hydrocarbon-bearing zone. A copy of this plan and approval letter shall be available on the facility where the welding is being conducted. A Hot Work Permit is required anytime hot work activities are going to be conducted outside of a BSEE approved designated safe welding area. This includes the use of non-intrinsically safe equipment (i.e. cameras, radios, etc.). Hot Work NOT involving Welding, Burning and/or Spark producing activities The following provisions apply to the use of specific types of devices and tools which should not result in the emission of flames or sparks. Portable Electronic Devices: o Laptops or Hand Held Computers o Digital Cameras o Non-Intrinsically Safe Radios o Cellular Phones Pneumatic (air-operated) Tools: o Chipping or needle guns with brass needles. o Rivet busters. o Impact wrenches. o Drilling holes where bits are lubricated to minimize heat. o Sawing or cold cuts where blades are lubricated to minimize heat. Requirements: Completion of a Hot Work Permit. o The use of these devices and/or tools requires the completion of checklist items 1 5. o Checklist items 6 17 are not applicable when the work involved is subject to these provisions (i.e. does NOT include welding, burning or spark producing activities). Continuous monitoring with a gas detector. If LEL above 10% is detected; personnel must immediately stop work, vacate the area and inform the person-in-charge. A Fire Watch will not be required during these activities. NOTE: The use of abrasive grinding or cutting wheels is considered spark producing activities and is subject to ALL provisions of the Hot Work Permit.

3 Hot Work involving Welding, Burning and Spark Producing Activities Prior to the commencement of any welding, burning or spark producing activities, whether in designated or undesignated areas, the Person in Charge (PIC) and/or Project Supervisor shall ensure the following: Review the qualifications of the welder(s) to assure that they are properly trained and qualified in accordance with ANSI B31.3, AWS D1.1 and/or other applicable welding codes (i.e. B31.8 and B31.4 for pipeline weld repairs). Welder Qualification Standards: 1. Structural Welding: All structural welding on Fieldwood Energy facilities shall be done by qualified welders who have been tested and qualified in accordance with appropriate provisions of AWS Structural Welding Code, AWS D1.1. Structural Welding includes but not limited to the following: Structural members of the facility Stairways Walkways Handrails Grating Deck Plating Temporary Crane Installation Temporary Living Quarter Installation Structural support Installations Boat Landings 2. Pressure Piping and Process Equipment: All welding on pressure piping and process equipment on Fieldwood Energy s facilities shall be done by qualified welders who have been tested and qualified in accordance with appropriate provisions of ANSI B31.3, Petroleum Refinery Piping Code. Any welding performed on coded process equipment shall be conducted by a qualified welder. 3. Qualifications: Contract employers are required to maintain current certifications and qualifications of welders. Inspect the area in which the work is to be performed for potential fire and explosion hazards. Verify that all welding and burning equipment has been inspected. o Verify welding leads are completely insulated and in good condition. o Verify that oxygen and fuel gas bottles are in a secure place.

4 o Verify each welding or burning unit bottles are equipped with fittings, gauges, regulators, flame arrestors and leak free hoses. o Verify all engine-driven welding machines located on production or process platforms are equipped with spark arrestors and drip pans. o Verify all engine-driven welding machines are equipped with manual or automatic air intake shut down devices. Verify that all welding ground return cables have been properly mounted. o All Ground Return Cables must be mounted in locations that can be verified to have unbroken continuity between the ground clamp and the welding site. o Whenever possible, the Ground Return Cable (Ground Lead) should be run along with the Welding Cable (Welding Lead) to the worksite. The Ground Return Cable should be mounted in reasonable proximity to the worksite so it can be monitored during the welding operation. o When the Ground Return Cable must be mounted in a location away from the welding site, it shall be mounted on a welded structural component. o Mounting surfaces must be properly prepared before installing Ground Return Cable clamps. o Ground Return Cables must not be attached to socket-mounted handrails or other non-welded components. Portable Electric Tools Use of electric tools (with cords or batteries) such as drills, saws, grinders, etc. must meet ALL requirements of open flame hot work and the hot work permit, including fire watch, shutin of wells, production equipment, flameproof covers, or tarps, etc. as defined in this safe work practice. BSEE Approved Designated Safe Welding and Burning Areas Facilities may have designated safe welding and burning areas. These areas must be BSEE approved, with approval letter on file, must be clearly marked/identified and the facility drawing must illustrate the safe welding and burning areas on the facility. Safe welding areas will be placed only in unclassified areas as defined by API RP 500. All safe-welding areas will have solid decking immediately beneath them to prevent welding slag from falling into the water below the facilities or to a lower deck. There will be no equipment containing hydrocarbons or other flammable substances within 35 feet horizontally from the safe welding site. Properly designed and placed welding sheds shall be kept free of flammables around all sides.

5 Prior to the commencement of any welding or burning within an approved designated welding and burning area the Person in Charge (PIC) and/or Project Supervisor shall ensure the following: Verify a copy of the BSEE approved designated welding and burning plan and letter is on file. Review the qualifications of the welder or welders to assure that they are properly trained and qualified in accordance with ANSI B31.3, AWS D1.1 and/or other applicable welding codes. Inspect the area in which the work is to be performed for potential fire and explosion hazards. Verify all welding and burning equipment has been inspected. Welding, Burning and/or Spark Producing Activities in Undesignated Areas If welding, burning or spark producing activities are to be conducted within 10 feet of the well bay, all producing wells in that well bay must be shut in. If welding, burning or spark producing activities are to be conducted within 10 feet of a production area, all production equipment (i.e. vessels, pumps, tanks, panels, etc.) in that area must be shut in. Process piping is not classified as production equipment. o Welding near process piping without shut-in in is allowed as long as the piping and associated connections are verified to be properly made-up, maintained and adequately shielded with fire resistant guards or curtains. If welding, burning or spark producing activities are to be conducted within 35 feet of equipment containing hydrocarbons or other flammable substances, on the same level, above or below, requires one of the following: o Relocate equipment at least 35 feet from the welding or burning area. o Relocate equipment on lower decks or upper decks at least 35 feet from the point of impact where slag, sparks, or other burning materials could fall or fly. o If moving of equipment is impractical, you must do one of the following: Protect equipment with flame-proofed covers Install shielding using metal or fire resistant guards or curtains (i.e. tarps) Flame resistant tarps are available via purchasing requisition through your Purchasing Coordinator. Only Flame Resistant tarps that conform to ANSI FM 4950 are to be used. Discard old tarps that are not flame resistant. Render the flammable substances inert NO welding, burning or spark producing activities will be conducted while drilling, completion, workovers, or conducting wireline operations unless: o Fluids in the well are non-combustible, and o The entry of formation hydrocarbons into the wellbore have been precluded by either mechanical means or by a positive overbalance toward the formation.

6 NO welding, burning or spark producing activities shall be done on process piping, containers, tanks, or other vessels which have contained a flammable substance unless: o The process piping or vessel has been either cleaned and degassed or rendered inert. Monitoring shall be conducted throughout the hot work operation to maintain zero LEL in all areas inside process piping, containers, tanks or vessels. o All vessel inlet/outlet piping has been blocked by blanks, or process piping disconnected from the vessel prior to hot work. o All process piping has been positively isolated by blanks or vented plugs prior to hot work. Isolation by in-line valves (double block and bleed) for hot work is allowed only with approval by Fieldwood Construction Engineer or Fieldwood Construction Foreman. All water discharge point sources from hydrocarbon handling vessels shall be monitored as necessary by designated qualified personnel, in order to stop welding and burning operations in case flammable fluids are discharged as a result of equipment upset or malfunction. During all welding, burning or spark producing activities, one or more persons shall be designated as a fire watch. The following will be adhered to: o Persons assigned as a fire watch shall be trained and have adequate skills/knowledge to recognize potential hazards, utilize equipment and initiate emergency response. o No other duties shall be assigned to fire watch during welding or burning operations. o Fire watch shall have useable firefighting equipment available for use. o Fire watch shall maintain continuous surveillance with a portable gas detector during welding or burning operations. o Fire watch shall remain on duty for at least 30 minutes after welding or burning operations have ceased. Hot tapping operations shall only be conducted with BSEE and Fieldwood Engineering approval. After it has been determined that it is safe to proceed with the welding, burning or spark producing activities, the designated person-in-charge (PIC) and/or Project Supervisor shall issue written authorization for the work using the Welding and Burning Authorization - Hot Work Permit see Section D, chapter 15, Part A).