1701-09 - Hot Work Operations (public).docx

Page 2 of 2 Procedure 1701-09

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/s/ CAPT A. Jesse Stark, NOAA

Section 7

Responsible Position

CAPT A. Jesse Stark, NOAA Director, Marine Operations Chief, SEMB

Hot Work Operations

1. Purpose

1.1 Numerous safety and health hazards are associated with welding, cutting, and brazing. Failing to observe necessary precautions during these operations can result in severe risks, including: fires, explosions, electric shocks, and harm to one's health. This procedure provides the minimum requirements for performing hot work aboard a National Oceanic and Atmospheric Administration (NOAA) ship.

1.2 This version adds details on required respiratory protection and ventilation to prevent hazardous hot work fumes and gas / vapor exposure levels to workers.

2. Scope

2.1 This procedure applies to all ships in the NOAA fleet.

2.2 This procedure applies to contractors, industry representatives, shipyard workers, and other individuals that may work aboard NOAA ships.

2.3 A Ship Specific Instruction (SSI) is required to list designated hot work areas and qualified individuals.

2.4 Hot Work includes a range of activities. Riveting (hot), welding, burning, the use of powder-actuated tools, or similar fire-producing operations are always defined as hot work and require full compliance with this procedure at all times. Grinding, drilling, abrasive blasting, etc., are considered hot work only in the presence of readily combustible or flammable materials (including solids, liquids and vapors). (For example: needle gunning/grinding on an open deck in the absence of combustibles is not considered hot work; however, needle gunning/grinding on a gooseneck to a fuel tank is considered hot work.)

Hot work must not be performed:

· During fueling or oil transfers;

· If it is likely to cause a fire or explosion;

· On surfaces that will emit toxic fumes when heated;

· In confined spaces without marine chemist’s “Safe for Hot Work” certificate; or

· In spaces, or adjacent spaces, that contain concentrations of flammable vapors greater than ten (10) percent of the lower explosive limit (LEL), except in designated hot work spaces (see below).

3. Responsible Positions

3.1 The following positions or groups have action item responsibilities within this procedure:

· Ship Commanding Officer

· Chief Marine Engineer

· Officer of the Deck

· Hot Work Competent Person

· Chief, Safety and Environmental Management Branch

· Fleetwide Industrial Hygiene Officer

4. Responsibilities and Procedures

4.1 Responsibilities

(A) The Ship Commanding Officer (CO) ensures all hot work operations are conducted per this procedure.

(B) The Hot Work Competent Person is responsible for ensuring hot work operations, involving welding or molten metal, are conducted safely, according to this procedure, including preparing required permits and completing hot work operation prerequisites (section 4.3).

(C) The hot work operator conducts all hot work operations safely.

(D) Fire watch personnel maintain communication with Officer of the Deck (OOD), ensure fires do not start as a result of hot work operations, and in the event that a fire does start, fire watch personnel notify the OOD, sound the fire alarm, and begin extinguishing the fire.

(E) Safety and Environmental Management Branch and Fleetwide Industrial Hygiene Officer are available to support this procedure and provide training, as needed.

4.2 Hot Work Procedures

(A) Hot work operations are only performed by a trained and authorized hot work operator as designated by the Chief Marine Engineer (CME) or Hot Work Competent Person and approved by the Ship CO. A list of the designated hot work operators is maintained aboard the ship (posted where other qualification lists are maintained). In addition to the hot work operator, all hot work operations must have at least one person on fire watch at the hot work location. If hot work, sparks, or heat transfer may affect more than one space, multiple fire watches must be used.

(B) The hot work operator uses required personal protective equipment (PPE), as indicated in the OMAO Procedure 1701-06 – Personal Protective Equipment, including:

(1) Eye and face protection;

(2) Proper electrically insulated welding gloves or electrical safety gloves when removing or replacing electrodes;

(3) Half or full-face air purifying respirator must be used unless local exhaust ventilation is provided; see OMAO Procedure 1701-07 – Respiratory Protection Program. Respiratory protection levels are determined by task and location.

(4) Leather gloves, non-synthetic fabric aprons, and jackets as appropriate.

(C) Hot work operations may only be conducted if:

(1) A fire watch is assigned for hot work. (Per the definition of hot work: grinding, drilling, or similar operations are considered hot work only in the presence of readily combustible or flammable materials (including liquids, vapors or solid materials). They do not require a fire watch in the absence of combustible materials.

(2) All firefighting systems are operational and any disabled sensors to allow work to be completed are clearly identified and communicated.

(3) During periods when fire system components are disabled, or removed from the ship, an equally effective means of fire detection or suppression must be used.

(D) Hot work operations in confined spaces may only be performed if:

(1) The ship is in port;

(2) Safe for Hot Work Certificate is issued by Marine Chemist;

(3) All Confined Space Entry requirements indicated in OMAO Procedure 1701-10 – Confined Space Entry Program are met; and

(4) Gas cylinders, manifolds, and other cutting equipment remain outside of the confined space.

(5) Safety of life at sea is in jeopardy, as determined by the CO or CME.

(E) During welding operations:

(1) When practical, a shielding should be provided and/or access restricted to protect others from viewing the arc;

(2) Worker should position themselves to avoid breathing welding fumes/gases and should stay upwind when working outdoors;

(3) Gas supply must be secured at the cylinder or manifold when equipment will not be used for periods greater than thirty (30) minutes or will be left unattended for periods greater than fifteen (15) minutes

(4) All cylinders must be stored upright and individually secured with non-flammable restraints (i.e. safety chains)

(5) Torches and electrodes must be disconnected from the hoses / supply cables when not in use for periods greater than thirty (30) minutes or left unattended for periods greater than fifteen (15) minutes.

(6) When working indoors, welder must use: Local Exhaust Ventilation (LEV) that exhausts to the exterior atmosphere, a properly maintained fume extractor, or wear proper respiratory protection.

(F) Designated Hot Work Areas:

(1) Each ship should strive to designate a workshop for hot work to be performed; this designated hot work area should be the first place considered for performing hot work operations.

(2) Designated hot work areas must be prepared and maintained per Section 4.3(A) of this procedure.

(3) The precautions section of NOAA Form (NF) 57-17-09 - Hot Work Permit must be completed by the CME, or their designee, prior to commencing hot work (no signatures necessary).

(4) The OOD is notified when hot work will be performed and when completed within a designated area.

(5) Any hot work performed on a bulkhead within a designated area will still require the completion of a hot work permit, including all signatures.

(6) A list of the designated hot work areas must be maintained in the SSI.

(7) When designated hot work areas are adjacent to fuel storage tanks, or contain sounding tubes connected to fuel tanks, fire retardant matting or covers should be used to protect tank and tube areas from heat sources. The CME should consider a Job Hazard Analysis (JHA) to help identify risks and controls.

(8) Designated hot work areas must have fixed or portable ventilation (LEV) or a fume extractor to adequately remove smoke and fumes and keep flammable vapor concentrations within safe limits. See Section 4.3(A).

(9) The requirement to stand a fire watch remains in effect in designated hot work areas when riveting, welding, or burning. However, grinding, drilling, or similar operations are considered hot work only in the presence of readily combustible or flammable materials (including liquids, vapors or solid materials); they do not require a fire watch in the absence of combustible materials.

4.3 Hot Work Prerequisites

(A) Before hot work operations may commence, the following preparations of the hot work area must be completed:

(1) The subject space and adjacent spaces are inspected to determine potential fire hazards;

(2) Combustible materials inside the subject space, within thirty-five (35) feet of the hot work area, are moved to another space, covered with a fire proof cloth, or shielded with a metal guard;

(3) Combustible materials inside adjacent spaces are removed from the opposite side of the subject space bulkhead, overhead, or deck below. Machinery and equipment that cannot be moved in the subject space is covered by a fire proof cloth, or shielded with a metal guard;

(4) The edges of the fire proof cloth are tightened or secured to provide significant overlap and protection to keep sparks from getting under the cloth.

(5) Lockout / tagout requirements in OMAO Procedure 1701-05 – Lockout / Tagout are complied with, if applicable;

(6) Ducts, sounding tubes and pipe / cable penetrations / chases that could carry sparks to other spaces must be blanked off with proper shielding or guarding;

(7) Hot work surfaces must be as clean as practicable of any coating or oil / grease / solvent etc. particularly chlorinated solvents that could increase the overall exposure to airborne concentrations of hazardous particles, fumes, or vapors.

(8) Adequate ventilation (fixed or portable) is in place to effectively remove smoke and maintain flammable vapor concentrations within safe parameters while keeping them away from the worker’s breathing zone. LEV is recommended utilizing fixed LEV with flexible exhaust ducting vented directly to the exterior or, in cases where fixed LEV is not available, a portable air filtering LEV such as a fume extractor. Contact the NOAA Fleet Industrial Hygiene Officer with questions on fume extractors.

(9) In the absence of LEV, wear a full or half face respirator with a HEPA cartridge must be worn (including Powered Air Purifying Respirator (PARP)).

(10) While conducting hot work on stainless steel, due to the presence of Hexavalent Chromium (known carcinogen), a full or half face respirator with a HEPA cartridge must be worn regardless if LEV is present. Contact the NOAA Fleet Industrial Hygiene Officer with questions on respiratory protection and the availability of hot work health exposure assessments.

(B) Before hot work operations may commence outside of a designated hot work area, the following administrative requirements must be in place:

(1) The CME or Hot Work Competent Person certifies the area or space “Safe for Hot Work”; during shipyard repair periods, this duty may be delegated if the space is certified safe for hot work by a marine chemist.

(2) The CO or designated representative approves the hot work and documents approval in the ship’s deck log;

(3) A Hot Work Permit (NF 57-17-09) is completed, including precautions and all signatures (ship specific requirements can be added to the permit).

(4) The NF 57-17-09 is posted in the adjacent space on the bulkhead next to the entrance of the hot work space.

(C) Before hot work operations may commence, the following support personnel must be in place or notified:

(1) A trained and competent fire watch, per Section 4.4 of this procedure, is posted in each affected space where a fire may occur as a result of the hot work operations;

(2) Communication is established between each member of the fire watch, the hot work operator and the OOD;

(3) The OOD makes an announcement on the ship’s public address system notifying all shipboard personnel of the ensuing hot work operations outside of designated hot work area; and

(4) The fire watch notifies the OOD when hot work commences.

(D) A certified Marine Chemist must issue a “Safe for Hot Work” certificate before hot work operations are conducted in any of the following locations:

(1) Within a confined space;

(2) Within or on the boundaries of tanks that have been used to carry combustible liquid chemicals, petroleum products, or sewage;

(3) Upon any pipeline, heating coil, pump, fitting, or other equipment connected to such tanks.

Additionally, for contractors working aboard:

(4) Within any space adjacent to tanks that have been used to carry liquid chemicals or petroleum products, unless distance between such tank and hot work is greater than 25 feet.

(E) Contractors conducting hot work:

(1) Contractors are encouraged to use NOAA Hot Work Permit (NF 57-17-09) for approval of hot work aboard a NOAA ship, including in shipyard.

(2) If the shipyard / contractor prefers their form, it must be equal to the NOAA form in content or the shipyard must demonstrate a clear benefit for using their form.

(3) The shipyard / contractor must brief the CO and CME on their form and seek written approval for use. The CO, CME, or OOD must be informed before any contractor hot work is performed. This notification is to be documented on the form.

(4) Per NOAA’s Standard Spec, the shipyard / repair contractor must brief NOAA on their OSHA compliant Hot Work procedure.

(5) For ships in extended repair periods with minimal officers and crew aboard, the contract representative, ship command, and shipyard must have an agreement on how to proceed.

(F) A fire watch is required in each space where sparks or heat transfer may ignite combustibles. Multiple fire watch personnel may be required. The fire watch:

(1) Must maintain communication with OOD and other personnel on fire watch;

(2) Has the authority to stop any hot work operation, for any reason;

(3) Has no other assigned duties while maintaining a fire watch;

(4) Reviews all posted permits and certificates;

(5) Is knowledgeable in sounding the fire alarm;

(6) Is properly trained in the use of firefighting equipment;

(7) Is equipped with appropriate firefighting equipment;

(8) Is equipped with appropriate PPE, as required for the operation; and

(9) Is maintained without interruption, including meals and other breaks.

4.4 Procedures Following Completion of Hot Work

The hot work operator notifies the OOD and CME.

(A) The fire watch:

(1) Remains on fire watch for thirty (30) minutes after completion of hot work operations or longer until the affected metal surface areas are cool to the touch;

(2) Inspects the work area and all adjacent spaces for hot spots and smoldering embers before securing the fire watch; and

(3) Informs the OOD of fire watch termination.

(4) Don a respirator with a HEPA cartridge in the presence of visible smoke.

(B) The OOD:

(1) Makes an announcement on the ship’s public address system notifying all shipboard personnel of the completion of hot work operations when hot work operations occurred outside of designated hot work area;

(2) Returns to service any disabled fire system or part thereof;

(3) Thoroughly inspects the hot work area and all adjacent spaces at the end of their watch;

(4) Directs subsequent security watches to conduct heightened inspections for fire or smoke for at least eight (8) hours following the completion of the hot work; and

(5) Ensures all appropriate entries are made in the ship’s deck log.

4.5 Training Requirements

Training will occur before accepting duties and will be repeated upon change in assigned duties, upon deviation from established procedure, and upon identifying inadequacies in personnel knowledge.

Documentation of training must include the employee’s name, date(s) of the training, type(s) of training, and any documentation of completed training (i.e. Certificate of Completion). Share training documentation with MO Training and Readiness and retain on board.

(A) Hot Work Competent Person:

(1) Must complete Shipyard Competent Person Training or Navy Gas Free Engineer Training.

(2) May contact Safety and Environmental Management Branch for a Hot Work procedure briefing.

(B) Hot work operator:

(1) Must receive CME approval and be added to the list of authorized hot work operators prior doing hot work. To assist in evaluation of hot work operator skills, the CME may use Hot Work Personnel Qualification Standards (PQS), see Attachment A.

(2) Must complete Hot Work Health Hazard Training prior to conducting hot work that generates fumes by molten metal (welding, torch cutting, etc.). Contact NOAA Fleet Industrial Hygiene Officer for assistance.

(3) May contact Safety and Environmental Management Branch for a Hot Work procedure briefing.

5. Records and Reports

· NF 57-17-09 - Hot Work Permit (Retain for 1 year)

· NF 57-17-10 - Confined Space Entry Permit

· NF 57-11-13B - Deck Log

· Marine Chemist “Safe for Hot Work” certificate

6. References

29 CFR, Part 1910, Subpart Q – Welding, Cutting, and Brazing. Occupational Safety and Health Administration.

29 CFR, Part 1915, Subpart B – Confined and Enclosed Spaces and Other Dangerous Atmospheres in Shipyard Employment. Occupational Safety and Health Administration.

U.S. Department of Commerce Occupational Safety and Health Manual http://hr.commerce.gov/s/groups/public/@doc/@cfoasa/@ohrm/documents/content/dev01_006463.pdf

Document Management System

· OMAO Procedure 1701-05 – Lockout/Tagout

· OMAO Procedure 1701-10 – Confined Space Entry

· OMAO Procedure 1701-06 – Personal Protection Equipment

· OMAO Procedure 1701-07 – Respiratory Protection Program

7. Definitions

Adjacent Space A space that borders the subject space in all directions, including points of contact, corners, diagonals, decks, tank tops, and bulkheads.

Fire System Any system used to detect, suppress or extinguish a fire.

Hot Work Riveting (hot), welding, burning, the use of powder-actuated tools or similar fire-producing operations; any operation that raises the temperature of the workpiece equal to or greater than 204°C (400°F); or grinding, drilling, abrasive blasting, or similar operations in the presence of or against the accumulations of readily combustible materials or flammable or combustible liquids or vapors when the atmosphere exceeds 10 percent of the LEL.

Marine Chemist An individual recognized by the National Fire Protection Agency as qualified to test confined spaces and determine their condition with respect to oxygen sufficiency, explosive vapors, or toxic gases.

Competent Person An individual trained and authorized to conduct testing of oxygen and explosive gas levels. He/she evaluates the space, develops ways to control hazards, and signs a hot work permit (must have completed Shipyard Competent Person, or NAVY Gas Free Engineer training and been designated by Command).

Flammable Liquid / Gas Flammable liquid means any liquid having a flashpoint at or below 199.4 ºF (93 ºC).

8. Notes

Effect on other documents: Supersedes all previous versions of OMAO Procedure 1701-09 – Hot Work Operations.

Document History

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