API 2009: Safe Welding, Cutting, and Hot Work Practices in the Petroleum and Petrochemical Industries

Question 1

What is meant by the term “competent person?” (API 2009-2002, Section 3.3)

Answer 1

A person identified by the employer as being capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to personnel, and who has authorization to take prompt corrective measures to eliminate them (OSHA 1926.32). The concept of “competent person” is performance-based relative to the context of the work to be done.

Question 2

What is meant by the term “lower flammable limit?” (API 2009-2002, Section 3.11)

Answer 2

The concentration of a vapor in air (or other oxidant) below which propagation of flame does not occur on contact with an ignition source. The lower flammable limit is usually expressed as a volume percentage of the vapor in air. Sometimes called Lower Explosive Limit (LEL).

Question 3

What is meant by the term “exposure limit?” (API 2009-2002, Section 3.5)

Answer 3

For chemical agents, a measure of the maximum airborne concentration limits for toxic substances to which workers may be exposed without protection (e.g., respirators). Exposure limits are usually expressed in parts per million or milligrams per cubic meter. Material Safety Data Sheets (MSDSs) from the manufacturer or supplier of the material should list exposure limits.

Question 4

What is meant by the term “confined space?” (API 2009-2002, Section 3.4)

Answer 4

An enclosure with known or potential hazards and restricted means of entrance and exit, which is not normally occupied by people, and is usually not well ventilated. Examples of confined spaces in the petroleum industry include: process vessels, vessel tower skirts, flare stacks, boilers, storage tanks, tank cars and trucks, vaults, large-diameter piping, and under certain circumstances, spaces located below ground level, such as pits (OSHA 1910.146).

Question 5

What is meant by the term “hot work?” (API 2009-2002, Section 3.8)

Answer 5

An operation that can produce enough heat from flame, spark or other source of ignition, with sufficient energy to ignite flammable vapors, gases, or dust.

Question 6

What precautions should be taken before welding or cutting is performed above or near oily surfaces? (API 2009-2002, Section 9.3)

Answer 6

If hot work is to be done there should be no (0%) detectable flammable concentration. Any source of detectable flammable vapors should be found and eliminated before hot work begins.

Question 7

What are five ways to reduce exposure to welding fumes? (API 2009-2002, Section 5.4.1)

Answer 7

1. Using alternate equipment, procedures or welding materials.
2. Using local fume-capture ventilation.
3. Using administrative controls to limit potential welder exposure.
4. Teaching welders how to minimize exposure (stay upwind and keep head out of plume).
5. Using personal protective respiratory protection.

Question 8

Except in inert spaces, what should the concentration of flammable vapors be in order to permit entry into a confined space? (API 2009-2002, Section 9.3)

Answer 8

Less than 10% of the LFL, regardless of the type of respiratory protection required, in order to permit entry.

Question 9

Under what circumstances is a fire watch person required? (API 2009-2002, Section 6.5)

Answer 9

Properly trained and equipped fire watch personnel shall be required whenever a permit is required for hot work.

Question 10

What equipment should fire watch personnel have readily available? (API 2009-2002, Section 6.5)

Answer 10

Fire watch personnel should have appropriate functional fire extinguishing equipment readily available.

Question 11

What are some activities usually considered to be hot work? (API 2009-2002, Section 3.8)

Answer 11

a) Electric arc and gas welding
b) Chipping,
c) Flaming
d) Grinding
e) Gas cutting
f) Abrasive blasting
g) Brazing
h) Soldering

Question 12

When should a hot work permit be obtained? (API 2009-2002, Section 8.2)

Answer 12

Except in areas specifically designated as safe for hot work, a hot work permit shall be obtained before starting any work that can involve a source of ignition.

Question 13

What information and conditions should be included in a hot work permit? (API 2009-2002, Section 8.2)

Answer 13

a) The equipment on which work is to be performed and the location of work.
b) Identification and location of relevant MSDSs (where appropriate).
c) The type of work to be performed (e.g., cutting, welding, grinding).
d) The protective equipment and protective measures required, including rescue equipment for work in confined spaces.
e) Standby fire protection equipment and/or personnel required.
f) The area/equipment required to be tested with an oxygen and combustible gas detector and, if required, tested for toxic materials, plus the test results.
g) Frequency of atmospheric testing and whether continuous monitoring is required.
h) Any special precautions which are necessary to complete the job safely, including conditions for stopping work.
i) Indication that affected personnel have been notified.
j) Signatures of authorized individuals including (as a minimum) the competent person issuing the permit.
k) Signature of the permit recipient (who in some instances may be a contract worker).
l) The date and time the permit was issued.
m) The permit’s expiration date and time.