DOCUMENT: 4301-06-301

HOT WORK PROCEDURE - SP #1 REVISION DATE: 1-DEC-23

PAGE: 1 OF 14
LAKE CHARLES SOUTH SAFETY & HEALTH

Note: When contractors are involved in the job, a Westlake Coordinator shall be involved in the
Pre-Job discussion and sign on permit as such.
1 Purpose:
To establish a fire prevention permit procedure for working safely with welding, burning, spark
producing or open flame-producing equipment referred to in the following document as “Hot
Work”.

2 Scope:
2.1 To provide communication between operations and maintenance/contract personnel
involved, regarding the safety of the jobsite conditions, including the potential hazards
and safety information while performing Hot Work.
2.2 A Hot Work Permit must be used to control all Hot Work performed on Westlake
property, except for the following:
2.2.1 Permanent designated shop locations
2.2.2 Temporary fabricating areas may be treated as permanent designated shop
locations by means of evaluation and mutual agreement between the Operations
Supervisor, Field Engineering and the Safety Department.
2.3 This procedure is to be utilized for any off-site facilities as well. (Brine field, Pipeline,
etc.)

3 Definitions:

Affected Employee- Employees impacted by the performance of permitted work which may
include hot work.

Authorized employee- Employees trained and authorized to perform permitted work in the
plant.

Class 1 Hazardous Locations- Flammable gases or vapors are or may be present in the air in
quantities sufficient to produce explosive or ignitable mixtures.

• Division I- Ignitable concentrations of flammable gases or vapors may exist under normal
operating conditions, exist frequently due to repair, maintenance operations, leakage or be
released as a result of breakdown or faulty operation of equipment and simultaneous failure
of electrical equipment.

• Division II- Locations where flammable gases and liquids are handled, processed or used
but will normally be protected by mechanical ventilation or a closed system in which they
can only escape in the event of an accidental breakdown, rupture or abnormal operation,
locations adjacent to Division I areas where flammables may occasionally exist unless
prevented by clean air ventilation and effective safeguards.
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Class 2 Hazardous Locations- Combustible dust is or may be present.

• Division I- Locations were combustible dust is or may be suspended in the air under normal
conditions in quantities sufficient enough to cause explosions or ignitable mixtures, where
mechanical failure or abnormal operation of machinery may produce such explosions or
ignitable mixtures or where combustible dust of an electrically conductive nature may be
present.

• Division II- Locations where combustible dust will not normally be suspended in the air in
quantities sufficient to produce explosions or ignitable mixtures, dust accumulation will
normally be insufficient to interfere with the normal operation of electrical equipment,
combustible dust may be suspended in the air as a result of infrequent malfunctioning or
handling of process equipment

Combustible Dust- Particulate solid that will burn violently when suspended in air over a range
of concentrations, regardless of particle size or shape. Note: any “material that will burn in air” in
a solid form can be explosive when in a finely divided form as a powder or dust.

Combustible Material- Capable of reacting with oxygen and burning if ignited. Examples
include oil, paper, various chemicals products, wood, plastic, textile fibers such as carpet and
cardboard.

Designated Hot Work Area (Temporary)- A specific location approved, on a temporary basis,
for hot work operations that is maintained fire safe, that is of noncombustible or fire-resistive
construction, essentially free of combustible and flammable contents, and suitably segregated
from adjacent areas.

Designated Hot Work Area (Permanent)- A specific location designed and approved for
continuous hot work operations that is maintained fire safe, such as a maintenance shop or a
detached outside location, that is of noncombustible of fire-resistive construction, essentially
free of combustible and flammable contents, and suitably segregated from adjacent areas (no
hot work permit required).

Equipment Owner- The person assigned to an area/department that normally controls and
operates the equipment.

Field Review- A review of the work at the job site location that includes all aspects of the job
scope for which the permit is written prior to the permit being written. Examples include location
of safety showers, line break locations, isolation verification etc.

Fire Watch– An individual assigned, trained and qualified to monitor and observe hot work
activities. Aid in preparing work area for hot work, take necessary action(s) to prevent and
control sparks caused by hot work and fighting incipient fires caused by hot work activities. The
fire watch would also contact operations in the event of a fire.
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Fire Safe- An area where combustible or flammable materials have been removed from the
immediate area (Greater than 35 feet) where hot work operations are being conducted.

Flammable Atmosphere- A mixture of dangerous substances with air, under atmospheric

conditions, in the form of gases, vapors, mist or dust which are ignitable and after ignition has
occurred, combustion spreads to the entire unburned mixture.

Hazardous Atmosphere- Any atmosphere that may expose employees to the risk of death,
fire/explosion, the ability to self-rescue, injury or acute illness is defined as, but not limited to:

I. Flammable gas, vapor or mist in excess of 10% of its lower flammable

limit (LFL) or lower explosive limit (LEL); and/or,

II. Airborne combustible dust at a concentration that meets or exceeds its

lower flammable limit (LFL) or lower explosive limit LEL).

Hot Tap- The technique of attaching a welded branch fitting to piping or eq u i pm e nt as it

remains in service, and then creating an opening in that piping or equipment by drilling or
cutting a portion of the piping or equipment within the attached fitting. Hot Tapping by definition
involves Hot Work on equipment “in service”

Hot Work- Any operation that can produce a spark, arc or flame hot enough to cause the
ignition of ordinary combustible materials, combustible dusts, flammable gasses or vapors.
Examples of hot work include welding, cutting (Saws-all, Porta-band, etc.; “Metal to Metal”),
burning, resistance welding, soldering, brazing, torch applied roofing, sand-blasting, grinding,
abrasive wheel cutting, servicing of electrical equipment capable of producing sparks or other
operations like that are capable of initiating fires or explosions.

Hot Work Permit- An authorization permit used as a safety planning tool to ensure necessary
safety precautions have been addressed prior to beginning work on site.

Hot Work Permit Authorizing Individual- The individual designated by site management to
authorize hot work.

Ignition Source- Non-intrinsically safe equipment such as Portable Electronic Devices, Light
Plants, Vehicles, Golf Carts etc.

Isolation Verification- Prior to starting work, authorized employees including contractors and
affected employee shall walk out the isolated system to verify that isolation and deenergizaton
has been accomplished. Examples of verification would include but are not limited to blind
location, activating start switches, checks with voltage meter, open bleeder valves, etc.

Incipient Fire – The initial or beginning stage of a fire, which can be controlled or extinguished
by portable fire extinguishers, Class II standpipe or small hose systems without the need for
protective clothing or breathing apparatus.
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Lower Explosive Limit (LEL) - The lower limit of flammability of a gas or vapor at ordinary
ambient temperatures expressed in a percent of the gas or vapor in air by volume. For the
purposes of this procedure, the %LEL limit for hot work permit authorization is 0.0% LEL. A
variance must be obtained prior to conducting work with readings above 0.0% LEL.

Process Area- Area employed in production in which an action, operation, or treatment

embracing chemical, industrial, manufacturing, or processing factors/methods is carried out
utilizing substances that may contain or could lead to a potential flammable and/or combustible
hazard.

Safe Work Permit - A multifaceted safety planning tool to ensure that necessary safety
precautions have been addressed prior to beginning work on site. The Hot Work permit is used
to authorize Hot Work

Welding blanket/curtain- A heat-resistant fabric designed to be placed in the vicinity of a hot

work operation with light moderate exposures such as that resulting from chipping, grinding,
heat treating, sand blasting, and light welding. Designed to protect machinery and prevent
ignition of combustible materials such as wood that are located adjacent to the underside of the
blanket.

Welding Pad- A heat-resistant fabric designed to be placed directly under a hot work operation
such as welding and cutting. It is intended for use in horizontal applications with severe
exposures such as that resulting from molten substances or heavy horizontal welding designed
to prevent the ignition of combustible materials that are located adjacent to the underside of the
pad.

Westlake Coordinator- A Westlake employee or representative approved by Westlake

management that will facilitate a healthy pre-job conversation between operations and
contractor as an additional layer of protection for jobs performed by contractors.

4 Responsibilities:
4.1 The Hot Work Permit will be issued by the Operations Supervisor, Lead Operator, “B”
Operator. In situations where the equipment to be worked on falls outside of an
operating unit the equipment owner will be the issuer.
4.2 Hot work permits are issued for equipment used in welding, burning, grinding,
cutting or producing an open flame. (See Hot Work Definition for guidance)
4.3 Hot work permits require testing with an active combustible gas monitor.
4.4 The permit issuer will use the hot work permit as a guide to prepare the area for Hot
Work.
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4.5 All combustible materials shall be removed from the area within 35 feet of the hot
work operation. This may involve sweeping, hosing down, etc. to assure
combustibles will not be ignited.
4.6 If easily ignitable combustibles cannot be removed, the area and/or combustibles must
be wetted and/or covered with a fire blanket. Welding or cutting in flammable process
units requires watering sparks and slag.
Note: In the event that the area is wetted down, personnel operating the arc
welding or cutting, shall be protected from possible shock.
4.7 The Maintenance Foreman or Contractor Supervisor will be responsible to ensure that
precautions have been taken as outlined on the permit. The Maintenance Foreman or
Contractor Supervisor will also provide verbal job safety instructions to the employees.
4.8 When hot work is to be performed by Contract employees the Contractor’s Supervisor
will be the requester, sign the permit, and serve as supervisor for the work.
Note: When contractors are involved in the job, a Westlake Coordinator shall be
involved in the discussion prior to the job and sign on permit as such.
4.9 The employees working under the permit are responsible to follow the precautions listed
on the permit and ask questions to clarify anything that is not understood.
4.10 The paper copy of the permit will be kept in a prominent location in the control room
while the permit is active. In the event of a unit upset, the permit will serve as a
reference for work being performed in the unit. The field cardboard copy of the permit
will be issued to the craftsmen performing the work and will be placed in possession of
the person performing the work, fire watch or placed with the welding machine or
equipment being used.
4.11 The employees working under the permit are responsible for notifying their supervisor,
who will notify the issuer (Operations, Field Engineer) at the completion of the job, if
the job needs to be revalidated (retested) when a break in work is more than 30 minutes,
or at the expiration of the permit. They will return the permit to their supervisor at the
end of the job or expiration of the permit.
4.12 The field copy of the permit will be returned to the issuer/equipment owner by the
supervisor when it is no longer needed, the permit “Time” has expired or upon
completion of the job.
4.13 The issuing equipment owner/control room will keep the permits for seven days, per Works
Managers Retention letter. EDMS #4301- 06-309.
4.14 Operations or Shipping Representatives:
4.14.1 Control the issuance of permits for work located in their assigned areas.
4.14.2 Are responsible for ensuring that at a minimum, the requirements of this
procedure are followed in their units.
4.14.3 Do not issue permits when unsafe conditions exist, or adequate mutual
understanding has not taken place.
4.14.4 Sign the permit authorizing the area has been walked out, tested and that all
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hazards have been mitigated, and the job is ready to commence.

4.15 Maintenance / Contractor Supervisor:

Note: When contractors are involved in the job, a Westlake Coordinator shall be involved
in the discussion and sign on permit as such.
4.12.1 Complete permit requirements assigned to Maintenance or persons functioning
as required. (I.e. covering sewer openings and trenches)
4.12.2 Account for safety requirements during the planning process by providing
verbal job safety instructions before beginning work.
4.12.3 Do not accept permits when unsafe conditions exist, or adequate mutual
understanding has not taken place.
4.12.4 Sign the permit acknowledging that the job has been walked out with
operations, they agree that hazards have been mitigated and accept the job.
4.12.5 In the event that Hot Work activities have stopped for greater than 30 minutes,
revalidation (retesting) of the work area shall be performed by operations or
issuer, prior to commencing the work.
4.13 Safety Department:
4.13.1 Review written program and requirements for updating as needed.
4.13.2 Review permits in the field prior to issuance.
4.14 Training Department:
4.14.1 Ensure documented qualifications for Operations Representatives are
maintained for employees who issue Hot Work permits.
4.14.2 Ensure employees are properly trained in the Hot Work procedure as needed
to meet the requirement.
5 Issuance of Hot work permit:
5.11 Hot work can only be permitted when the area is free of combustible and / or
flammable material and atmospheric monitoring is within acceptable ranges. If
this cannot be accomplished the hot work must be relocated outside the area to a
designated work area.
• Eliminate ignition sources by selecting alternative work methods, equipment or
moving the location of the hot work to a non-hazardous location
• Implement safeguards and controls (examples - fire blankets, enclosures and wetting
or cleaning surfaces)
5.12 If there are any doubts if conditions are safe by anyone authorized to sign the hot work
permit, they should withhold the issuance of the permit and consult with the safety
department.
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5.13 It is the responsibility of anyone who becomes aware of changes in the conditions which
might cause fire, exposure to gases or any other unsafe conditions to halt work
immediately and notify the Operations Representative that issued the permit and
their supervisor.
5.14 Ensure that all energy sources have been properly isolated. Blinds are required while
performing hot work on process equipment last containing flammables. If this cannot be
accomplished then refer to the Safety Department.

5.15 After the Hot Work permit is issued, changes in the scope of work will require a new
permit to be issued for the job. Any minor additions such as changes to PPE shall be
initialed by the Operations Representative that issued the permit and the
Maintenance/Contractor Supervisor on the permit. Initial on the permit at the location
change was made. No Verbal changes are allowed. The Maintenance/Contractor
Supervisor must review the changes with all workers covered by the permit.
6 Requirements for hot work:
6.1 A trained fire watch, who shall not be assigned any other duties.
6.2 Continuous atmospheric monitoring by an active monitor shall be required for the
duration of the hot work activity.
6.3 All hot work will be conducted following OSHA's 29CFR 1910.252 "Welding, Cutting and
brazing."
6.4 Notify Safety prior to work beginning.
6.5 Permit Signatures
6.5.1 Equipment Owner/Operator
6.5.2 Maintenance/Contractor Supervisor
6.5.3 Fire Watch
6.5.4 Safety
6.5.5 Westlake Coordinator when contractors are performing work

7 The acceptable atmospheric air monitoring ranges for Hot Work Permitting must be in the
following ranges:
7.1 Oxygen – Must be in the range between 19.5% and 23.5%
7.2 LEL – 0%
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8 If the LEL is greater than 0.0% hot work permitting must be approved by the Department
Manager and Safety Department. In no case will a permit be issued when meter readings of
10%LEL or greater are obtained.
Note: A false reading can exist due to the presence of an inert gas like nitrogen or argon. A
sufficient amount of oxygen must be present to give an accurate LEL reading. In most meters
this is 16% oxygen, see manufacturer’s instructions.
9 Toxicity – 0% if potential for toxins exists during hot work.
10 The permit issuer will verify, evaluate, and utilize an active combustible gas detector to test the
work to be conducted with the person doing the work and his supervisor.
11 The issuer will survey the work location to verify that conditions are acceptable per permit
requirements.
12 No Hot Work will be performed in buildings and operating units where the sprinkler
system is impaired unless a backup system has been installed by Shift Safety and /or our
sprinkler maintenance contractor.
13 For Hot Work, the issuer will examine the work area for combustible materials visually (oil,
grease, diesel, etc.) and with an approved active LEL/O2 instrument from the point of operation,
out 35 feet in all directions.

13.1 The meter must be bump tested in a safe atmosphere for proper operation and
calibration prior to each use.
13.2 Check calibration date on the instrument prior to use. (30-day Maximum)
13.3 The issuer must be trained in the use of the LEL/O2 instrument used to test the
atmosphere.
13.4 The issuer will complete the permit and review it with the requester. Paper copy will be
kept by the Control Room and the Cardboard copy will go to the job.
13.5 At the completion of the work, the owner/issuer will be notified. The hot work permit shall
not be closed until 30 minutes following the hot work activities.
13.5.1 Notification will be accomplished by returning cardboard copy to the
Owner/Issuer. The Hot Work Permit shall be kept on file (i.e. control room)
until completion of the work.
13.6 A Hot Work Permit shall be issued only when all preparations are made and the hot work
is ready to commence. The issuer specifies the start time and expiration time of the
Permit.
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13.7 Following any break in continuity of the job, meaning no hot work is being performed
for 30 minutes or greater, such as, time spent in shops on fabrication, lunch, etc. The
permitted area shall be revalidated (retested), by operations, with an active monitor to
confirm atmospheric monitoring is within acceptable ranges. The results will be
documented on the field copy of the permit in the Results/Time section.
13.8 All permits will be voided and new permits issued after a unit upset.
13.9 Hot Work Permits are generally written to coincide with the current operational shift. The
permit duration is 12 hours.
13.9.1 It may be extended up to 2 hrs. to accommodate completion of a job
provided that the same personnel are involved. Permit may be issued on
one shift and carry over to the second shift provided the same personnel
are involved.
14 Special Cases:
14.1 If “hot work” is to be done on a piece of process equipment entirely in a designated
shop location and the equipment is free from flammable materials.
14.2 The Equipment owner will issue the initial permit to assure safe working conditions.
15 General:
15.1 When performing Hot Work near sewer openings or trenches anywhere in the
complex, they must be evaluated for flammable atmospheres and covered and
sealed.
15.2 When performing Hot Work near combustible walls, partitions, ceiling or roof of
combustible materials, fire resistive shields or guards shall be provided to prevent
ignition.

15.3 When performing Hot Work on a metal (noncombustible) wall, a partition, piping,
ceilings, or on roofs, precautions shall be taken to prevent ignition of combustibles on
the other side, due to conduction or radiation. This can be done by removing the
combustibles or providing fire resistive shielding and placing a fire watch on the side
of the combustibles.
15.4 When performing Hot Work on, near or above a cable tray containing plastic
instrument tubing and/or exposed electrical wiring, the exposed area shall be
adequately covered with fire blankets to prevent damage to lines.
15.5 When performing Hot Work overhead, the area below shall be barricaded or a watch
posted to alert personnel.
15.6 Isolating and clearing must be performed when Hot Work is being performed on
process lines or vessels that may contain (or have contained) a flammable or
explosive material (including well water). Installation of blinds is the preferred
method of control. Removal of spool pieces or similar procedures which will provide
equivalent protection is acceptable. All valves controlling flows to and from the work
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shall be closed and locked with bleed valves open and locked.
15.7 When welding or cutting on used containers (drums, barrels, tanks, etc.), shall be
cleaned thoroughly as to make absolutely certain that there are no flammable
materials present. Any pipes or connections shall be disconnected or blanked. All
containers shall be vented to permit the escape of air or gases before preheating,
cutting or welding. Purging with an inert gas is recommended.
15.8 Oxygen gas must be protected from oil, grease and fuel. Cylinders, hoses, regulators
and torches must be clean and oil-free.
15.9 Appropriate PPE must be worn for any Hot Work activity performed.
15.10 In the event of Hot Work in areas with combustible dust atmospheres or storage of
large quantities of exposed, readily ignitable materials such as bulk sulfur, baled
paper or cotton, consult with safety department for guidance.
15.11 In the event that Hot Work is to be performed during a total plant firewater deluge red
tag impairment, follow the guidelines established in Appendix 1 (see below) of this
procedure.
15.12 When an inert atmosphere is required to eliminate a potentially flammable
atmosphere, the following steps shall be taken:
15.12.1 Close all container openings, except fill and vent openings;
15.12.2 Maintain the flow of Inert Gas throughout the entire Hot Work;
15.12.3 Oxygen content of the container must be monitored throughout the entire
Hot Work and maintained near zero percent oxygen.
16 DESIGNATED SHOP AREAS:
16.1 Welding and Burning Permits are not required in designated shop areas, except for
process-contaminated equipment as provided in the section “Special Cases” of this
procedure.
16.2 Plant Sandblast yards are not exempt and will require a hot work permit for welding
and burning in these areas.
16.3 These designated shop areas are listed below. Changes in this listing can be made
when an Area Supervisor or Maintenance Foreman of the affected area makes
requests to the Manager of Safety for specific additions or deletions:

CHLOR/ALKALI “A”:
Powerhouse “A” Maintenance
Cogen Powerhouse Maintenance Shop
‘A’ Chlorine Maintenance Shop
‘A’ Chlorine Electrolyzer Repair Shop
North Liquefaction Maintenance Shop
South Liquefaction Maintenance Shop
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‘A’ Caustic Maintenance Shop

Pels Maintenance Shop
Membrane Pipe Fabrication Shop (Construction)
Riggers Loft
Carpenter Shop (Including Scaffold Storage Areas)
Garage (Includes Equipment Parking Areas South, East, and West of the Garage and Service
Building)
Machine Shop (Includes Cathode Repair Shop and Refrigeration).
Electric Shop Instrument Shop
Tank Car Repair Shop
Shipping Cylinder Building Maintenance Shop
Shrink-wrap machine at PELS
DERIVATIVES:
Per/Tri Shop
Tri-Ethane II Shop
VCM-S Shop
Construction Fabrication Shop (Northwest of Derivatives I/E Shop)
Instrument/electrical Shop
CHLOR/ALKALI “C”:
C-Shop
Electrolyzer Repair Shop
“C” Chlorine Maintenance Shop
“C” Power Maintenance Shop
“C” Caustic Maintenance Shop
Construction Fabrication Area (along West fence line)
Brine Fields:
Contractors Maintenance Shop at Sulphur Field
Starks Control Maintenance Shop

17 Hot Work in Confined Spaces:

21.1 When arc welding is suspended for any substantial period of time, such as lunch or
overnight, all electrodes shall be removed from the holders. The holders shall carefully
be located so that accidental contact cannot occur and the machine shall be switched
to the off position.
21.2 All welding and cutting operations inside a confined space shall be adequately vented
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to prevent accumulation of toxic materials or possible oxygen deficiencies.

21.3 No gas cylinders are allowed inside any confined space. This does not apply to supply
breathing air cylinders.
21.4 The gas supply to the torch shall be positively shut off at some point outside the
confined space whenever the torch is not being used or whenever the torch is left
unattended for substantial period of time, such as during lunch period. This is to
eliminate the possibility of a fire in the enclosed/confined spaces as a result of gas
escaping through a leaking or improperly closed torch valves.
21.5 Overnight and at the change of shifts, the torch and hose shall be removed from the
confined space. Open end fuel gas and oxygen hoses shall be immediately removed
from the enclosed spaces when they are disconnected from the torch or other gas
consuming device.

18 Fire Watch:

22.1 Will be required when welding, burning, cutting, grinding, arc gouging and/or open
flame torches are used.
22.2 Shall be trained to understand the inherent hazards of the work site and of the Hot
Work activities.
22.3 Will inspect the work area with the Maintenance/Contractor Supervisor for sources of
combustible materials and ensure that safe conditions are maintained during the Hot
Work operation.
22.4 Will participate in all Pre-job meetings with the permit Issuer, work crew and work crew
supervisor.
22.5 The individual assigned as the fire watch cannot leave the area when hot work
activities have started without the supervisor first assigning another trained person to
relieve them.
22.6 Have the authority to stop the work if unsafe conditions develop.
22.7 Stay in constant communication with workers in the area.
22.8 Be familiar with the unit and procedures for sounding an alarm in the event of a fire.

22.9 Shall have fire-extinguishing equipment readily available and be trained in its use.
22.10 Shall remain at worksite for at least 30 minutes after completion of any Hot Work
activities to detect and extinguish smoldering fires.
22.11 Must sign the back of the Hot Work Permit acknowledging they have been trained and
understand their duties.
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22.12 Owners of areas that are not occupied 24/7 or monitored by guard tours, shift safety or
other means, the need for a documented walkthrough of the area three hours after the
Hot Work is completed should be based on the type and/or scope of the work.
22.13 Additional fire watch personnel will be needed for all multi-level jobs, along with
100% spark containment. If this cannot be obtained, you must get the safety
department involved.
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Appendix 1:

Requirements to be followed in order to perform hot work during a total plant firewater red tag
impairment:

• All fire watches to have 20# Portable ABC Fire Extinguisher while hot work is being performed.
• Wet area around the hot work to reduce the chance of ground fires.
• 100% Spark containment with welding blanket whether work is on ground or at elevation.
• No Fire-Retardant Plastic allowed for use as welding blanket – utilize fabric style.
• Elevated jobs should have multiple fire watches for levels in between the work area and the ground
that cannot be seen by an attentive fire watch.
• No flammable / combustible material, gases, liquids, or the like within a 35 ft radius in all directions
of the hot work (including over and under the work space).
o If combustibles and flammables cannot be moved or properly covered and protected,
then the Safety Department must be notified to review prior to issuance of permit.
• All drains, trenches and catch basins must be covered within 35-ft radius.
• Fire watch should handle small incipient fires only and report to Operations. For fires beyond that of
incipient, report emergency to (337) 708-5700 (ext 5700 in plant phone) or the responsible control
room without endangering yourself.