Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.
1 +, 1 +

01 ' 5

The Right to Information, The Right to Live

Step Out From the Old to the New

Mazdoor Kisan Shakti Sangathan

Jawaharlal Nehru

IS 3016 (1982): Code of practice for fire precautions in

welding and cutting operations [MTD 11: Welding General]

! $ ' +-
Satyanarayan Gangaram Pitroda

Invent a New India Using Knowledge

! > 0 B

BharthariNtiatakam

Knowledge is such a treasure which cannot be stolen

IS :3016-1962
Reaffirmed 2006
1990 ))
((Reaffirmed

Indian Standard
CODE OF PRACTICE FOR
FIRE PRECAUTIONS IN WELDING AND
CUTTING OPERATIONS

( First Revision )
First Reprint AUGUST

UDC

6217915556240142

1993

: 00676

0 Copyrlghr 1982
BUREAU
MANAK

OF
BHAVAN,

INDIAN
9

BAHADUR

NEW

Gr 5

DELHI

STANDARDS
SHAH

ZAFAR

MARG

110002

December 1982

18:3016-1982

Indian Standard
CODE OF PRACTICE FOR
FIRE PRECAUTIONS IN WELDING AND
CUTTING OPERATIONS

( First Revision )
Welding General Sectional Committee, SMDC 14
Refmsenting

ChoirmM
&tar

Ministry of Railways

A. K. BEATTAOUYYA

MCdNS
CHEXIBT & METALLUECWT-II,
RDSO, LIJCKNOW ( AlternateI
Shri A. K. Bhattacharyya
)
PBODUWION ENOINEER. ICF.
MADRAS ( A&rmttc IIto
_
Shri A. K. Bhattacharyya
)
SEBI J. K. AIILUWALIA
SHBI T. K. BA~U ( Altsrnafc )
SH~I S. BALABUBRAHPANYAX
SHBI K. BALMANOHAE
SEXI R. V. KALE ( Altemat~ )
SHBI S. K. BAAU
SHRI R. BANERJEE ( Alf~r~te)
SEBI S. N. BASU

to

Stewarts

& Lloyds

Binny Ltd, Madras

Hindustan
Shipyard
Indian

Oxygen

of India

Ltd, Calcutta

Ltd, Vishakhapatnam

Ltd, Calcutta

Directorate
General
of Supplies
and Disposals,
New Delhi
Electronics & Electricals Ltd, Bombay
SHEI S. BHATIA
.Peico
.
SHIU E. K. VENKATABA~ANI ( A&mate )
National Test House, Calcutta
SHBI J. N. BHATTAOHARYYA
Sam K. L. BA~UI ( Altrmalc )
M. N. Dastur & Co Pvt Ltd, Calcutta
SEEI S. K. BURMAN
SHRI D. B. GHO~FI ( Alternate I )
SHRI: B. B. SAHA ( Aitarnutc II )
Central Boilers Board, New Delhi
SHRI S. C. DEY
AssogeFtin
of Indian Engineering
Industry,
SHEI C. 6. GIROTRA
S-I

R. S. AQQARWAL (Alternate]

( dontinwd on porr 2 )

_Q

cqyright 1982

BURFALJ OF INDIAN STANDARDS

This publication
is protected
under the Indian Coprignt Act ( XIV of 195? ) and
reproduction
in whole or in pa ,t by any means except with written permirion
of the
publisher
shall ba deemed to be an infringement
of copyright under the said Act.

ISr'3016- 1982
( Continuedfrompage1 )
Representing

Members
SHBI V. G~JRAL

Indian Iron & Steel Co Ltd ( SAIL ), Burnpur

D & H Secheron Electrodes Ltd, Indore

SEBI D. S. HONAVAR
SHBI S. R. JANA ( Alternate )
Bharat Heavy Electricals Ltd, Hyderabad
SHRI R. KBISHNAMURTJIY
SHRI N. K. SETHI ( Alternate I )
SHBI K. POORANOHAN~RARAO
( Alternnfe II )
Tata
Engineering
and Locomotive
Co Ltd,
SIIRI A. V. MULAY
Jamshedpur
SHRI P. S. Josrr~ ( Alfernate )
Engineer-in-Chiefs
Branch, Army Headquarters
SHRI N. MUM MOORTI~Y
SHRI M. K. TADANI ( Alternate )
Walchandnagar
Industries Ltd, Walchandnagar
SHRI K. M. POLII:
&RI G. D. APTE ( Akewr?zte )
Larsen & Toubro Ltd, Bombay
SHRI H. L. PIGABIIAKAR
SHRI J. K. NANDA ( Alternate )
Engineers India Ltd, New Delhi
SHRI J. R. PI~ASIII~;R
Indian Hume Pipes Co Ltd, Bombay
SEBI B. RAMASWAMY
SHBI S. A. VIJAY KEERTEI ( Alternate )
Research and Development
Centre for Iron and
DR V. RAMASWAMY
Steel ( SAIL ), Ranchi
DR S. K, CHOIJDHURY ( &fern& )
Ministry of Defence ( DGI )
SHRI P. B. RAO
SRRI A. L. LAL~ ( Alternate )
Department of Atomic Energy, Bombay
SHRI V. S. G. RAO
SHBI L. M. TOLANI ( Alternate )
Bharat Heavy Plate and Vessels Ltd, VishakhaSARI A. P. SANYAL
patnam
SHRI R. D. PENNAT~UR ( Allernate )
Directorate General of Technical Development,
SHRI R. SABANOABAJAN
New Delhi
SERI S. .K. BIIATIA ( Alternate )
Directorate General of Employment and Training,
SHRI G. S. SETHI
New Delhi
Bokaro Steel Plant ( SAIL ), Bokaro
SHBI P. P. SHBIVASTAVA
SHBI ANIL PANDYA ( Alternate )
Mukand Iron & Steel Works Ltd, Bombay
SHRI S. G. N. SWAMY
SHRI R. K. SRIVASTAVA ( Alternate )
Indian Register of Shipping, Calcutta
SHBI II. K. TANEJA
SHRI S. C~AND~A ( Alternate )
Apar Pvt Ltd, Bombay
SHIU J. R. UPAD~YAY
SH~I PATWARD~AN ( Alternate )
i;dvani-Oerlikon
Ltd, Bombay
SHRI P. S. VISVANATH
Director General, ISI ( Ex-o&o Member )
SHRI C. R. RAXA RAO,
Director ( Strut & Met )
Secretor)
SIIRI P. DAXSIIINA MURTY
Deputy Director ( Metals ), ISI
( Confinuedon pllge 19

IS:3016-

1982

Indian Standard
CODE OF PRACTICE FOR
FIRE PRECAUTIONS IN WELDING
CUTTING OPERATIONS

AND

( First Revision )
0.

FOREWORD

0.1 This Indian Standard

( First Revision ) was adopted
by the Indian
Standards
Institution
on 1 June 1982, after the draft finalized
by the
Welding General Sectional Committee
had been approved
by the Structural and Metals Division Council.
0.2 This standard was first published in 1965. In this revision the concept
of hot work permit system has been introduced
with a view to establishing some control over welding and cutting operations
using naked flame
The provisions relating to general precautions
have
or producing sparks.
been amplified.
1. SCOPE
1.1
tion
use
and

This standardcovers
the recommendations
for the practices for prevenof loss of life and/or property by fire or expIosions arising out of the
of gas and electrical-equipments
for the purposes of welding, cutting
similar operations.

1.2 General precautions

recommended
cover the normal work area designated for the fabrication
and maintenance
activities using welding, cutting
and allied processes and also special situations
having
potential
tire
hazards.
1.3 Special
precautions
recommended
cover the situations or locations
which are susceptible
to fire or explosion
hazards
arising out of the
presence of naked flame or sparks, capable of igniting the combustible
materials present in the area.
2. GENERAL PRECAUTIONS
that the management
2.1 Hot Work Policy - It is recommended
industrial
establishments
should consider the necessity of preparation
3

of
of a

IS 13m.6 -

1992

The purpose
policy statement for introducing
( hot work permit system.
of introducing
the c hot work permit system is to establish some control
over welding and cutting
operations
using naked flame or producing
sparks, capable of igniting
combustible
materials
in areas outside the
normal specified ones for carrying out such activities regularly.
2.1.1 The type and extent
in view the following:
a) The size and facility
b) The complexity

Wan+&Pwdt

keeping

of the plant,

of the operations,

c) The degree of hazards

areas.
2.2 Bol

of such a system should be prepared

present

and

at the work site and in surrounding

System

2.2.1 fdentijcation of Hazardous Areas - In introducing

the hot work
policy and the permit system, it should be ensured that the specific areas
throughout
the plant considered as hazardous by the Competent Authority,
for any type of hot work, should be identified and prominently
marked as
hazardous
area in consultation
with the various departmental
heads.
2.2.2 Ajplication for Hot Work Permit - For conducting
hot work of any
type, inside the designated
hazardous areas, or in close proximity
to the
hazardous
areas, or near that area for prolonged
period or in any new
locations, the departmental
head or this authorised
person should put up
application
for Hot Work Permit filling in a suitable Hot Work Permit
form.
2.2.2.X Hot work #errnit form - A suitable form should be developed
specifically for the purpose of considering the plants operations, and degree
of hazards present.
It should incorporate
specifically the type and nature
of precautions
that should be taken in performing
the hot work at the
particular
location and time.
It should also mention
the Competent
Authorities
through whom, the application
should be corroborated
before
seeking permission from the person incharge of the plant, by designation,
such as Plant Manager, Works Manager, Site Incharge, etc. In Appendix A,
an example of Hot Work Permit form has been included for reference.
2.2.3 Accordance of Permission - The person incharge of the plant shall
make a thorough
inspection
of the place, if possible, accompanied
by a
fire officer, before cutting or welding operations
are commenced,
particularly in ( a ) any new place where hot work is proposed for the first time,
and ( b ) where the work is to be extensive in proximity
to the marked
hazardous
area.
He shall then either accord his sanction with or without
conditions
or insist upon the adoption of alternative
methods of carrying
out the work, should he find the conditions unsafe for hot work operations.

IS t 3016- 1962
2.2.4 Su)ervision of the System - The Competent
Authority should supervise the working of the systemby issuing clear instructions
regarding
the
precautions
required
to be taken at different hazardous
areas marked,
periodically
checking the hazardous
areas, notice boards, equipments
for
fire fighting and extinguishing
and training
of personnel
for handling
small fires and alarm systems.
2.3 General Precautions Before Welding and Cutting
2.3.1 Cutting and Welding Equipment - All cutting and welding
apparatus shall conform to relevant Indian Standards where available and
also fulfil the requirements
laid down in IS : 818-1968*.
2.3.1.1 Installation of cutting and welding aiflaratus - The installation
of
all cutting and welding apparatus
shall fulfil the requirements
laid down
in IS : 818-1968* and in respective Indian Standards.
2.3.2 OpGrators of Cutting and Welding Equi$ment - Only responsible
operators, fully trained in the care and use of cutting and welding equipment, shall be permitted
to carry out cutting and welding operations in or
near hazardous locations.
2.3.2.1 Cutting or welding operators shall not work alone in or near
any hazardous location, but shall be provided with an assistant trained in
safety precautions.
Implements
necessary
for ensuring
safety and for
carrying out rescue operations should be provided wherever necessary.
2.3.3

Protective Clothings and Seat for Operators

2.3.3.1 Protective clothings - Wherever

necessary,
the operators
of
welding
and cutting equipments
should wear protective
clothings,
such
as gloves, aprons, foot guards, goggles, helmets, etc. The clothings
of
operators should be free from oil or grease and from open pockets, trouser
flaps, cuffs, etc.
2.3.3.2 Seat - The usage of empty thinner
or oil drums as a seat
for operator
or as a support for job shall be avoided to avoid fire and
explosion risk.
2.3.4 Protection of Flooring
2.3.4.1 WoodenJlooring - Where any cutting or welding is to be done
over a wooden
flooring it shall be swept clean and protected
by such
means as ( a ) thoroughly
wetting with water, ( b ) covering with damp
sand, and ( c ) sheet metal, asbestos or similar heat resistant materials
at
Provision
shall be made to
points where sparks or hot metal shall fall.
*Code of practice
and cutting operations

for safety and health

(first revision ).

requirements

in electric

and gas welding

IS I 3016- 1982
protect the welders and operators from the hazards
the floors are wet or covered with metallic sheets.

of electric

shock when

2.3.4.2 Protection of floors covered with oil, grease dirts, etc - Some,
installations
of machineries,
for example rolling mills, oil reservoir and
burner installations
in melting shops, floors are very often covered with
grease, oil, dirts, etc. During cutting or welding operations for maintenance
purposes, adequate precautions shall be taken to ensure that the oil, grease,
dirts may not catch fire from sparks, flame or hot metal droplets or hot
metal pieces,
The floor shall be swept clean before starting any welding
or cutting.
2.3.5 Protection of Rope and Cordage - During cutting or welding operations, rope and cordage shall be protected
from the heat of cutting or
Partiwelding blowpipes and from sparks, slags, and hot metal particles.
cular care shall be exercised in the case of ropes supporting loads, guy
ropes and ropes securing scaffolding.
2.3.6 Protective Guards - In ail protective guards for covering
or other combustible materials, only non-flammable,
fire-resistant
should be employed for shielding sparks, hot metals, etc.

the floor
materials

2.3.6.1
All protective guards shall be sufficiently large and fit tightly
enough not to permit any sparks, slags or hot metal droplets to roll underCurtains shall be weighted d,um
neath or bounce through any openings.
against the floor or ground with such things as angle iron, pipe, bricks ti
sand so that sparks cannot possibly get underneath.
2.3.6.2
Wherever there are floor openings or holes in walls opening
doorways, or open or broken window which cannot be closed or covered
readily, precautions shall be taken to ensure that no sparks or hot metal
droplets pass through such openings to the adjacent
locations or the floor
below which may cause fire or explosions.
2.3.6.3
When welding or cutting very close to a wooden construction, it shall be protected
from direct heat.
Wooden beams, partitions,
floorings or scaffoldings shall be protected always from the direct heat or
the welding flame by sheet metal or asbestos curtain guards.
2.3.7 Disposal of OJbCuts and Electrode Ends - Before any cutting operation is commenced,
arrangements
shall be made to prevent the cut-off
pieces from dropping into a place where there is any possibility of starting
This shall be done by:
a fire.
a) welding

a rod or bar to the piece to be cut off,

b) securing

the piece to be cut off with wire or chain,

c) having a helper
receptacle.

to

hold

the

piece

or

catch

or
it in a suitable

IS t 3016 - 1982
2.3.8 Fire extinguishing
equipments
suitable to fight the type of hazards
shall be kept ready within easy reach of the welding and cutting operators
and their assistants.
Such equipments
may consist of pails of water, sand
filled buckets, portable extinguisher P, etc, depending
upon the nature and
quantity of the combustible
materials exposed to fire hazards.
2.3.8.1 Special
of fire as follows:

provisions

shall be made to deal with

any

outbreak

Cutting and welding operators, and every other person concerned,

shall be instructed
to watch for and be ready immediately
to
extinguish
any fire that may occur and know how to transmit
a
call to the nearest fire station;

Ample supply of dry sand in suitable containers shall be provided;

Suitable
extinguishers
conforming
to IS : 1648-1961*
shall be
available for immediate
use;
I
d) Hoses connected to an effective water supply, or where such
supply is not available
an ample supply of water in suitable
containers
shall be available;
and
All
persons
concerned
should
be instructed
and trained
where
e)
necessary in using efficiently all the equipment
and devices listed
in 2.3.8.1(a) to 2.3.8.1 (d).
NOTE - Appropriate fire authorities should be consulted to ensure that the type

b)
4

of extinguisher provided is suitable for the kind of fire which may be anticipated
any particular location.
2.4

General

Precautions

During

Welding

in

and Cutting

of explosions most fires

2.4.1 Detection of Fire - With the exception
start as small ones.
At the beginning
extinction
of small fires seldom
presents much ofia problem,
but once a fire begins to gain headway
it
may develop into a conflagration
of disastrous proportions.
Therefore,
prompt detection of fire;during welding and cutting is of prime importance.
2.4.2 Signalling of Fire Alarm - The first impulse
on discovering a fire is only to try to extinguish
it.
led to long delays in sending the alarm.

of many individuals
This has frequently

2.4.3 The welding and cutting operators

and their helpers
shall be
instructed
and practically trained to sound the alarm as soon as the fire is
discovered,
and to handle fire extinguishers
of different types.
2.4.4 Somebody,
other than the welding
or cutting
operator,
shall
always be put on the watch for sparks or hot metals which may cause small
fires beyond the protective guards and give immediate
alarm if small fires
break up.
*Code of practice
and its maintenance.

for fire safety of buildings

( general ) : Fire fighting equipment

IS : 3016= 1982
2.4.5 Oxygen gas from gas cylinder
or vented out near any naked flame.

should

not be used as cooling agent

2.4.6 In operating
oxyfuel gas cutting apparatus,
the oxygen pressure
An oxygen pressure greater than necessary
shall be set appropriately.
increases the amount of sparks and slag flow over and above the cost.
2.4.7 The detection
of fire, signalling
promptly
an alarm and acting
immediately
to try to extinguish
the fire require training
to the workers
and their assistants to act effectively under such circumstances,
Where the
welders and their assistants are not trained in handling
small fires, they
should have means to call the attention
of other people trained in fire
fighting.
2.4.8
pipe,

Backjre and Flashback

2.4.8.1 Backfire is caused by the return of the flame into the blowthe flame being either extinguished
or reignited at the nozzle.

2.4.8.2 Flashback is much more severe and potentially

more hazardous.
In this, flame returns through the blowpipe into the hose and even
regulators.
It may also reach the fuel gas cylinder,
causing heating and
decomposition
of the contents.
2.4.8.3 The main reason is the feeding of high pressure gas into the
low pressure line forming
a highly combustible
gas mixture
through
This can happen
which the flame can propagate
at a very high speed.
due to a number of reasons, for example nozzle becoming partially blocked,
the control valves not being fully closed or leaking,
incorrect
pressure
settings and overheating
of the blowpipe.
2.4.8.4 The welding or cutting operator
should check before commencement
of work that there is adequate supply of gas, pressure settings
are correct and there is no leakage in the equipment
that is regulators
and blowpipes and all the gas connections.
Damaged or defective nozzles
should not be used. When working on heavily scaled material, the surface
should be cleaned prior to welding and/or cutting to prevent scales flying
The use of properly designed hose check
off and blocking the tip nozzle.
valves can minimise the risk of flame travelling
into the hoses.
2.4.8.5 Where gases are drawn from pipelines,
must be used at the outlets of acetylene pipelines.

flashback

arrestora

2.4.8.6 In spite of precautions

mentioned
at 2.4.8.4 and 2.4.g.5
The operator
shall be alert and
sometimes backfire or flashback occurs.
take the following
actions promptly
as necessary in the sequence given
below:
a) The oxygen control
followed by closing

valve on the blowpipe shall be closed quickly

of the other control valve;

ISr3616-1982
b) In case of flashback travelling towards regulators, the pressure
adjusting screw of the oxygen regulators shall be lossened quickly
followed by loosening the pressure adjusting screw of the other
regulator;
c) The oxygen cylinder valve shall be closed quickly followed
closing the other cylinder valve;
d) If there is a suspicion that the fire has reached
both the regulators shall be taken out;

by

the regulators,

e) After backfire or flashback is over and if it is not severe enough

to damage the equipment, the blowpipe should be cooled by
immersing in a bucket of water with a trickle of oxygen flow
through the nozzle; and
f) It shall be ensured that flashback or backfire has been quenched
properly before relighting the blowpipe.
2.5 General

Precautions After Welding and Cutting

2.51 Watch Against Smouldering Fires -When

cutting and welding operations are carried out in such locations where sparks, molten slag or hot
metal pieces may start smouldering fires in slow burning inflammable
material such as cotton waste soaked with lubricating oil or grease, wood
chips, paper bags or rags, etc, it is necessary that a watchman be deputed
The
at the scene of the work at least one hour after the job is through.
watchman shall look carefully for smoke or fire before leaving the site,
2.5.1.1 When a watchman is deputed, a 60 minute per hour watch
on the spot where the job was done is needed and not just a casual tour of
the plant.
This .is considered to be the most dependable method of
precaution against smouldering fires, particularly in smaller workshops or
other premises.
2.5.1.2 The more dangerous the surroundings is, the greater shall
be the frequency and longer the period during which the surrounding
should be checked for suspicious heat, smoke or glowing spots. According
to the rules in force in some countries, the possibility of a smouldering fire
shall be guarded against for at least eight hours at the scene of the work,
2.5.2 Fire Detection Device - When it is desirable to instal in big plants,
storehouses, etc, a fire detection device which automatically actuates the
alarm, one of the following two most familiar types may be selected:
P) The fixed temperature type, designed to operate when the temperature in the vicinity of the alarm reach a predetermined level.
Such an alarm can be set to operate when the temperature reach
135C, 150C or 200C; and
9

IS x 3016 - 1982
b) The rate of rise type, designed
rise of temperature.

to operate

when

there

is a rapid

2.5.2.1 The decision as to which type to use for a certain location

should be taken only by competent
authorities
after careful analysis
of
needs.
Each of these systems has its own advantages
for particular
installations.
2.5.2.2
requirements

When an automatic
must be met:

alarm

system is installed,

certain

general

A reliable signal must be transmitted;

The
signal must reach all personnel,
including
those trained
for
b)
fire protection,
no matter where they are located;
Cl The signal must be of such a nature that it will be instantly
recognised;
and
4 The signal must be used for no other purpose than to sound the
alarm for fire.

3. SPECIAL

PRECAUTIONS

3.1 Special precautions

welding operations:

shall

be taken

in

conducting

a) In hazardous locations;
b) In close proximity
to hazardous locations;
c) Near hazardous
locations for prolonged
locations.

any

and
period,

cutting

and

any

and

new

3.1.1 As specified in 2.1 and 2.2.2 hot work permit should be obtained
before conducting
any hot work in hazardous locations.
3.1.2 In the hot work permit,
taken before,
during
and after
indicated clearly.

the special
the cutting

precautions
required to be
and welding work shall be

3.1.3 The persons entrusted

in doing the hot work at the particular
location shall ensure implementation
of the special precuationary
measures
indicated
in the permit with meticulous care and sincerity.
3.2 Welding and cutting operations
using naked flames of any kind or red
hot glowing objects of any kind, such as sparks, hot molten metal globules,
etc, should not be carried out for purpose of repair, additions or alterations
of any kind, in the hazardous
locations,
if the proposed
work can be
carried out by suitable alternative
methods.
10

IS t3016-1982
3.2.1 If the work pieces have to be welded or cut in the hazardous
locations, endeavour
should be made, either, to:
a) remove the movable work pieces to a designated
safe location
where there will be no possibility of any fire hazards, or
b) remove all the movable hazardous
materials in the vicinity of the
work pieces to safe location for a temporary
period where there
will be no possibility of fire hazards.
3.2.2 The safe distance between flammable
material
and the working
place should be as decided by the Competent
Authority
having regard to
the flammability
of such materials,
approach of the source of ignition and
the confinement
of the space.
It is recommended
that the safe distance
should, generally,
be not less than 15 metres.
3.2.3 If the work piece to be welded or cut cannot be moved and if all
the fire hazards cannot be removed, then guards .must be used to confine
the flame, heat, sparks and slag, and to protect the immovable
material
adequately ensuring safety from explosion and fire hazards ( see also 2.3 ).
3.2.4 In conducting
welding and cutting operations
in close proximity
to hazardous
locations,
it should be considered
unsafe,
unless there is
absolutely no chance of the source of ignition getting into the hazardous
location, or flammable
vapour or gas,. liquid or dust coming in contact
with the source of ignition from the adjacent hazardous location.
Adequate
protective measures sho.uld be taken using effective guards to ensure safety,
under such situations.
3.2.5 Before starting welding or cutting in any new locations, it is always
necessary to collect information
from the nearest Shop Superintendems
or
Foremen, on the flammable,
combustible
or explosive materials that might
be existing and might lead to a fire or explosion in the presence of a source
of ignition.
3.2.5.1 Only after satisfactory investigation
carried out by a Competent Authority,
hot work permit
should be endorsed
with or without
conditions for the special precautions
that should be observed to ensure
safety from fire hazards.
3.2.6 Special situations having potential fire hazards should be considered in detail and special precautions
that should be taken to .ensure
safety, should be worked out.
Prescribed
Special precautions
for special
situations should be informed to all concerned and if deemed fit, exhibited
on notice boards.
The persons concerned
should strictly
follow the
prescribed special precautions
and periodic checks should be carried out
by the Competent
Authority.
11

tS g 3016.1982
3.3 Recommended

Precautions, for Special Situations

3.3.1 Location Having Combustible Material or Dust - Welding and cutting

operations
shall not be carried out in or near hazardous
location having
combustible
material or dust, for example any ventilation
or other duct
system. Welding and cutting operations may be carried out only after any
accumulated
combustible
material or dust has been completely
removed
from the place.
Where practicable,
a section of the duct in which such
work is to be done should be isolated from the remainder
of the system,
the fans should be shut dowrrso that they cannot be started again till the
work is complete and declared safe to start the fan.
3.3.1.1 Where it is impracticable
to clear up the combustible
dust
from the location as in case of a dusty room or tunnel, any inert dust, such
as limestone,
gypsum, etc, may be used for general dusting around the
It is necessary
operational
area before commencement
of the operation.
to ensure that more than 80 percent of the inert dust i is in suspension
depending
on the nature of the combustible
dust, to assure reasonable
safety from the explosion hazards.
3.3.2 Drums, Barrels, etc - Cutting or welding shall not be done on any
drum, barrel, tank, or other container until it has been cleaned so thoroughly as to make absolutely
certain
that no flammable
materials
or
substances such as acids which, under the action of heat, may produce
flammable
gases or vapoms are present in them,
3.3.2.1 Where steam is available this may be used to remove materials
Washing with strong soda solution will remove
which are easily volatile.
heavier oils,
After thorough
cleaning,
the container
should, wherever
possible, be filled with water before any cutting or welding operation
is
performed.
3.3.2.2 In practically
every case it will be found possible
the container
in such a position that it may be filled with water
a few centimetres
of the point where cutting or welding is to be
doing this, however, care shall be taken to make sure that there
or opening
to provide
for the release of heated
air from
container.

to place
to within
In
done.
is a vent
inside the

3.3.2.3 Where it is not practicable

to fill the container
with water,
a protective gas such as carbon dioxide or nitrogen
can be used, feeding
in a continuous
stream at low pressure, at the commencement
of the work.
Care should
be taken in using carbon
dioxide.
If carbon
dioxide
flows with great speed from the container
into the space to be washed,
there is a possibility of it being loaded with static electricity
and sparks
may easily be given off. The carbon dioxide should, therefore, be gradually
introduced
so that no dimness or frost is observed at the outlet of the gas
container.
Further, the protective gas ( carbon dioxide or nitrogen ) should
12

IS t 3016 - 1982
not be introduced into the tanks or the vessel at the.commencement of the
work but there should be a constant stream of the gas introduced during
the work so as to prevent inlet of unsuspected dangerous gases from outside
and to rinse out any possible dangerous mixture that might be formed on
the inside of the tank. The use of carbon tetrachloride for this purpose
is not recommended, as it gives off poisonous vapour when heated.
If
possible, periodic examination of the air contents of the vessel should be
made wherever possible by means of a detector of combustible gases,
where such an instrument is available.
3.3.2.4 While purging a container with carbon dioxide or steam,
care should be taken to purge for sufficient length of time to ensure
complete removal of volatile liquid or vapour.
Purging gas should not be
used at high velocity which may generate static electricity and cause
concern for fire hazards.
3.3.3

Any plant, drum, barrel,-tank or other container on which welding

or cutting has been carried out should be allowed to cool down sufficiently
to obviate the risk of ignition or explosion when the flammable material

is let inside the container.

3.3.4 Cutting During Rescue Operations - Before resorting to cutting during

rescue operations, a check shall be made to determine whether explosive
or flammable liquids, gases, or vapourq are present, and no cutting shall
be done until these are absorbed or expelled.
3.3.5 Cutting or Welding in Conjined Spaces - When cutting or welding is
being carried out in any confined space, suitable precautions shall be taken
to prevent the ignition of any timber or other flammable material that
may be present. .Fur!hermore, sufficient ventilation shall be provided. No
oxygen shall be blown in. The escape path shall be kept at safe location
with means of easy reach, such as, ladder.
3.3.6 Gas Mains and Apparatus - No cutting shall be carried out on any
gas main pipe or apparatus unless such main, pipe, or apparatus is totally
isolated from live gas plant and completely purged of gas and relieved of
pressure.
3.3.7 Coal Bunkers - Where practicable, no cutting or welding shall be
carried out in or near coal bunkers or other fuel storages, without the
removal of the fuel; however, where this is not practicable, special precautions shall be taken to prevent ignition of the fuel itself or any gases given
off by the fuel.
3.3.0 Srinklcr Installations - Sprinkler installations if provided shall be
checked before commencing any welding or cutting operations to ensure
that it is in working order and shall be maintained in good working
condition even during extensive repairs or alterations of the building while
13

19: 3016.1982
cutting and welding operations
are in progress and at least half an hour
after such operation
ceases. If the sprinkler system must be shut down for
certain period of time, this shall be done when welding and cutting operations are not in progress.
3.3.8.1 Where cutting or welding operations
are to be carried out on
a sprinkler
installation
itself, such work shall be done by an approved
.
sprinkler
contractor.
All fire-prevention
precautions
required
by these
clauses shall be taken, and in addition,
in hazardous
locations, an officer
of the fire station shall, where possible, be in attendance.
Where possible
the water shall be cut off only from that portion of the installation
which
is actually under repair. Further, alternate
water supply arrangement
shall
be provided for the period of the water supply system is out of commission.
3.3.9
repair,
carried

Stores and Depots of InJlummable Liquids and Gases

3.3.9.1 When no other suitable means of carrying

out the required
addition
or alteration
is available,
cutting
and welding may be
out in the installations
for storage of inflammable
liquids and gases.

3.3.9.2 After all necessary investigations

and tests, the Site-Incharge
or Superintendent
of the installation
or Officer Incharge of fire precautions
shall issue the permit for carrying
out the required
work at scheduled
time.
The permit shall be renewed daily when required.
3.3.9.3 Officer Incharge
of fire precautions
shall ensure
that the
portion
in the circuit of the liquid or gas circulation,
for example,
the
storage tank, pipelines,
valves, pumps, etc, where welding
and cutting
work shall be carried out, is blanked or isolated and purged with steam or
inert gas or washed thoroughly
so as to make absolutely
certain that no
inflammable4iquid
gas is present in an amount which can catch fire under
the action of heat, spark, flame, welding
spatter or red hot objects.
A
combustible
gas indicator
shall be used to determine
ihe cdncentiation
of combustible
gas in the air, and if this concentration
is greater
tban
O-2 percent,
the hot work permit
shall not be signed by the Officer
Incharge
of fire precautions
until the concentration
is obtained below that
limit.
3.3.9.4 Before cutting and welding on any part of the supporting
structure
for inflammable
liquid or gas storage
vessels precautionary
measures similar to 3.3.9.3 shall be observed. Where necessary, the storage
vessels, pipeline,
etc, shall be propped up adequately
to support the load
while the supporting
structure is cut or welded for required
modification
or repair.
3.3.10

On Wharfs and Ships

3.3.10.1 Master responsible for precautions - Wherever

a ship
the Master shall be responsible
for taking adequate
precautions

14

may be,
against

18 x 3016 - 1982
explosion or fire during and after all cutting and welding operations, and
no such operation shall be carried out except with the permission of the
Master 6r Officer-Incharge.
3.3.10.2 Provision ofjre-Jghting facilities - During cutting and welding operations ships at wharfs or in docks shall have their hydrant and
hose system in good working order and connected to a water supply which
shall be adequate and frequently tested.
If the ships pumps cannot be
used, arraygements shall be made to obtain supply from shore, preferably
by connectmg the ships hydrant and hose system to an effective shore
supply. Pumps shall not be put out of action until the shore supply is
assured.
Supply trom shore shall be tested frequently to make certain
that the supply is immediate and of sufficient pressure to enable distribution all over the ship. In addition, fire extinguishers and buckets of water
or sand shall be laid out ready in the vicinity.
NATE - Spaces under, over, or adjacent
shall be treated as being in the vicinity .

to the cutting

and

welding

operations

3.3i10.3 Provision of guards -- When cutting or welding where sparks

might lodge in wooden parts or drop through pipes or openings to the
space below, sheet metal guards, asbestos or fireproof millboard curtains
or similar .non-combustible devices shall be used to keep sparks close to the
work being dor,e. The guards shall be large enough and sufficiently tight
not to permit sparks to roll underneath flammable material or slide
through openings.
Curtains shall be weighted to the deck floor, or
ground, 30 that sparks do not possibly get underneath.
3.3.10.4 Cutting or welding shall be performed only after consultation between the Master of the vessel and the responsible Official Incharge
of the arrangements for securing the goods. The greatest consideration
shall be given to the commodity immediately beneath the deck, and the
work proceeded with when it ha? been ascertained that there is no risk
involved. Welding cleats and ring bol13 to secure heavy goods on weather
decks shall be carried out before the ship is loaded.
Cutting cleats and
ring bolts on weather decks shall be carried out after the tween deck
cargo has been discharged.
3.3.10.5 Cutting or welding in tanks, etc - When cutting and welding
operations are being done in a ships tank or similar locations, an assistant
should be stationed at the manhole entrance to the tank to cut off the gas
supply to cutting and welding equipment quickly on hearing the slightest
backtire explosion.
Provision should be made for adequate ventilations
of such confined locations.
Lifting tackles should be kept ready at hand
in case the operator needs to be rescued from inside the confined space
against dangerous accumulations of harmful gases or fumes formed during
hot work operations.
15

IS t 3016- 1982
In case of an oil tank on board, containing flammable oil, welding
and cutting operations shall not be carried out unless the oil tank, and
any compartment or space adjacent to the oil tank have been made free
of flammable gases by draining out or removing the contents and by
thoroughly washing with hot water or by steaming to remove all traces
of flammable liquid. Proper tests should be carried out to check the
absence of flammable
vapours in exblosive
before
concentrations,
commencement of any hot work.
3.3.10.6 Cutting or welding on decks or bulkheads - When cutting
through or at edges, suitable receptacles containing a layer of sand should
be provided in such a manner as to collect all the molten slag, sparks
and hot metal particles generated during the hot work operations.
In the
vicinity of wooden decks, damp sand may be employed as a fire arrester
and to protect the deck.
3.3.10.7 Cutting or welding in engine rooms - When cutting or welding in an engine room, particular care shall be taken to see that the space
where the work is carried out is clear of oily waste, and the Officer-Incharge shall make an inspection after the workmen leave, and satisfy
himself that there is no fire hazard.
3.3.10.8 Cutting or welding near magazines - Cutting or welding shall
not be carried out in close proximity to a magazine, or any other
compartment containing explosives.
There shall be at least the space of
a compartment,
or two bulkheads, between the operations and the
explosives.
This shall refer also to decks above and below a magazine,
If necessary, the explosives shall be removed to another compartment in
a safe place and carefully guarded.
3.3.10.9 Watch to be kept - Where cutting or welding operations are
being done on or about a ship a watch shall be maintained in the vicinity,
irrespective of any precaution undertaken by those responsible for such
operations.
After cutting or welding in the work vicinity of flammable
cargo or ships fittings, when finishing work or knocking off for the day,
the ships watchman shall be instructed to keep a strict watch during the
night in the vicinity where the work was carried out. The watchman
should report immediately in case any smoulding fire is detected in the
vicinity of the area where hot work operations were carried out earlier.
3.3.10,lO Mineral oil on water surfaces - Special care shall be taken
to prevent sparks, slag, or hot metal particles coming into contact with
mineral oil on water surfaces, particularly in the vicinity of wharfs and
ships.
NOTE
Cases are on record where thin layers of oil discharged from ships or
accidentally from tankers or waterside oil tanks have been ignited during cutting
operations, even under severe winter conditions with ice on the surface of the
water.

16

16:3016~ 1982

APPENDIX
A
( CZuuse2.2.2.1 )
WORK PERMIT
HOT WORK

AND SAFETY PERMIT

Permit valid from

Special Instructions

AM
Date

PM

Inside refinery
1. No smoking
To

2. Safety hat must be worn

AM

3. In case of liquid/gas release. Stop work

and immediately advise process supervisor
concerned

Date

PM

4. IO case of fire alarm, All welding machines/mobile equipment must be stopped.

Gas cylinders closed, everybody leaves the
work site. Contractor personnel to go to
designated safe areas.
PERMISSION
NATURE
EXACT

IS HEREBY

GRANTED

TO . . . .. . . . . .*. .. . . . . . . . . . . . . . . . a......

OF WORK . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . *. . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION

OF JOB . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THE FOLLOWING

ITEMS MUST BE CHECKED

ISSUING PERMIT

Item

DOnS

1. Personally inspected equipment]work

&ea

2. Surrounding area, hot lines checked and

covered
3. Equipment properly drained and wedged
open
4. Equipment properly steamed and gas freed
5. Equipment water flushed
6. Proper ventilation and lighting provided
7. Gas test made and found gas free/gassy
17

BEFORE
,Not Required

X8:3016-1982
Item
8. Following
release

precautions
taken
of oil or gas in the area

Done

.Not Required

Explosive

Limit

against

Equipment Blinded/Disconnected/Isolated
9. Sewer openings
10. Control

covered

for welding

a) Outside
b) Inside

sparks provided

the equipment
the equipment

11. Following
vided:

standby

Fire/Water

fire

equipment

pro-

Hose/Extinguisher

12. Following
personal
protective
equipment
provided:
Safety Hat/Gloves/Goggles/Safety
Shoes/
Boiler Suit/Dust
Respirator/Face
Shield/
Air Mask/Apron
13. Proper

means

14. Equipment

of exit available

properly

tagged

15. Portable equipment/Hose

grounded
16. Checked for trapped
in equipment

Nozzles
oil/gas

properly

behind

lining

17. Life line provided

18. Process/Mechanical/Contractor
provided
19. Area cleaned
20. Iron sulfide

standby

up; oil, rags removed

removed

or kept wet

GAS TEST RESULTS

HYDROCARBON
CARBON
GAS TEST

GASES

MONOXIDE
MADE

BY

Percent

of Lower

Percent
OXYGEN
HYDROGEN
18

DEFICIENCY
SULPHXDE

Yes/No
%

18 t 3016 - 1962
( Continusdjiom pog~ 2 )

Subcommittee for Safety Health and Hygiene Aspects of

Welding, SMDC 14 : 5
Convener
SHBI N. V. KBISHNAN

Rcprarsnhng
Central

Labour

Institute,

Bombay

Atomic Energy Commission,

Bombay
SaarS.Ha~a~~xdm
Oxygen Ltd, Calcutta
SERI A. K. DAS
SHBI M. K. SEN ( Altemafs )
Bharat Heavy Electricals
Ltd, Hyderabad
SHBI A. DORAISWAHY
Larsen & Toubro Ltd, Bombay
DB. R. C. PANJWANI
SHRI S. K. BHATTAOHABYA ( Altcrnatc )
National
Environmental
Engineering
Research
Baas V. RAXAN
Institute ( CSIR ), Nagpur
Chief Inspectorate
of Explosives,
Nagpur
REPRESENTAWJE

19

BUREAU

OF

INDIAN

STANDARDS

Headquarters;
Manak Bhavan, 9 Bahadur Shah Zafar Marg. NEW DELHI 110002
Talephones : 331 01 31, 331 13 75
Telegrams : Manaksanrtha
( Common to all offices)
Regional Ofices:
Telephones
Central
: Manak Bhavan, 9 Bahadur Shah Zafar Marg,
331 01 31
[ 3311375
NEW DELHI-11 0002
OEaetern : 1 /14 C.I.T. Scheme VI I M, V. 1. P. Road.
36 24 99
Maniktola, CALCUTTA 700054
Northern : SC0 445-446, Sector 35-C,
21843
131641
CHANDIGARH
160036
41 24 42
Southern : C. I. T. Campus, MADRAS 600113
412519
( 41 29 16
twestern : Manakalaya, E9 MIDC, Marol, Andheri (East),
6 32 92 95
BOMBAY 400093
Branch Oflees:
Pushpak Nurmohamed Shaikh Marg, Khanpur,
26348
[ 26349
AHMEDABAD
380001
SPeenya Industrial Area, 1st Stage, Bangalore Tumkur Road
38 49 55
BANGALORE 560058
138 49 56
Gangotri Complex, 5th Floor, Bhadbhada Road, T. T. Nagar,
66716
BHOPAL 462003
Plot NQ. 82/83, Lewis Road, BHUBANESHWAR
751002
6 36 27
5315, Ward No. 29, R. G. Barua Road, 5th Byslane,
3 31 77
GUWAHATI 781003
6-8-56C L. N. Gupta Marg ( Nampally Station Road),
23 1083
HYDERABAD 500001
63471
R14 Yudhlster Marg, C Scheme, JAIPUR 302005
I 6 98 32
21 68 76
117/418 B Sarvodaya Nagar, KANPUR 208006
121 82 92
62305
Patliputra Industrial Estate, PATNA 800013
6 21 04
T.C. No. 14/1421, University P.O., Palayam
1621 17
TRIVANDRUM
695035
lnspecflon Office (With Sale Point) :
Pushpenjali, 1st Floor, 205-A West High Court Road,
Shankar Nagar Square, NAGPUR 440010
institution of Engineers ( India ) Building, 1332 Shivaji Nagar,
PUNE 411005
*Sales Offke In Calcutta II at 5 Chowrlnghro Approach, P.O. Prlncrp
Street, Calcutta 700072
Wales Offlcr In Bombay Is at Novelty Chambers,
Grant Road,
Bombay 400007
SSales Ofke In Bangalore la at Unity Bulldlng, Narrrlmharaja
Square
Bangalore 560002

261 71
62436
97 66 00
80 65 28
22 88 71

Prlntod lt Slmso Prlntlng Proor. Dolhl. India