Hot Work

BP U.S.
Pipelines and Logistics (USPL) Hot Work

Safety Manual Page 1 of 20
Hot Work
1. Purpose
Hot work is work that could produce a source of ignition, such as sparks, flames, or temperatures high
enough to cause the ignition of flammable gases or combustible materials.
The purpose of this policy is to define the requirements for performing hot work that requires a permit and the
responsibilities of individuals serving in roles regarding hot work operations.
2. Scope
This policy applies to all employees and contractors while performing hot work for USPL.
The following policies in this safety manual are either referenced or are applicable to this policy and should be
consulted for specific related requirements and guidance:
Air Monitoring Electrical Safety

Authorization to Work Level 2 Hazards Identification and Task Risk
Assessment (HITRA)
Confined Space Entry
3. Minimum Requirements
Supporting
Minimum Requirements
Documentation
1. A Hot Work Permit shall be completed and issued prior to conducting Sections 6 and 7,
Primary Source Ignition (PSI) hot work (except in a designated area or performing Appendices I and
shielded PSI outside a Class 1 area); and Secondary Source Ignition (SSI) Class 1 hot II
work.
2. All Hot Work Permits shall be issued by an Asset Operator or Asset Operator Designee Section 5
and shall be received by a Performing Authority. Self-permitting is prohibited.
3. An Area Monitoring Plan shall be developed and implemented before Class 1 hot work is Section 10,
performed. Section A of Hot
Work Permit
4. Air monitoring for the presence of flammable gas shall be conducted prior to conducting Section 10,
Class 1 hot work and shall be performed continuously while performing PSI Class 1 hot Appendices III
work, and if LEL > 0% while performing SSI Class 1 hot work. and IV
5. If air monitoring (initial or continuous) detects the presence of flammable gas (LEL > 0%), Section 10,
hot work shall not proceed until an LEL Mitigation Plan is developed and implemented to Section A of Hot
identify the source of the flammable gas and verify that the LEL is less than 10%. Work Permit
6. Hot work is prohibited in explosive atmospheres (LEL ≥10%). Section 8 and 10
7. Designated areas shall be kept free of combustible materials and shall be physically Section 6
marked around the perimeter.
8. A Fire Watch is required while PSI Class 1 hot work is being performed and additionally Section 11,
Revision Date: July 8, 2014 Effective Date: December 31, 2014
Next Review Date: July 8, 2019
Paper copies are uncontrolled and valid only at the time of printing. The controlled version of this document can be found in DRM
in the HSSE Policies folder.
BP U.S. Pipelines and Logistics (USPL) Hot Work
during PSI non-Class 1 hot work performed within 35 feet of shielded combustible Appendix V
materials.
9. Individuals performing hot work roles shall be trained to execute their responsibilities as Section 12
defined in this policy
10. All personnel performing hot work on behalf of USPL have the responsibility and authority Section 7
to stop any work they consider to be unsafe.
4. Definitions
Asset Operator (AO)—A BP employee who is responsible for the operation of the asset where work is being
performed. The Asset Operator shall be accountable for the asset equipment being in a safe condition for the
scope of work to be performed. The Asset Operator or an Asset Operator Designee (if used) is responsible for
the completion of the ATW form.
Asset Operator Designee (AOD)—A BP employee or contractor individual who is authorized to issue ATWs
and / or permits on behalf of the Asset Operator.
Note: Reference the Authorization to Work policy for additional information
Authorized Gas Tester—An individual responsible for operating air monitoring equipment to monitor the area
where hot work will be performed for the presence of flammable gas.
Class 1 area—An area in which flammable gases or vapors are or might be present in the air in quantities
sufficient to produce explosive or ignitable mixtures. For the purposes of this policy, Class 1 areas are defined
to include Division 1 and Division 2 classified areas. Consult Facility Hazardous Area Classification diagrams
to identify where Class 1 areas are defined. For hot work not performed at a facility, such as on the Right-of-
Way the following are examples of Class 1 areas:
• Within 100 feet of all leak sites or pipeline repair operations where a line will be or has been
opened. This can be expanded due to the size of the leak.
• Within 10 feet of any at-grade or below-grade sumps or drains.
• Within 50 feet horizontally in all directions from any edge of pumps located outdoors where
pressure > 275 PSIG.
• Within 10 feet horizontally of an outdoor valve, flange, manifold, meter, or scraper trap.
Combustible material—A material that, in the form in which it is used and under the conditions anticipated,
will ignite and burn.
Designated area—A specific location designed and approved for hot work operations that is maintained fire-
safe, such as a maintenance shop or a detached outside location, that is of noncombustible or fire-resistive
construction, essentially free of combustible and flammable contents, and suitably segregated from adjacent
areas. Hot work performed in a designated area does not require a Hot Work Permit.
Note: Class 1 areas are never designated areas.
Note: Designated areas are not required to be “structures”.
Fire Watch—An individual who is assigned the responsibility of monitoring hot work and the surrounding area
for incipient fires and changing conditions.
Flammable gas—A term used for brevity in this policy to include all combustible and flammable gases and
vapors that burn in air when the concentration of the gas or vapor is within the range of concentration where
combustion can occur.
Hot work—Work that could produce a source of ignition or temperatures high enough to cause the ignition of
flammable gases and combustible materials. Examples of hot work include but are not limited to:

Arc welding
Sandblasting
Grinding
Using electrical and electronic equipment that is not certified or intrinsically safe or explosion-proof
(such as mobile phones, cameras)
Using internal combustion engines (including vehicles) in a Class 1 area (e.g., a tank dike)
Thermite brazing (e.g. Thermite welding, Cadwelding, welding test leads.)
Applying hot coatings(e.g. shrink sleeves, Tapecoat 20)
Using holiday detectors for checking coating integrity
Using torches to remove casing from line pipe
Using torches to solder test lead wires
Installing vent pipes to a casing
Note: Pneumatic tools are considered a safer alternative to other power tools but consideration must be given
to heat generated at the point of operation.
Hot work operator—An individual who operates hot work equipment to perform hot work operations.
Lower Explosive Limit (LEL)—The minimum concentration (percentage) of a flammable gas that will
propagate a flame in the presence of an ignition source. The more explosive the gas, the lower the LEL. A
mixture below this level is considered too “lean” to burn. LEL is usually expressed as a percentage (from zero
to 100% explosive) and is often used interchangeably with Lower Flammability Limit (LFL).
Performing Authority (PA)—A BP employee or contractor individual who receives a permit issued by the
Asset Operator or Asset Operator Designee.
Note: Reference the Authorization to Work policy for additional information.
Permit Issuance—The act of the Asset Operator or Asset Operator Designee issuing a permit to a
Performing Authority. Permit Issuance is documented in Section C of the ATW form.
Note: Reference the Authorization to Work policy for additional information
Non-permissible Area—An area where hot work is prohibited.
Primary Source Ignition (PSI) hot work—Work with equipment and tools that, when used in a normal
manner, are likely to ignite a flammable or combustible atmosphere, solid materials, and liquids. PSI hot work
is often referred to as “naked flame” hot work. High energy is present in the form of a flame, electric arc, or
incandescent sparks. Examples of PSI hot work include but are not limited to the following:
Welding and burning

Grinding / spark producing abrasive blasting
Preheating or annealing welded fabrications where the surface temperatures may exceed 392°F.
Primary Source Ignition (PSI) Class 1 hot work—PSI hot work that is performed either inside a
Class 1 area or outside a Class 1 area that could be impacted by the hot work.
Note: PSI hot work such as grinding has been known to generate sparks with enough force to
transport them up to 35 feet from the point of the hot work; therefore, it is possible to perform PSI hot
work up to 35 feet away from a Class 1 location and yet still introduce an ignition source into a Class
1 area.
Primary Source Ignition (PSI) non-Class 1 hot work—PSI hot work that is performed outside of
and will not impact a Class 1 area.

Secondary Source Ignition (SSI) hot work—Any work with equipment and tools that, when used in a
normal manner or due to errors or malfunctions, may create lower-energy sparks and ignite a flammable or
combustible atmosphere. SSI hot work is also referred to as “spark potential” hot work. Examples of SSI hot
work include but are not limited to the following:
Using electrical and electronic equipment that is not intrinsically safe or explosion-proof (e.g., most
electronic communication devices, flashlights, power tools)
Using internal combustion engines (including vehicles) in a Class 1 area (vehicle entry into tank
dike)
Using a rotating steel brush
Electrical isolation testing
Producing a friction spark, typically from a rusty surface
Note: The use of hand tools such as hammers and chisels is not considered hot work.
Note: The use of watches, hearing aids, and other medical devices are specifically exempted as SSI sources.
Secondary Source Ignition (SSI) Class 1 hot work—SSI hot work that is performed inside a Class
1 area.
Secondary Source Ignition (SSI) non-Class 1 hot work—SSI hot work that is performed outside a
Class 1 area. SSI non-Class 1 hot work does not require a Hot Work Permit.
Shall—Is used where a provision is mandatory
Should—Is used where a provision is preferred
5. Roles and Responsibilities

5.1. Asset Operator (or designee)
A. Shall issue permits to the Performing Authority or can delegate permit issuance to the AOD.
B. Shall determine if changes can be made to a permit if permit conditions are exceeded or if the permit
should be cancelled and a new permit issued
1. If the Asset Operator determines that changes to the permit can be made, he/she shall
document their approval of the changes by initialing the changes where they are documented
on the permit
C. Shall evaluate hot work with regard to simultaneous operations (SIMOPS) so that operations that
could likely expose flammable gas or combustible materials to ignition in the hot work area do not
occur, or are controlled during hot work operations.
Note: Refer to the Authorization to Work policy for additional requirements
5.2. Authorized Gas Tester (can also be the Fire Watch)

A. Shall not be a PSI Hot Work Operator while performing AGT duties.
B. Can be a Hot Work Operator during SSI Class 1 hot work.
C. Shall verify that the air monitoring device to be used is calibrated according to the manufacturer’s
instructions.
D. Shall perform initial, continuous, and repeat air monitoring of the hot work area for the presence of
flammable gas per the area monitoring plan, when required (see Section 10)
E. Shall verify that an LEL Mitigation Plan is developed and implemented when required (see Section
10.6).

F. Stops hot work if at any time air monitoring readings are > 10% of the LEL
Note: Refer to the Air Monitoring policy for additional information regarding the Authorized Gas Tester
and air monitoring equipment.
5.3. Fire Watch (can also be Authorized Gas Tester)

A. Shall not be a PSI Hot Work Operator while performing Fire Watch duties.
B. Shall verify that fire protection equipment is in place and ready for use (see Section 11).
C. Shall stop work if unsafe conditions develop during hot work operations (e.g. combustible materials
are introduced into the hot work area).
D. Shall remain within communication range of the person(s) performing the hot work and shall
maintain a line of sight with the hot work.
E. Shall watch for fires in all areas exposed to hot work and, if a fire occurs, shall communicate to hot
work operators to cease all hot work.
1. The Fire Watch can try to extinguish a fire only when the fire is obviously within the capacity of
the equipment available.
2. If the Fire Watch determines that the fire is not within the capacity of the equipment, the Fire
Watch shall implement evacuation procedures immediately.
F. Shall remain in the hot work area at least 30 minutes after the hot work has ceased (including for
work breaks) to detect and extinguish possible smoldering fires.
1. Shall document that the above requirement was completed on the Hot Work permit (Section
E).
5.4. Hot Work Operators

A. Shall verify hot work equipment is fit for purpose and intact.
B. Shall review and sign the Hot Work Permit to acknowledge their agreement to abide by the
conditions documented on the permit.
C. Shall cease hot work operations if unsafe conditions develop and notify the Performing Authority
immediately for evaluation and appropriate action.
5.5. Performing Authority

A. Shall receive issued Hot Work Permits from the Asset Operator.
B. Shall verify that all hot work operators have signed the Hot Work Permit to acknowledge their
agreement to abide by the conditions documented on the permit.
C. Shall observe the permitted hot work to verify that the work is performed within the conditions
documented on the Hot Work Permit.
D. Shall reassess the job site and revalidate the permit before work can resume if permitted work is
interrupted or if the job site is left unattended, or if necessary, cancels the permit and returns it to the
AO / AOD.
E. Shall stop work, suspend the permit and notify the AO / AOD if permit conditions are exceeded.
Note: Refer to the Authorization to Work policy for additional requirements.
6. Designated Areas
The purpose of a designated area is to provide a safe area where PSI hot work can be performed without
permitting. A designated or “free burn” area does not require a Hot Work Permit, a Fire Watch, or air
monitoring because the procedures for establishing the designated area eliminate or effectively control
flammable and combustible hazards.
A. Designated areas shall be:
1. located at least 35 feet from a Class I area;
2. kept essentially free of combustible materials; and
3. physically marked around the perimeter.
7. Hot Work Permit

The Hot Work Permit (Appendix I) has five purposes: (1) to serve as written permission to do the work; (2) to
provide a minimum safety checklist; (3) to show the steps necessary for making the worksite safe for
conducting hot work; (4) to alert operating personnel to work in progress; and (5) to provide a record of safety
steps taken so that the work is performed within established conditions. Appendix II offers guidelines for
determining whether a Hot Work Permit is required. Appendix III summarizes specific permit requirements.
7.1. General Requirements

A. Before beginning hot work, an assessment shall confirm that other options not involving hot work
have been considered and ruled out.
B. The following activities are exempted from hot work permitting:
1. Performing hot work in a designated area.
2. Bulk liquid transport loading / unloading operations.
Note: Bulk liquid transport loading / unloading operations are based on the requirements of NFPA
30 and are therefore exempt from hot work permitting.
3. Performing SSI hot work outside of a Class 1 area.
4. Performing shielded PSI hot work outside of a Class 1 area.
Note: For the purposes of this policy, shielded PSI refers to equipment which is considered PSI but
intrinsically shielded in a way that prevents ignition of nearby ordinary combustibles, e.g. using a
gasoline powered / diesel fired hot water pressure washer cleaning pipeline pigs in a non-Class 1
area. Performing shielded PSI hot work in a Class 1 area shall require a PSI Class 1 Hot Work
permit.
5. Replacing the Scully cord at the truck loading rack.
C. Individuals who have a role in the hot work permit process, possessing the technical and procedural
competencies as defined by the USPL Training and Competency Matrix (for employees) and the
contractor management process (for contractors), shall provide input to the permit to address permit
conditions related to the hot work.
D. For SSI Class 1 hot work (e.g. vehicle entry into tank dikes, snow plowing under the load rack, the
use of tools that are not intrinsically safe in a Class 1 area), the Asset Operator can validate the
conditions as well as issue the Hot Work Permit to the Performing Authority via telephone. In such
instances, the Performing Authority shall sign the Hot Work Permit on behalf of the Asset Operator in
Section E of the permit under “Performing Authority (SSI Class 1) Phone Validation of Permit with
Asset Operator”.
E. A Hot Work Permit is valid for no more than one work shift for the individuals working under the
permit, or for the duration of the scope of work documented on the permit, whichever period is
shorter.
F. If hot work is suspended and the job site is left unattended (including normal work breaks) during a
shift, the permit shall be revalidated before further hot work can continue; revalidation involves

inspecting the hot work area for any change in previous conditions and conducting and documenting
air monitoring if PSI hot work is to recommence in a Class 1 area.
G. If permit conditions are exceeded (e.g. LEL > 10%) work and the permit shall be suspended until
the Asset Operator determines if changes can be made to the permit or if the permit should be
cancelled and a new permit issued.
1. If the Asset Operator / Asset Operator Designee determines that changes to the permit can be
made, he/she shall document their approval of the changes by initialing the changes where
they are documented on the permit
H. The Hot Work Permit should be at the job site until the hot work is completed or the permit expires.
At the Asset Operator’s discretion, the Hot Work Permit may be kept at an alternate location, e.g. in
the office for the permit for cutting grass.
I. All personnel involved in the hot work operation have the authority and responsibility to stop work
that they consider to be unsafe.
J. The original completed Hot Work Permits shall be retained locally for a minimum of one year.
8. Non-Permissible Areas
A. Hot work is prohibited in the following areas:
1. In areas prohibited by management.
2. In sprinkler-equipped buildings where sprinklers are impaired, unless the requirements of
NFPA 25 are met, specifically Chapter 15 – Impairments.
3. In the presence of explosive atmospheres (≥10% of the LEL).
4. In the presence of uncleaned or improperly prepared tanks, vessels, or other containers and
equipment that have previously contained flammable or combustible materials when their
contents might be exposed to an ignition source.
a) Reference the Confined Space Entry policy for requirements regarding post-cleaning
certification of a gas / product space.
9. Hot Work Site Preparation

Hot work shall be assessed in relation to simultaneous operations (SIMOPS). In completing the ATW, the
Asset Operator shall determine whether the hot work to be performed will negatively impact any other
operations occurring at the same time. The Asset Operator shall decide whether the hot work can proceed
and shall identify what controls are necessary to perform the hot work safely with respect to other operations.
9.1. All PSI Hot Work

A. The following conditions shall be verified before PSI hot work is performed:
1. Combustible materials shall be protected from ignition by relocating, shielding, or by other
protective means:
Note: Consideration should be given to spark containment techniques which lessen the
distance sparks are able to travel freely.
2. A fully charged and operable 20-pound (minimum) fire extinguisher appropriate for the type of
potential fire shall be available for use in the work area.
3. Sewer openings, ducts, and drains within 35 feet of the point of hot work shall be sealed with
an impervious material. Where sealing is insecure or impractical, other methods shall be
implemented to prevent sparks from entering.
4. The location of the hot work relative to combustible and flammable materials and classified
areas will determine the need for a Fire Watch, as outlined in this policy (see Section 11).
9.1.1. Welding, Torch Cutting, and Brazing in a Confined Space or Partially Enclosed Space
A. When welding, cutting, or brazing operations are to be conducted in a confined space or partially
enclosed space the following ventilation requirements shall apply:
1. General mechanical ventilation at a rate of 2,000 cubic feet per minute (cfm) per welder shall
be provided; or
2. Local mechanical ventilation using freely movable hoods placed by the welder as near as
practicable to the work being welded and provided with a rate of air-flow sufficient to maintain a
velocity in the direction of the hood of 100 linear feet (30 m) per minute in the zone of welding
when the hood is at its most remote distance from the point of welding shall be provided.
3. Local mechanical ventilation or airline respirators are required when welding, cutting, or
brazing on hazardous metals (e.g. galvanized, stainless, chrome-molly, metals containing lead
other than as an impurity).
4. All replacement air shall be from a clean source outside of the confined space or partially
enclosed space.
Note: Refer to Appendix VII General Mechanical Ventilation Guidance for Welding, Cutting and
Brazing in Confined Spaces or Partially Enclosed Spaces for additional information.
B. If the minimum rates stated above cannot be achieved, supplied air respiratory protection shall be
worn by all entrants in the confined space or partially enclosed space in conjunction with ventilation.
Note: For the purposes of this policy, a partially enclosed space is a space that does not meet the
definition of a confined space but is configured in a manner that would cause the accumulation of
welding fumes without mechanical ventilation.
9.1.2. PSI Class 1 Hot Work

A. The following conditions shall be verified before PSI Class 1 hot work is performed:
1. A Fire Watch shall be assigned.
2. Affected excavations, conduits, and manholes within 35 feet of the hot work shall either be
monitored for the presence of flammable gas or shielded so that an ignition source is not
introduced.
3. Initial and continuous air monitoring shall be performed and initial air monitoring results shall
be documented on the Hot Work Permit (see Section 10 and the Air Monitoring policy).
9.1.3. PSI Hot Work within 35 Feet of Buildings or Other Structures

A. The following conditions shall be verified before PSI hot work is performed inside of or within 35 feet
of buildings or structures whose building materials or contents may be combustible or flammable:
1. Openings or cracks in walls, floors, or ducts within 35 feet of the hot work shall be tightly
covered with fire-retardant or noncombustible material to prevent the passage of sparks to
adjacent areas.
2. Ducts that might carry sparks to distant combustible or flammable materials shall be shielded
and / or shut.
3. If hot work is done on one side of a wall, partition, ceiling, or roof, one of the following
precautions shall be taken:
a) Combustibles on the other side shall be relocated.
b) If it is impractical to relocate combustibles, a Fire Watch shall be provided on the side of
the combustibles.

9.2. SSI Class 1 Hot Work

A. The following condition shall be verified before SSI Class 1 hot work is performed:
1. Initial air monitoring shall be performed and documented on the Hot Work Permit (see Section
10 and the Air Monitoring policy).
10. Air Monitoring (Class 1 Areas)

Flammable and combustible liquids and gases are or might be present within Class 1 areas. In order to
perform hot work safely in these areas, air monitoring is required so that flammable gas in the work area is
detected and properly controlled. Appendix IV summarizes air monitoring requirements for hot work.
Note: If the hot work will be performed in a tank or vessel, the air monitoring requirements for confined spaces
shall apply (see the Air Monitoring and Confined Space Entry policies).
Note: When the possibility exists for an oxygen-deficient atmosphere, the oxygen level could be below the
level required by the air monitoring device to give the correct flammability (LEL) reading. This could occur
where a tank, vessel, or piping contains an inert gas such as nitrogen or carbon dioxide. For this reason it is
important to monitor oxygen levels prior to monitoring for LEL.
10.1. General Requirements

A. All BP equipment used for air monitoring shall be in accordance with the Air Monitoring policy.
B. Initial air monitoring shall be conducted prior to the issuance of all Hot Work Permits.
C. Initial air monitoring should be conducted as close to the start of the hot work as possible
D. Initial air monitoring shall be conducted according to the Area Monitoring Plan (Section D of the Hot
Work Permit).
E. If air monitoring indicates the presence of flammable gas, the hot work shall not proceed until an LEL
Mitigation Plan is developed and implemented (see Section 10.6).
F. Hot work is prohibited if air monitoring readings are ≥10% of the LEL.
10.2. Initial Hot Work Air Monitoring (PSI Class 1)

A. Initial air monitoring shall be performed by an Authorized Gas Tester surveying at least a 35-foot
radius from the point of the hot work.
10.3. Continuous Hot Work Air Monitoring (PSI Class 1)

A. PSI Class 1 hot work requires attended continuous air monitoring by the Authorized Gas Tester
while the hot work is being performed.
B. The Authorized Gas Tester should survey the perimeter of the permitted area at least once an hour.
C. When not conducting a periodic perimeter survey, the Authorized Gas Tester should be primarily
positioned between the hot work and any potential sources of flammable gas.
Note: The use of several air monitors around the hot work should be considered, depending on the
work location. If more than one continuous monitor is in use, only one instrument is required to be
actively attended.
Note: Readings from continuous air monitoring and hourly surveys are not required to be recorded
on the Hot Work Permit.
D. Repeat air monitoring shall be performed, and the results documented on the Hot Work Permit
(Section A) prior to recommencing PSI Class 1 hot work if hot work was suspended and the worksite
is left unattended (including for normal work breaks) during a shift

10.4. Air Monitoring (SSI Class 1)

Vehicles, mobile plant equipment, and other non-intrinsically safe equipment present potential ignition
sources. Consequently, SSI hot work in Class 1 areas (such as a tank dike) requires a Hot Work Permit
to be issued and air monitoring performed.
A. Initial air monitoring shall be performed prior to conducting SSI hot work in Class 1 areas.
1. Before a vehicle or equipment that is not intrinsically safe is allowed to enter the Class 1 area,
an Authorized Gas Tester shall survey the area along the planned path of the vehicle or
equipment to its destination.
2. Only when flammability readings are 0% LEL, or less than 10% of the LEL with an
implemented LEL Mitigation Plan, can the vehicle or equipment proceed into the classified
area.
B. Continuous air monitoring is not required while performing SSI hot work in Class 1 areas if the initial
air monitoring readings are 0% of the LEL for the area.
1. If while SSI Class 1 hot work is being performed the hot work operator suspects the presence
of flammable gas, the hot work shall cease immediately, and air monitoring shall be conducted
so that a safe atmosphere can be verified before the hot work can continue.
C. If initial air monitoring readings are greater than 0% of the LEL, continuous air monitoring shall be
conducted while the hot work is performed.
D. If hot work is suspended and the worksite is left unattended, repeat air monitoring shall be
conducted as part of revalidating the permit for recommencing SSI Class 1 hot work if:
1. The initial air monitoring readings were > 0% of the LEL for the Class 1 area, or
2. Flammable gas is suspected in the Class 1 area (e.g. there is visual indication of a release, or
abnormal hydrocarbon odor).
E. Performing SSI Class 1 Hot Work for multiple Class 1 areas (e.g. lawn mowing multiple tank dikes at
a facility, corrosion surveys) can be performed using a single Hot Work Permit as long as the
following requirements are adhered to:
a) The full scope of the hot work to be performed is defined on the permit (e.g. lawn mowing
tank dike 3, 5, & 7).
b) Initial air monitoring is performed for the first Class 1 area and the results documented on
the Hot Work Permit.
c) After the Hot Work Permit is issued, air monitoring is performed for each subsequent
Class 1 area prior to entering the area with an ignition source. The results of the air
monitoring from each Class 1 area shall be recorded on the Hot Work Permit (Section A).
d) The Hot Work permit is updated as necessary (e.g. LEL Mitigation Plan is developed and
implemented if subsequent Class 1 areas register the presence of LEL).
10.5. Area Monitoring Plan

A. An Area Monitoring Plan shall be developed before Class 1 hot work is performed.
B. The Area Monitoring Plan can be documented in Section D of the Hot Work Permit, or can be
attached as a separate document.
C. The following information shall be included in the Area Monitoring Plan:
1. The area that will be monitored by the Authorized Gas Tester
a) For PSI Class 1 hot work, at a minimum, this includes a 35-foot radius from the point of
the hot work.
b) For SSI Class 1 hot work, at a minimum, this includes the planned path of the vehicle or
equipment to its destination
c) Hot work in a confined space requires air monitoring for flammable gas throughout the
entire space (see the Confined Space Entry policy).
2. Potential sources of flammable gas within the area to be monitored.
Note: Examples of potential sources of flammable gas include sumps, drains, flanges, valves,
liquid boots, excavations, and all confined areas and equipment located within them, such as
floating roof pontoons, piping, excavations, and vessels.
3. The wind direction.
10.6. LEL Mitigation Plan

The LEL Mitigation Plan documents the location of confirmed sources of flammable gas and the controls
needed to reduce the LEL reading to less than 10%.
A. An LEL Mitigation Plan shall be developed and implemented if the presence of flammable gas is
detected (LEL > 0%) at any time prior to or during the hot work.
B. If at any time the LEL reading is ≥ 10% of the LEL, the hot work shall stop immediately and shall not
be allowed to resume until controls are implemented to reduce the LEL level to less than 10% and
the Asset Operator / Asset Operator Designee approves changes to the permit
C. The LEL mitigation plan shall reduce and / or maintain the LEL to less than 10% and shall include
the following information:
1. The percent LEL that was detected.
2. The identified source(s) of the flammable gas within the hot work area.
3. The controls, if any, that shall be implemented to effectively reduce the flammability level to
less than 10% of the LEL within the hot work area.
4. The percent LEL measured after controls, if any, have been implemented.
D. If the LEL is > 0% after controls have been implemented, an assessment shall be performed to
determine if a Cold Work Permit for Toxic Substance Exposure is required.
11. Fire Watch

A. A Fire Watch shall be required whenever the hot work meets any of the following criteria:
1. The hot work consists of PSI Class 1 hot work.
2. The hot work will be performed:
a) within 35 feet of shielded combustible material;
b) within a 35-foot radius of wall or floor openings that expose combustible materials;
c) where combustible material is adjacent to the opposite side of walls, ceilings, or roofs
being worked on; or
d) where fire alarms or suppression systems have been disabled.
Note: These criteria are summarized in Appendix V.
B. The Fire Watch shall be in the ready position at all times while hot work is being performed. The
ready position consists of:
1. being attentive to the hot work being performed;
2. having the fire extinguisher in position at the job site prior to the start of work; and
3. maintaining a line of sight to the hot work being performed
C. A second Fire Watch shall be required if one Fire Watch cannot directly observe combustible
materials that could be ignited by the hot work operation.
12. Training and Competency

A. All personnel serving in roles listed in Section 5 of this policy shall complete training in the
requirements of this policy. The following persons shall complete additional training:
1. Authorized Gas Testers—shall be trained in the use of the air monitoring equipment they will
be operating.
2. Fire Watch—shall be trained in the selection and use of fire extinguishers including a hands-on
component.
Note: Refer to the USPL Control of Work Training and Competency matrix for specific training
requirements.
13. References
1. American Petroleum Institute, API Recommended Practice 500, “Classification of Locations for Electrical
Installations at Petroleum Facilities Classified as Class I, Division 1 and Division 2,” 2nd ed., November
1997.
2. American Petroleum Institute, API Recommended Practice 2009, “Safe Welding, Cutting, and Other Hot
Work Practices in the Petroleum and Petrochemical Industries,” 7th ed., February 2002.
3. BP GP 44-60, “Guidance on Practice for API RP 500 Area Classification.”
4. Facility Hazardous Area Classification diagrams.
5. National Fire Protection Association, NFPA 25, “Standard for the Inspection, Testing, and Maintenance of
Water-Based Fire Protection Systems,” 2002.
6. National Fire Protection Association, NFPA 51B, “Standard for Fire Prevention during Welding, Cutting,
and Other Hot Work,” 2003.
7. OSHA, U.S. Department of Labor, 29 CFR 1910.252, “Welding, Cutting, and Brazing: General
Requirements.”
8. National Fire Protection Association, NFPA 101, “Life Safety Code,” 2012.

Appendix I
Hot Work Permit
This example of the Hot Work Permit is for reference only. Yellow highlighting represents revisions made to the permit
and will not appear on the printable form. For a downloadable version of the permit, go to DRM. The electronic
version can be filled out online or printed and completed as hard copy.


Appendix II
Hot Work Permit Applicability
Is there an acceptable
alternative to hot work? Yes Complete job with cold work. Hot
Work Permit is not required.
No
Is the hot work specifically Yes Hot Work Permit is not required.
exempted, e.g. transport
loading, SSI non-Class 1?
No
Will hot work be performed Yes Examine the designated area, then
in a designated area? complete hot work there. Hot Work
Permit is not required.
No
Is the proposed hot work to Yes Hot work and permit are not
be performed in a non- authorized.
permissible area?
No
Is the proposed work to be Yes Obtain a Hot Work Permit.

performed outside of a
designated area?

Appendix III
Hot Work Permit Requirements
PSI Class 1 PSI non SSI Class 1 SSI non-

Class 1 Class 1
Examine
designated
area, then
Fire Watch Hot work to be complete Fire Watch not No requirements /
performed in a Yes
hot work. required no permit
designated Hot Work
area? Permit not
required
Air monitoring No
required Initial Air
monitoring
Combustibles Fire Watch required
Yes
relocated at least not
Complete 35 feet? required Continuous air
sections A, B, LEL > 0%? Yes
monitoring
C, D, and E of No required
Hot Work No
Fire Watch
Permit Continuous air
required
monitoring not
required
Air monitoring
not required
Develop LEL Complete
mitigation plan sections A and
if LEL is E of Hot Work
detected Complete sections Permit.
B, C, D (if
applicable), and E
of Hot Work
Permit

Appendix IV
Initial and Continuous Hot Work Air Monitoring
Requirements
Hot work to be performed?

Air monitoring not required. Fire
Watch may be required.
Yes No
Yes
Primary Source Ignition Hot work will be performed in a
(PSI) hot work? Yes Class 1 area or may impact Class
1 area?
Initial and continuous air monitoring
No required. Complete Area Monitoring
Plan in Section A of Hot Work Permit
Secondary Source Ignition (SSI) Hot work will be performed in a

hot work? Yes Class 1 area? Yes Initial air monitoring required.
LEL > 0%?
No No
Air monitoring not required.
Continuous air monitoring not
Yes required unless flammable gas is
suspected.
Complete LEL Mitigation Plan in Yes LEL > 0%?

Section A of Hot Work Permit
Implement controls to No
reduce LEL to < 10
%. Hot Work may not No LEL < 10% ? Yes Continue continuous monitoring
proceed if LEL > 10% for duration of hot work

Appendix V
Situations Requiring a Fire Watch
Will PSI Class 1 hot work be performed? Yes Fire Watch Required
No
Will PSI hot work be performed where shielded flammables or Yes

combustibles are located less than 35 feet from the hot work?
No
Will hot work be performed where wall or floor openings are within Yes
35 feet and combustibles in adjacent areas will be exposed?
No
Yes
Will hot work be performed where combustibles are adjacent to
partitions, ceilings, or roofs that will be worked on?
No
Are fire alarms and fire suppression systems being disabled for Yes
the hot work?
No
Fire Watch Not Required

Appendix VI
Types of Hot Work
Example: Tank Dike
The entire area inside the tank dike is a Class 1 area, so hot work performed inside the dike area is Class 1 hot work.
Hot work performed outside the dike is non-Class 1 hot work.

Appendix VII
General Mechanical Ventilation Guidance for Welding,
Cutting and Brazing in Confined Spaces or Partially
Enclosed Spaces
The following table provides guidance in determining the appropriate fan/blower configuration to achieve the required
2,000 cfm per welder:
No. of Size/Type of Fans or Horns with Minimum CFM Ratings per Maximum
Fans or Number of Welders in the Confined Space Number of
Horns Welders in a
Confined Space
1 20” air-driven entryway-mounted reaction fan = 10,000 cfm 4
1 Model 3 HP Coppus air horn = not adequate cfm 0
2 Model 3 HP Coppus air horn = 2,500 cfm 1
The maximum number of welders allowed in a confined space or partially enclosed space in the above table was
calculated using the total airflow (cfm) provided by the manufacturer for each model of air mover. An inlet air pressure
of 80 psi to drive the air movers was used. This must be maintained at the site for all the air movers. Because of
ventilation inefficiencies and losses due to entryway attachments, internal airflow restrictions, and variations in the
actual air inlet pressure, a safety factor of 0.75 was incorporated into the equation to determine the maximum number
of welders.
There must be enough fresh, breathable, makeup air entering the confined space or partially enclosed space to
balance the volume being exhausted to effectively “flush” the space with clean air. Consequently, some entryways
and nozzles should be left open to allow clean air to enter the space. Open entryways and nozzles should preferably
be located at the lower levels and the exhaust air fans/blowers at higher levels above the work. Most welding fumes
are heavier than air and adding ducting near the floor or work area to the Coppus-type fan is recommended to move
the fumes away from the welder.


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BP U.S.

Pipelines and Logistics (USPL) Hot Work

Air Monitoring Electrical Safety

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Welding and burning

Revision Date: July 8, 2014 Effective Date: December 31, 2014

5. Roles and Responsibilities

5.2. Authorized Gas Tester (can also be the Fire Watch)

Revision Date: July 8, 2014 Effective Date: December 31, 2014

5.3. Fire Watch (can also be Authorized Gas Tester)

5.4. Hot Work Operators

5.5. Performing Authority

7. Hot Work Permit

7.1. General Requirements

Revision Date: July 8, 2014 Effective Date: December 31, 2014

9. Hot Work Site Preparation

9.1. All PSI Hot Work

9.1.2. PSI Class 1 Hot Work

9.1.3. PSI Hot Work within 35 Feet of Buildings or Other Structures

Revision Date: July 8, 2014 Effective Date: December 31, 2014

9.2. SSI Class 1 Hot Work

10. Air Monitoring (Class 1 Areas)

10.1. General Requirements

10.2. Initial Hot Work Air Monitoring (PSI Class 1)

10.3. Continuous Hot Work Air Monitoring (PSI Class 1)

Revision Date: July 8, 2014 Effective Date: December 31, 2014

10.4. Air Monitoring (SSI Class 1)

10.5. Area Monitoring Plan

10.6. LEL Mitigation Plan

11. Fire Watch

12. Training and Competency

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Is the proposed work to be Yes Obtain a Hot Work Permit.

Revision Date: July 8, 2014 Effective Date: December 31, 2014

PSI Class 1 PSI non SSI Class 1 SSI non-

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Hot work to be performed?

Secondary Source Ignition (SSI) Hot work will be performed in a

Complete LEL Mitigation Plan in Yes LEL > 0%?

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Will PSI hot work be performed where shielded flammables or Yes

Fire Watch Not Required

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Revision Date: July 8, 2014 Effective Date: December 31, 2014

Revision Date: July 8, 2014 Effective Date: December 31, 2014

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