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Hot Work Operations – Pipeline Welding on Active Plant
Industry: Oil & Gas · Country: United Arab Emirates · Location: Processing Unit 4 – Gas Compression Area
Risk assessment covering hot work activities including welding, cutting, and grinding on and near active gas pipelines. The area presents significant fire and explosion risk due to the presence of flammable hydrocarbons.
Task Steps
- Obtain hot work permit from Operations and HSE department
- Gas test the work area to confirm safe atmosphere (LEL <10%)
- Isolate and depressurize pipeline section if required
- Set up fire watch and fire extinguisher at work site
- Install spark containment screens and fire blankets
- Perform welding or cutting with certified welder
- Continuous gas monitoring during entire hot work period
- Post-work inspection and fire watch for 30 minutes after completion
Risk Assessment (1 risks)
Risk #1 — Physical (high, score 10)
Hazard: Ignition of flammable atmosphere from welding sparks
Consequences: Fire, explosion, multiple fatalities
Control measures:
- Continuous gas monitoring with audible alarm (LEL <10% to proceed)
- Hot work permit system with dual authorization
- Fire watch stationed 24/7 during operations
- Full site evacuation plan activated
- Immediate work stop if gas detection alarm activates
