API RP 2009-2002 Safe Welding Cutting and Hot Work Practices in the Petroleum and Petrochemical Industries (Seventh Edition)《石油和石化行业安全焊接、切削及其它热作业实践》.pdf

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1、Safe Welding, Cutting, and HotWork Practices in the Petroleumand Petrochemical IndustriesAPI RECOMMENDED PRACTICE 2009SEVENTH EDITION, FEBRUARY 2002REAFFIRMED AUGUST 2007Safe Welding, Cutting, and Hot Work Practices in the Petroleum and Petrochemical IndustriesSafety however, theInstitute makes no r

2、epresentation, warranty, or guarantee in connection with this publicationand hereby expressly disclaims any liability or responsibility for loss or damage resultingfrom its use or for the violation of any federal, state, or municipal regulation with which thispublication may conict.Suggested revisio

3、ns are invited and should be submitted to the general manager of the APIStandards Department, American Petroleum Institute, 1220 L Street, N.W., Washington,D.C. 20005.INFORMATION CONCERNING SAFETY AND HEALTH HAZARDS ANDPROPER PRECAUTIONS WITH RESPECT TO PARTICULAR MATERIALS ANDCONDITIONS SHOULD BE O

4、BTAINED FROM THE EMPLOYER, THE MANU-FACTURER OR SUPPLIER OF THAT MATERIAL, OR THE MATERIAL SAFETYDATA SHEET.iiiCONTENTSPage1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Purpose. . . . . . . . . . . . . . . . . . . . .

5、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Retroactivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6、 . . . . . . . . . . . . . . 11.4 Concept of Hazard vs Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 General Hot Work Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REFERENCED PUBLICATIONS. . . . . . . .

7、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 JOB ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8、 . . . . . . . . . . 54.1 Job Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 Review by Qualied Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 HAZARD EVALUATION AND RISK REDUCTION

9、. . . . . . . . . . . . . . . . . . . . . . . . 55.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 Physical Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10、65.3 Potential Acute Health Hazards and Risk Reduction. . . . . . . . . . . . . . . . . . . . . . . 65.4 Potential Chronic Health Hazards and Risk Reduction. . . . . . . . . . . . . . . . . . . . . 65.5 Flammable Liquids, Vapors, Solids, or Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . .

11、 . 75.6 Combustible Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.7 Ignition Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.8 Water . . . . . . . . . . . . . . . . . . . . . .

12、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.9 Wind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.10 Equipment with Liners, Blisters, or Patch Plates. . . . . . . . . . . . . . . . . . . .

13、 . . . . . 85.11 Electrical Hazards to Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.12 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 IMPLEMENTATION OF SAFEGUARDS . . . . . . .

14、 . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1 General Concepts of Safeguards and Risk Reduction . . . . . . . . . . . . . . . . . . . . . . 96.2 Equipment Purging and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.3 Protection of Personnel. . . .

15、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.4 Safeguards Against Ignition Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.5 Fire Watch Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16、. . . . . . 117 TESTING FOR HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.1 Flammability Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.2 Oxygen Testing. . . . . . . . . . . . . . . . . .

17、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.3 Monitoring for Toxic Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.4 Frequency of Monitoring the Atmosphere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 HOT WORK PERM

18、ITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.2 Permit Requirements . . . . . . . . . . . . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . 138.3 Issuing and Closing-out the Permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.4 Interrupted Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148.5 Extending the P

20、ermit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14vPage9 HOT WORK IN CONFINED SPACES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149.1 Conned Space Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21、. . . . . . . . . . . 149.2 Oxygen Content in Conned Spaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149.3 Flammable Vapor Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149.4 Conned Space Ventilation . . . . . . . . . . . . . . . .

22、. . . . . . . . . . . . . . . . . . . . . . . . . 149.5 Frequency of Monitoring in Conned Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.6 Pyrophoric Iron Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1510 WORK INSIDE VESSELS, EXCHANGE

23、RS, AND TANKS . . . . . . . . . . . . . . . . . . 1510.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1510.2 Maintaining a Safe Work Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610.3 Inspection of

24、Internals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1611 WORK ON THE EXTERIOR OF VESSELS, EXCHANGERS, AND TANKS NOT IN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1612 WORK ON EQUIPMENT IN SERVICE . . . . . . .

25、 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1612.1 Decision Process for Work on Equipment in Service . . . . . . . . . . . . . . . . . . . . 1612.2 Hot Work With Hydrocarbons Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1612.3 Work on the Exterior of Atmospheric

26、Pressure In-service Vessels . . . . . . . . . . 1812.4 Hot Work on Equipment under Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1812.5 Leak Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1813 WORK IN BUILDINGS AND

27、 PITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914 WORK ON PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914.1 General Considerations for Work on Piping . . . . . . . . . . . . . . . . . . . . . . . .

28、 . . . 1914.2 Piping Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1914.3 Venting of Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2014.4 Piping Contamination and Coating . . . . .

29、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2014.5 Hot Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20APPENDIX A BIBLIOGRAPHY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21APPEND

30、IX B INERTING VESSELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Figures1 Typical Hot Work Activity Flow for Equipment Not in Service . . . . . . . . . . . . . . . 22 Example Decision Process for Authorization of Work on Equipment in Service . . . . . . . . . . .

31、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Tables1 Welding Hazards and Possible Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10vi1Safe Welding, Cutting, and Hot Work Practices in the Petroleum and Petrochemical IndustriesSECTION 1INTRODUCTI

32、ON1.1 PURPOSE Gas and electric welding and cutting operations are impor-tant activities to support petroleum and petrochemical opera-tions. Personnel engaged in these operations should have athorough understanding of the duties they are to perform andthe potential hazards associated with the activit

33、y and materialsinvolved. This recommended practice provides information toassist welding, cutting and other hot work activities to be donesafely in petroleum and petrochemical operations. The under-standing of potential hazards, and application of this knowl-edge, can help reduce the probability and

34、 severity of incidents.1.2 SCOPEThis recommended practice provides guidelines for safelyconducting welding, cutting or other hot work activities inreneries, gas plants, petrochemical plants and other facilitiesin the petroleum and petrochemical industries. It includesspecic guidance to evaluate proc

35、edures for certain types ofwork on equipment in service. Not included in the scope are: a. Guidance for compliance with regulations or codes.b. Hot tapping (it is the subject of API Recommended Prac-tice 2201 Procedures for Hot Tapping on Equipment inService). c. Welding techniques, craft skills or

36、qualication ofwelders.d. Normal safe work practices such as fall protection, PPE,slip/trip/fall, etc.e. Entry or work in inert environments (see API 2217A).The principles and resources provided in this document arewidely applicable. Some activities (such as oil drilling or off-shore operations) may

37、be subject to specic regulations orunique work requirements which should be considered whendeveloping welding and hot work programs.While personnel doing welding and other hot work requirea high degree of skill and shall be qualied for the work theyare doing, the qualication of personnel falls outsi

38、de thescope of this document. API 2009 intends to maintain consistency and compatibil-ity with ANSI/AWS Z49.1 which provides much more detailon welding equipment, PPE and certain procedures andNFPA 51B that focuses on res and explosions with guidancecovering a broad spectrum of applications includin

39、g struc-tures. Additional guidance relating to welding equipment,techniques, processes and testing used in the chemical, oil,gas and pipeline industries is provided by API RP 582, APIStd 1104 and API RP 1107. 1.3 RETROACTIVITY Any provisions in this publication related to procedures ordesign are int

40、ended for new project reference such as revisingprocedures or designing new facilities, or when consideringmajor revisions or expansions. It is not intended that any rec-ommendations in this publication be applied retroactively toexisting facilities or evaluation of prior practice. This recom-mended

41、 practice should provide useful guidance when thereis a desire or need to review programs or facilities.1.4 CONCEPT OF HAZARD VS RISKHazards are properties of materials with the inherent abil-ity to cause harm. Flammability, toxicity, corrosivity, andstored chemical or mechanical energy all are haza

42、rds associ-ated with various industrial materials. Risk requires exposure.A hot surface or material can cause thermal skin burns or acorrosive acid can cause chemical skin burns, but these canoccur only if there is contact exposure to skin. There is no riskwhen there is no potential for exposure. De

43、termining the level of risk involves understanding haz-ards and estimating the probability and severity of exposurethat could lead to harm. While the preceding examples relatehazards to the risk to people, the same principles are valid forevaluating property risk. For instance, hydrocarbon vapors in

44、a ammable mixture with air can ignite if exposed to a sourceof ignition resulting in a re that could damage property.1.5 GENERAL HOT WORK PROCESSThe discussion of safe hot work in this publication fol-lows the process ow chart shown in Figure 1. This chartshows a typical ow sequence for welding acti

45、vities in thepetroleum and petrochemical industries. Sections of this doc-ument that discuss those steps are indicated. Other facilitiesmay have alternative work ow processes, or may combinesome steps.2 API RECOMMENDEDPRACTICE2009Figure 1Typical Hot Work Activity Flow for Equipment Not in ServiceJOB

46、 ANALYSISJOB ANALYSISCLOSE OUTWORK CLOSE OUTWORK EVALUATE WORK CONDITIONSEVALUATE WORK CONDITIONSAUTHORIZE WORKAUTHORIZE WORKCARRY OUT WORKCARRY OUT WORKIMPLEMENTSAFEGUARDSIMPLEMENTSAFEGUARDSTYPICAL HOT WORKACTIVITY FLOWFor Equipment Not in ServiceDeterminePermit ConditionsConform to PermitCondition

47、sAppropriate PersonsSign Work PermitPermit ConditionsMaintainedWork RequestSigned OffAlternate TechniquesConsideredReference Section465 Martin H. Finkel, ASSE Press1999AWS5F 3.1 Guide for Welding Fume ControlNational Board6ANSI/NB-23National Board Inspection Code(Section 23)NFPA751BStandard for Fire

48、 Prevention During Weld-ing, Cutting, and Other Hot WorkNIOSH8Pub 88-110 Criteria for a Recommended Standard:Welding, Brazing, and Thermal Cutting Pub 99-115Pocket Guide to Chemical Hazards andOther Databases (CD-ROM)OSHA91910.119Process Safety Management of HighlyHazardous Chemicals1910.146 Permit-

49、Required Conned Spaces1910.147Control of Hazardous Energy (Lockout/Tagout)1910.251-7 Subpart Q Welding, Cutting, and Brazing1910.1000 (and following) Subpart Z, Toxic andHazardous Substances1910.1200Hazard Communication1926.32Denitionsfor OSHA ConstructionStandards1926.350Gas Welding and Cutting1926.354Welding, Cutting, and Heating in Way ofPreservative Coatings1www. api.org2American Conference of Governmental Industrial Hygienists, 6500Glenway Avenue, Building D-5, Cincinnati, Ohio 45211.www.acgih.org 3American National Standards Institute, 25 West 43rd Street,