HOT WORK TRAINING

1
 Why is ‘Safe Hot Work’ important ?
• An estimated 562,000 employees are at risk for exposure to chemical and physical
hazards of welding, cutting and brazing

• For the construction industry, welders flash (burn to the eyes) accounts for 5.6% of all
construction eye injuries

• For the construction industry, welders flash (burn to the eyes) accounts for 5.6% of all
construction eye injuries

2
 What is the Hot Work ?

Hot Work comprises work activities that

involve the application or generation of
heat during their execution.

Examples :

- Cutting

- Welding

- Brazing

- Soldering

- Use of blow-lamps

Hot Work, in the main, is associated with the application of heat either directly to, or adjacent to plant, tanks,
vessels, pipes etc, that contain or have contained any explosive, flammable or toxic substance.
However, for completeness, due to the fire risks intrinsic to any Hot Work Activity, and the risk of personal
injuries due to hot debris, toxic fumes etc.,
3
Risk Point

The hazard arising from Hot Work

The main hazards likely to be encountered during welding and cutting

processes are:

● High temperature, causing burns and fires;

● Directly or indirectly evolved fumes, liable to cause injury to health;
● Thermal radiation causing burns and 'arc eye';
● Oxygen insufficiency or enrichment within confined spaces;
● Electric shock, which may also lead to a fall;
● Explosions (often fatal) during the welding of tanks, drums, and vessels
which have not been fully freed of flammable contents and inert gas purged.
Ignition source rate

4
Safety Measure

Do Basic procedure

General Safety Precautions

• Equipment shall be visually inspected by the user daily.

• Remove and replace defective equipment.
• All welding and brazing operations shall have proper ventilation.
• All unsecured work pieces shall be properly clamped.
• Turned off all equipment when not in use.
• A portable fire extinguisher shall be available within 3 m (10 ft).
• Remove & protect combustibles around the work area
• All sewers within 23 m (75 ft) shall be covered prior to work.
• A qualified fire watch shall be maintained during operations and
for 30 minutes afterwards.
• Cutting, welding, and brazing are not allowed in O2 enriched environments
(i.e., O2 concentration greater than 23.5%).
• Wearing the proper PPE

5
Safety Measure

Do PPE

Protective clothing required for welding and burning varies with the size,
nature and location of the work to be performed:

• Only fire resistant clothing must be worn.

• All welders shall use flameproof gloves.
• Clothes should be free from oil and grease.
• Flameproof leather (or suitable material) aprons should be considered
if long term exposure to radiant heat or spark is anticipated.

6
Safety Measure

Do Hot Work Permit

Hot Work Permit System

• A hot work permit system is devised

and used whenever welding, cutting
and bracing is to be done

• Hot work permit is bring prepared

by the supervisor and or the leadman
involved in hot work activities.
(enclosed/attached to the Daily Safety
Work Plan)

7
Safety Measure

Do Fire Prevention

* Clear the area of all combustible material such as;

paper, card board, rags, grease, liquid fuels, oil etc.

• Fuel container must be of metal and equipped with an air-vent.

• Fuel trucks will be properly grounded when refueling equipment.

• Equipment must be switched off during refueling.

8
Safety Measure

Do Fire Safety Precautions

• Make sure there is a fire extinguisher within 6 meters.

• A 10 kg.(20 Pound) or larger dry chemical Fire Extinguisher.

• Cover immovable combustible materials with a Fire Blanket.

• Observe all of the safety precaution listed on the Hot Work Permit.

• Appoint a Fire Watch person.

9
Safety Measure

Do Welding Operation

Electric Arc Welding Operations

• Electric welding machines shall be properly bonded and grounded

• Electric welding machine electrical outlets shall be the 110 volt (V),
3-pronged type with ground fault protection device;
220 V electrical outlets are not permitted.

• Welding cables shall be continuous within 3 m (10 ft) of the electrode holder.

• All damaged welding cables shall be removed from service;

temporary repairs and taped joints are prohibited.

• Proper welding screens shall be used near other personnel.

10
Safety Measure

Do Welding Operation

Gas Welding, Cutting, and Brazing Operations

• Lighted torches shall not be left unattended.
• Compressed type fittings shall be utilized on hose connections.
• All connections/equipment shall be checked for leaks before use
(e.g., soap solution).
• Gas regulators shall be turned off and hoses bled off at the end of shift or task.
• Hoses shall be protected from potential damage during operations.
• Flashback arrestors shall be placed at O2/acetylene cylinder regulators
as shown below in Figure 6. Figure 6.
Flashback Arrestor Position on O2/Acetylene Cylinders

* Compressed Cylinder

• Only strikers shall be used to light a torch; never light a torch with matches
or a lighter.
• When opening an O2 or fuel cylinder valve, always crack it open first.
• Stand to the side of a regulator, not in front of it when opening cylinder
valves.
• Acetylene cylinders in use shall have a handle or valve wrench in place at all
times.
11
 Cylinders Handling
--Oxygen and Acetylene cylinders mus --Flame arrestors on compressed gas
t be stored separately cylinders are required for all areas insi
de the LUBEREF facility.
--When not in use, the protective valv
e cap must be kept in place

x
12
Safety Measure

Hot Work in
Do Confined Spaces

• Ensure a CSE permit has been issued.

• Remove all flammable materials.

• Check if there is adequate ventilation.

• Check if there is adequate lighting.

• Identify what personal protective equipment must be worn.

• Position the welding power source outside the confined space.

• Cover or arrange welding cables to prevent contact with falling sparks.

• Station a person outside, to observe the work and raise the alarm in an emergency.

13
Safety Measure

Do Fire Watch

Fire Watch will be required when Hot Work is to be performed;

; in all locations where fire mat develop
; where combustible material stored within 10m (3.5ft.) of Hot Work
; if combustibles are greater than 10m (3.5ft.) away but are easily ignited

Duties and Responsibility

• A Fire Watch will be familiar with methods to sound an alarm.

• Remain on duty for at least 30 minutes after welding operation have stopped.

• He has the authority to stop work when;

Sparks are not contained
When a fire starts
When conditions of the permit are not being met

14
Safety Measure

Do Barricading System

• Physical barricading system is implemented

• Whenever there is Hot Work activities in the area

• Display appropriate signage in the area

15