UNITED OLEFINS COMPLEX PROJECT
HOT WORKS
SAFETY TRAINING
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HOT WORKS
Safety Training
CONTENTS:
I. What is a Hot Work ?
II. Training
III. PPE`s
IV. Hot Work Permit
V. Electric Welding
VI. Fire Prevention
VII. Fire Watch
VIII. Generator Sets
IX. Welding Equipment Checks
X. Oxy Cutting Equipment
XI. Fire Safety Precautions
XII. Compressed Gas Cylinders
XIII. Safe Practices
XIV. Heat Stress
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HOT WORKS
Safety Training
WHAT IS A HOT WORK ?
Hot Work means an open flame,
welding arc, non-explosion proof
electrical tools or equipment and
any heat source, capable of causing
ignition.
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HOT WORKS
Safety Training
TRAINING
•Management and Supervisors
must assure that Fitters,
Welders and their Helpers
are trained.
•All ID badges of workers
involved in Hot work, must be
color coded.
•Supervisor, Fitters,Welders and
Helpers must be competent.
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HOT WORKS
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PERSONAL PROTECTIVE
EQUIPMENT
◼ Personal protective equipment
can only be effective if the
equipment is selected based
on its intended use.
◼ Employees are trained in its
use, and the equipment is
properly tested, maintained
and worn.
◼ The best protection comes
from an interested
management and work force
committed to sound work
practices.
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HOT WORKS
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PROTECTIVE CLOTHING
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 sparks is
anticipated.
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PERSONAL PROTECTIVE EQUIPMENT
Hardhat Hood or
Face Shield with the
correct filter shade
lens
Leather, flame
resistant gloves
Leather safety boots
Respirator mask
with rubber soles
(for inadequate
and steel toe caps
ventilation)
Leather apron
Leather flame
Leather spats resistant jacket
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HOT WORKS
Safety Training
HOT WORK PERMIT
A Hot Work permit system is
devised and used whenever
welding, cutting or bracing is
to be done.
Hot work permit is being
prepared by the Supervisor
and or the Leadman involved
in Hot work activities
(enclosed / attached to the
Daily Safe Work Plan).
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HOT WORKS
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HOT WORK PERMIT
Date:__________________ ____ Start Time:___________________ Time Valid To:___________
Issued to:______________________________ Area:____________________________________
Describe Work To Be done:
_______________________________________________________________________________________________________________________
_______
Equipment No.: WO#:
GENERAL PREPARATIONS: (CHECK-OFF All Items Which Apply and INITIAL To Verify In Place)
Initials__________ Initials____________
Y N Y N
( ) ( ) Energy Sources locked, tagged, tried ( ) ( ) Radiation shutter locked closed
( ) ( ) Sew ers covered, closed or plugged ( ) ( ) Combustible materials removed
( ) ( ) LEL monitors provided ( ) ( ) Proper fire extinguisher available
( ) ( ) LEL Test % at Hrs. ( ) ( ) Running w ater / tarps / blankets
( ) ( ) LEL Test % at Hrs. ( ) ( ) Signs and barricades posted
( ) ( ) LEL Test % at Hrs. ( ) ( ) Vehicle entry
( ) ( ) LEL Test % at Hrs. ( ) ( ) Other
( ) ( ) Maint. Supervisor Approval for ( ) ( ) Other
LEL >0 but <10% ( ) ( ) Fire Watch Name:
( ) ( ) Supervisor has reviewed responsibilities ( ) ( ) Signs and barricades posted
w ith Fire Watch
CONDITIONS NOT ALL MET:
( )( ) Special Procedure prepared ( ) ( ) _____________________
PROTECTIVE EQUIPMENT:
First After FirstAfter First After First After
Break Break Break Break Break Break Break
Break
( ) Slicker Suit ( ) ( ) Rubber Boots ( ) ( ) Chemical Gloves ( ) ( ) Face Shield ( )
( ) Goggles ( ) ( ) Acid Hood ( ) ( ) Full Acid Suit ( ) ( ) Cartridge Respirator ( )
( ) Hearing Protection ( ) ( ) Breathing Air ( ) ( ) ( ) ( ) ( )
APPROVALS: _____________________ ___________________ ______________________________
(Full Name) Unit Operator Unit Supervisor Designated Maintenance Worker
TURN BACK TO OWNER:
( ) Work is NOT completed. DATE TIME Hrs. ___________________ Work area has been cleaned
( ) ( ) Tools and equipment have been put aw ay ( ) ( ) Tags and Locks have been removed
_______________________________________ _____________________________________________ 9
Maintenance Worker Unit Operator
HOT WORKS
Safety Training
FIRE PREVENTION
Clear the area of all combustible materials such as:
PAPER CARDBOARD RAGS
GREASE LIQUID FUELS OILS 10
HOT WORKS
Safety Training
FIRE PREVENTION
Fuel containers 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.
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FIRE SAFETY PRECAUTIONS
Make sure there is a fire
extinguisher within 6 metres.
A 10 kg. (20 pound) or
larger dry chemical Fire
Extinguisher.
Cover immovable combustible
materials with a fire blanket.
Observe all of the safety
precautions listed on the Hot
Work Permit.
Appoint a “Fire Watch” person.
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FIRE WATCH
Fire Watch is required during the Hot Work
activities with the FIRE EXTINGISHER
equipment readily available, and they must
be trained in its use.
Wears Red reflective vest.
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FIRE WATCH
A Fire Watch will be familiar with
methods to sound an alarm.
He will be remain on duty for at
least ½ hour after welding
operations have
stopped.
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FIRE WATCH
Fire Watch will be required
when Hot Work is to be performed:
• in all locations where fire may
develop;
• where combustible material
stored within 10m (35ft.)
of Hot work;
• if combustibles are greater than
10m (35ft.) away but are
easily ignited;
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FIRE WATCH
• adjacent to wall or floor
openings within a 10m
(35ft.) radius of
combustible material; and
• combustible materials are
adjacent to the opposite
side of metal partitions,
ceilings or roofs.
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FIRE WATCH
Fire Watch has the authority stop the work when
sparks are not contained, a fire starts or when
conditions of the Hot Work Permit are not being met.
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HOT WORKS
Safety Training
GENERATOR SETS
Position the Gen Set so
that it will not block work
activities.
Copper rod for grounding
must be secured to their
connections.
The exhaust from the
Generator / Welding, must
be directed away from the
workers and to the
Confined Spaces.
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Safety Training
GENERATOR SETS
A Fire Extinguisher
must be placed near the
Generator.
Cords, Leads and Hoses
must not be a tripping
hazards.
Inspect all leads,
grounds, clamps,
welding machine hoses,
gauges, torches each
day before use.
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WELDING, HEATING & CUTTING
Welding - Electric Rod
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Safety Training
WELDING EQUIPMENT CHECKS
Burns or cracks
in the insulation
Lincoln
Loose screws
Loose cable
Damaged or dirty connection points connection
Loose cable connection
Lincoln
Burned or split insulation
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ELECTRIC WELDING
• All work must have an
adequate ground.
• Welding rods are not to be left
in the electric holder
(heater) when not in use.
• All arcs must be shielded in all
construction areas.
•Never perform electric welding
from a metal ladder.
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USING WELDING EQUIPMENT
Perform daily inspections of the
Equipment prior to use.
Never touch any exposed portion
of the electrode with any
unprotected part of your body
while standing on, or resting
against the work being welded.
Never dip an overheating
electrode holder in water to cool
it down.
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USING WELDING EQUIPMENT
Always use an insulating mat if
you have to kneel on the work
piece.
Always dispose of electrode
stubs into metal bins.
Always place electrode holders
on insulation material when not
being used.
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USING WELDING EQUIPMENT
Always switch off the
Generator if work is
stopped for any extended
period of time.
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Safety Training
WELDING, HEATING & CUTTING
Oxy Cutting Equipment
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HOT WORKS
Safety Training
COMPRESSED GAS CYLINDER COLOUR CODING
OXYGEN ACETYLENE LPG NITROGEN
(BLACK) (CLARET) (SILVER GREY) (PEWTER)
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SAFETY SIGNS FOR GAS CYLINDER
STORAGE AREAS
Cylinder storage areas must be signposted with
Danger Warning signs such as:
Cylinder storage areas must be signposted with signs to identify each
type of gas stored in the area, such as:
NON- FLAMMABLE
NON-TOXIC
GAS
Acetylene and LPG Nitrogen Oxygen
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WELDING, HEATING & CUTTING
Compressed Gas Cylinders
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SECURING COMPRESSED GAS CYLINDERS
Always store cylinders:
• in racks;
• in the upright position; FULL EMPTY
• secured with steel chains or
clamps; and
• with the cylinder valve fully closed.
Because empty cylinders still
contain a small amount of gas, the
cylinder valve must still be closed.
Store full and empty cylinders
separately according to gas type.
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SAFE PRACTICES
• Keep oil and grease away
Free standing
from oxygen-regulator hose
cylinders
and fittings.
• Do not store wrenches,
dies, cutters or other grease-
covered tools in the same Chain
compartment with oxygen
equipment.
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AREAS WHERE CYLINDERS
MUST NOT BE STORED
Excessive heat can cause
cylinders to pressurise and
leak gas. Never store
cylinders near:
• hot process pipes;
• boilers;
• radiators;
• furnaces; or
• flammable liquid storage
containers.
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AREAS WHERE CYLINDERS
MUST NOT BE STORED
Never store cylinders near
Subject to damage
areas which could prevent from other activities
people evacuating a in the vicinity
building in an emergency.
This includes:
• doorways;
• emergency exits; and
• stairwells.
Electrical cord in
Never store cylinders in Contact with the
Cylinder
cylinder
areas where they can be laying in
knocked over and Horizontal
position.
damaged by vehicles and
mobile equipment.
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AREAS WHERE CYLINDERS
MUST NOT BE STORED
Never store cylinders in
areas where they can be
knocked over and
damaged by vehicles and
mobile equipment.
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MANUAL HANDLING OF CYLINDERS
Your hands should be free of grit,
grease and oil when manually
handling cylinders to prevent:
• the cylinders from slipping; and
• grit or oil entering the cylinder
valve.
Cylinders must be moved and
staged in bottle carts with
appropriate size wheels for the
area.
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HOT WORKS
Safety Training
TRANSPORTING CYLINDERS IN A VEHICLE
Always transport Acetylene and LPG cylinders in the
upright position.
Always secure cylinders with steel clamps or chains to
prevent excessive movement.
Never allow any part of a cylinder to overhang the vehicle.
Never transport cylinders in the cab of the vehicle.
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RAISING AND LOWERING COMPRESSED
GAS CYLINDERS WITH A CRANE
Cages must be used when
lifting, lowering or moving
cylinders with a crane.
Cylinders must be secured in
the cage at all times to
prevent movement.
Never attempt to lift or lower
cylinders by attaching chain,
wire rope or flat web slings
around the cylinder.
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RAISING AND LOWERING COMPRESSED
GAS CYLINDERS WITH A CRANE
Never use the cylinder
valve as an attachment
point for lifting a cylinder.
Never attach a sling to a
compressed gas cylinder.
The cylinder can easily slip
through the sling and fall
to the ground.
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HOT WORKS
Safety Training
POSITIONING CYLINDERS AND HOSES
Never store or locate cylinders:
• in a confined space;
• in front of the designated
entry/exit point of a confined
space; or
• near the ventilation intake point
for a confined space.
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HOT WORKS
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POSITIONING CYLINDERS AND HOSES
Position the hose so they
will not be:
• burned by sparks and
molten slag;
• cut by sharp metal or
objects; and
• crushed or damaged by
vehicles.
Make sure the hoses do not
become a trip hazard for
other people.
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HOT WORKS
Safety Training
CHECKING HOSES
Hoses must be free of cuts,
cracks, burns or worn patches.
Never use the wrong coloured
hose for the type of gas being
fed to the handpiece.
LPG
Acetylene
Oxygen
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HOT WORKS
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CHECKING HOSES
Replace leaking hoses
immediately.
Never use insulation tape to
repair leaks.
Use soapy water or detergent
on all connections to check
for leaks.
Always shut off the cylinder
valve and vent the equipment
before tightening any
connections.
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HOT WORKS
Safety Training
CHECKING THE HANDPIECE
Check valves must be fitted between
the handpiece (torch) and the hoses.
Select the proper welding or cutting TIP for
the job.
Make sure the tip is CLEAN and not blocked.
Always SHUT the gas OFF at the pressure
reducing regulators when changing tips.
Never shut off the gas by CRIMPING or
PINCHING off the hose.
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CHECKING PRESSURE REGULATORS
Always open the pressure
adjusting screw of the regulator
Kpa Kpa first. Open the cylinder valve
slowly, to prevent damage to the
regulator.
Never drop or hit pressure
regulators.
Maintain a uniform gas supply.
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CHECKING PRESSURE REGULATORS
Reduce gas pressure to the
working pressure of the
handpiece.
If you detect a leaking regulator
you must:
• close the cylinder valve;
• remove and tag the regulator;
and have it repaired.
Never allow oil, grease, diesel,
petrol or soap to come into
contact with an Oxygen
pressure regulator.
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HOT WORKS
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SAFE PRACTICES
• Anti-flashback arrestors shall be
installed on the regulator end of
the hoses and at the check valve ok
at the torch end of the hoses on
all fuel gas and oxygen
cylinders.
• Some regulators may be
designed with an anti-flash
arrestor built into the regulators
and may only be used upon
approval of the PMT Safety
Department and Owner.
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HOT WORKS
Safety Training
FLASH ARRESTER
◼ Picture with FLASH ◼ Picture of cylinder
ARRESTER, safety for without Flash Arrester.
flash back to cylinder.
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HOT WORKS
Safety Training
SAFE PRACTICES
• Before connecting regulators to
cylinders, carefully open the
cylinder valve a crack to blow out
any foreign particles.
• After the regulator is connected,
stand to one side of gauge while
the cylinder valve is opened.
• Open the cylinder valve slowly.
• Be certain that the second stage
of the regulator is closed before
opening the cylinder valve.
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PPE FOR GAS CUTTING AND WELDING
Always wear:
The correct filter shade for the
type of work being performed.
Use # 10 filter for welding and DONNING YOUR MASKS
# 4 filter gas cutting torch
work and a face shield when
gas cutting or welding.
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PPE FOR GAS CUTTING AND WELDING
Pliable, flame proofed leather
gloves or aluminised gloves
need to be used.
Leather shoulder covers, apron
or jacket while working on
overhead cutting and welding.
Safety boots and leather spats.
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RESPIRATORY PROTECTION
•Proper ventilation and or
respiratory protection shall
be provided whenever there
is the potential for the build
up of hazardous fumes or
vapors.
•Hot Work involving exotic
metals and or paints to be
performed inside confined
space requires the approval
of the Project Manager.
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WELDING GASES, FUMES AND RADIATION
Toxic gases
• Ozone
• Nitrogen Oxides
• CO2
Toxic fumes
• Cadmium Oxide
• Chromic acid
• Copper fumes
• Nickel fumes
• Vanadium fumes
• Zinc Oxide
Radiation
• Infra-red
• Ultra-violet
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BARRICADING SYSTEM
Physical barricading
system is implemented
whenever there is
Hot Work activities in
the area.
Display appropriate
signages in the area.
HOT WORK
KEEP AWAY
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STARTING UP THE EQUIPMENT
Always open the pressure
adjusting screw of the regulator
before opening the cylinder
valve.
Open the cylinder valve slowly,
using the standard valve key.
Never extend the length of the
key by attaching it to a spanner
or steel pipe.
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SAFE PRACTICES
• Open valves on fuel gas
cylinders (propane,
acetylene, natural gas) a
quarter turn only.
• Open oxygen cylinder valves
completely.
• The valve wrench must be kept in
place during use.
• Do not exceed 15 psi on the torch
side of the gauge when
using acetylene.
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SAFE PRACTICES
When lighting a handpiece
always:
• use a friction flint lighter;
• point the handpiece tip away
from you; and
• point the tip away from other
people.
Never use matches, cigarette
lighters,
burning paper, or lit cigarettes to
light handpieces.
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SAFE PRACTICES
Never remove the
machine guarding of your
Grinder.
A deadman switch is
required for all portable
Tools.
Make sure you are protected
by a GFCI.
Cords are need to be double
insulated.
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SAFE PRACTICES
Sparks generated
while grinding must
be contained.
Keep other worker
away from the
grinding activity.
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SAFE PRACTICES
Use a Fire Blanket to protect
combustible materials and
also for the welding slugs.
Use welding Screens for the
radiation hazards.
Avoid breathing fumes. Use
Exhaust systems
Maintain proper Housekeeping.
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SAFE PRACTICES
• Never use oxygen in pneumatic
tools to pressurize a container, to
blow out lines, or as a substitute
for compressed air or other gases.
• Do not use compressed gas to
clean your clothing, blow out
anchor holes, or otherwise clean
your work area.
WHIPLASH ARRRESTER
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HOT WORKS IN CONFINED SPACES
Ensure a Confined Space Entry
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.
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HOT WORKS IN CONFINED SPACES
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.
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SHUTTING DOWN THE EQUIPMENT
Always close the oxygen and
fuel gas valves in the order
recommended by the torch
manufacturer.
Never put a torch down until
the gases have been
completely shut off.
Roll up the torch, hose and
remove the regulators then
attach the cylinders protective
caps.
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SHUTTING DOWN THE EQUIPMENT
Use the handpiece valves for short
shutdowns.
For overnight, you must break down
the cutting torch and gauges. Then
place the protective caps on the
cylinders. You do this by:
• closing the oxygen and fuel gas at
the cylinder valve;
• open the torch valves and vent all
gas from the hoses and regulators;
and
• close the torch valves.
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HEAT STRESS
◼ The Supervisor should visually monitor personnel to note
for signs of HEAT STRESS. Employees should be
instructed to observe for symptoms of HEAT STRESS and
methods on how to control it.
◼ Provide adequate fluids to replace body fluids. Personnel
should replace water and salt lost from sweating.
◼ Encourage employees to drink water and train them to
recognize signs and symptoms of HEAT STRESS related
problems.
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HEAT STRESS
◼ Normal body temperatures
98.6 F, or 37 C.
◼ Learn not to burn.
◼ Listen to what your body
tells you … always.
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HOTWORK CHECK LIST
(This check list is not a procedure but serves as a guide to the field
personnel involved in hot work activities.)
1. Measure / determine / identify circulating gases in the area. Log
values as measured by means of acceptable gas testing equipment
operated by competent personnel.
2. Ensure that area nearby or vicinity is free from flammable or
combustible material or kept at a distance of at least 6meters away from
hot work activities. This must be certified free by competent Safety
Inspector.
3. Personnel performing specific hot work activity must be certified
competent in his field of work. This is verified from the craft specific ID
Badge.
4. Specific Hot Work Permit must be compiled, duly signed and
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HOTWORK CHECK LIST
5. Equipment used including its accessories must have passed
the current monthly equipment inspection program carried out by a
competent person.
6. Gas cylinders must be equipped with valve protection caps
and fitted snugly.
7. Gas cylinders must not be hoisted or transported by means
of magnets or choker slings.
8. When cylinders are transported by powered vehicles, these
must be adequately secured in upright position.
9. Gas cylinders must be mounted on a cart or trolley and
secured by chain.
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HOTWORK CHECK LIST
10. Gas cylinders must be kept far enough away (6 meters) from
the actual welding or cutting operation so that sparks, hot slag or
flame are contained. If this is impractical, fire resistant shields must be
provided.
11. Cylinders containing oxygen or acetylene must not be taken
inside confined spaces.
12. Cylinders whether full or empty must not be used as rollers or
supports.
13. No one shall use a cylinder’s contents for purposes other
than those intended by the supplier.
14. All hose in use, carrying acetylene, oxygen, or any gas which
may ignite or enter into combustion or in any way harmful to
employees must be inspected thoroughly at the beginning of each
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HOTWORK CHECK LIST
15. Hose which has been subjected to flashback or severe wear
or damage or in doubtful condition must not be used.
16. Torches must be inspected at the beginning of each working
shift. Defective torches must not be used.
17. Torches must be lighted by friction lighters or other approved
devices and not by matches or from hot work.
18. Welding cables must be made of completely insulated,
flexible type material capable of handling the maximum current
requirements of the work in progress.
19. Welding cables used must not have been spliced. Further,
cables in need of repair must not be used.
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HOTWORK CHECK LIST
20. All arc welding and cutting operations must be shielded by non-
combustible or flameproof screens which will protect employees and
other persons working in the vicinity from direct rays of the arc.
21. No welding, cutting, or heating shall be done where the
application of flammable paints, or the presence of other flammable
compounds, or heavy dust concentration creates a hazard.
22. Suitable fire extinguishing equipment must be immediately
available in the work area and must be maintained in a state of
readiness for instant use.
23. Competent fire watch must be assigned in the work area to guard
against fire during actual welding, cutting and heating operations and
for sufficient of time after completion of the work to ensure that no
possibility of fire exists.
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HOTWORK CHECK LIST
24. Ensure the fire watch is trained, bear the training colour
coding on the ID Badge and that he wears a red reflective vest.
25. When hot work is performed on walls, floors or ceilings,
since direct penetration of heat or spark transfer may introduce fire
hazard, specific precaution must be observed (fire watch and fire
extinguishing equipment).
26. Drums, containers, hollow structures that contained toxic
or flammable substance must be thoroughly cleaned, ventilated and
tested prior to hot work activity.
27. Oxygen must not be used for ventilation purposes, comfort
cooling, blowing dust from clothing or for cleaning the work area.
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HOTWORK CHECK LIST
28. Anti-flashback arrestors must be used on the regulator end
of the hoses and check valves on the torch end of the hoses of all
gas and oxygen hoses, and when used they must prevent ignition of
gas sources upstream from the torch.
29. Torches must be constructed of brass, bronze, or stainless
steel and bear a UL label or other accepted test laboratories.
30. Welding hoods must be worn by welders and helpers.
31 Welder must not stand in water while welding.
32. Safety goggles fitted with opaque side piece must be worn
under the welding hood.
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HOTWORK CHECK LIST
33. In addition, gloves, aprons and leggings must be worn by
welders for added body protection.
34. Welding electrodes must not be left unattended. Hot
electrode holders must not be dipped in water; to do so may expose
the welder to to electric shock.
35. Adequate ventilation must be in place to remove harmful
fumes and gases during welding works.
36. The area of any hot work must be thoroughly examined one
hour after the work has been completed. This operation must be a joint
effort by supervision and safety.
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HOTWORK CHECK LIST
37. Welding or cutting equipment must not be used without prior
authorization.
38. Any material being cut off must be properly supported.
39. Gas cylinders used must be removed immediately from the
work area after completion of activity.
40. Hoses and cables must run in orderly fashion and must not
block access ways.
41. On completion of the activity, all equipment used must be
returned to designated storage areas. Further, the area must be
cleaned up of all scrap materials, rods, butts by the person who did
the job.
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HOTWORK CHECK LIST
42. Welders must check equipment prior to use and pay particular
attention to (a) damaged insulation on welding leads, electrode
holders and connections, (b) faulty earth clamp and earth leads, (c)
faulty gas pressure gauges, pressure reducers, flashback arrestors
and torches.
43. Hot work permit must be closed by supervision after completion of
activity.
44. Appropriate signs and barricades must be installed at the area
prior to start of activity.
45. All welding operations shall have fire blankets to contain sparks
and slag.
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Safety Training
HOTWORK CHECK LIST
42. Welders must check equipment prior to use and pay particular
attention to (a) damaged insulation on welding leads, electrode
holders and connections, (b) faulty earth clamp and earth leads, (c)
faulty gas pressure gauges, pressure reducers, flashback arrestors
and torches.
43. Hot work permit must be closed by supervision after completion of
activity.
44. Appropriate signs and barricades must be installed at the area
prior to start of activity.
45. All welding operations shall have fire blankets to contain sparks
and slag.
46. Permits, Job Safety Analysis and Safe Work Plan must be current
and in place and the safe procedures and hazards discussed with the
people actually performing the work. 77
