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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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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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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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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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 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 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
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FIRE PREVENTION
Clear the area of all combustible materials such as:

PAPER CARDBOARD RAGS

GREASE LIQUID FUELS OILS 10

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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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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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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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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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WELDING, HEATING & CUTTING

Oxy Cutting Equipment

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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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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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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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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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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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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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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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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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FLASH ARRESTER
◼ Picture with FLASH ◼ Picture of cylinder
ARRESTER, safety for without Flash Arrester.
flash back to cylinder.

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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.

76
 HOT WORKS
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