1. Hot Work Safety Plan Thomas D. Barnes, CHMM, CET
Compliance Specialists Inc.
For Jay Industries, Inc

2. Outline Written Program Fire Prevention & Protection
Protection of Personnel
Health Protection & Ventilation
Communicate that welding safety standards cover these basic areas.
The written plan will cover regulatory issues, safety practices and specific local policies.
Welding plays a major part in industrial fires
Welding process present unique hazards requiring worker protection

3. Written Program What Who Where
Based on OSHA 29 CFR NFPA - Standard 51B, 1962
Communicate that a written plan has been developed for the facility.
The plan covers safe work polices and information for developing polices or procedures.
The safety officer will maintain the plan and make it available.
The plan will comply with these safety standards, the OSHA standards are copied in the plan book.

4. Fire Prevention and Protection
Basic Safety Precautions
Fire hazards removed
Guards
Restrictions
Special Precautions
Combustible material
Fire extinguishers
Fire watch

5. HOT WORK

6. Definitions
Hot Work - Use of equipment which produces any flame or sparks i.e. cutting, welding, grinding. Also electrical work in hazardous areas
Controlled Work Area - Area adjacent to and extending 35 feet from work area.
Fire Watch - Designated person to monitor the area during the hot work

7. Definitions
Hot Work Permit - A procedure for securing an area prior to starting hot work activities
Lower Explosion Limit (LEL) - Minimum amount of vapor required to cause vapor to ignite.
Ordinary Combustibles - Solid materials which will burn such as wood, paper or fabrics

8. Hot Work Assessment
Areas which are listed as not requiring permits to be issued must be kept clear of any flammable and combustible liquids and/or ordinary combustibles.
Areas listed as requiring a permit must have a permit issued prior to beginning any hot work in the area.

9. Hot Work Permit Hot Work Permit must be issued by area supervisor
Valid for only a specific time, date and job
Valid for a certain time period
Must be posted in the area
Returned to Maintenance and retained in files for a minimum of one year

10. Hot Work Permit Fire Watch - Assigned whenever:
Hot work could cause a fire from uncontrolled sparks or flames
Appreciable combustible materials are within 35 feet
Must be present for entire work time plus 30 minutes after work is completed

11. Hot Work Permit
Fire watch shall cease operations if any additional hazard is introduced or an emergency occurs.
Fire Watch must:
Have extinguisher immediately available
Keep unauthorized personnel and materials away from area
Know the alarm system and other emergency procedures
Check for vapors if vapors could be present

12. Prohibited Areas
The following areas/situations will not have hot work activities allowed:
In Flammable Storage Building
In area of VPI Tank, Dip Tank, or Chiller Tank.
Any gas or flammable liquid/gas line or equipment.
Confined spaces
Any area not authorized by management
Any area when sprinkler system is impaired

13. General Rules Always evaluate area before beginning work
Have permit issued if required
Protect all flammable and combustibles from sparks and/or flames
Use fire watch if necessary
Assure contractors use hot work procedures

14. Protection of Personnel
General
Proper use of cylinders
Fall protection
Eye protection
Protective Clothing
Describe general fall hazards and protection as pertains to welding.
Working in elevated positions.
Clear stable standing surface, proper guards, rails, toe boards, the use of harnesses, safety lines, etc.
Describe creating tripping hazards with welding equipment.
Introduce eye and clothing protection from heat and radiation.

15. Protection of Personnel
Proper Use of Cylinders/Regulators
Blow out valves
Assure proper regulators are used
Stand to side of regulator
Open slowly
No more than 15 psi
Always light acetylene first
Always turn oxygen off first
Always bleed lines after use
Describe general fall hazards and protection as pertains to welding.
Working in elevated positions.
Clear stable standing surface, proper guards, rails, toe boards, the use of harnesses, safety lines, etc.
Describe creating tripping hazards with welding equipment.
Introduce eye and clothing protection from heat and radiation.

16. Protection of Personnel
Fall Protection
Assure fall restraint or fall arrest is utilized at all times that a fall could occur
Limited/restricted sight
Numerous trip hazards
Describe general fall hazards and protection as pertains to welding.
Working in elevated positions.
Clear stable standing surface, proper guards, rails, toe boards, the use of harnesses, safety lines, etc.
Describe creating tripping hazards with welding equipment.
Introduce eye and clothing protection from heat and radiation.

17. Protection of Personnel
Eye Protection
Mandatory use
Three different light hazards
Visible
Infrared
Ultra Violet
Assure all personnel are protected
Direct
Reflection
Selection
Helmets or hand shields - arc welding & cutting
Goggles - gas welding & Oxygen cutting & brazing
Describe the health effects of heat, uv light, and light intensity.
Selection depends on the need for skin protection and type of light.
Explain the need for certified and tested lens.

18. Protection of Personnel
Eye Protection
Specifications for protectors
Use guide for the selection of the proper shade of lens for each welding operation meeting ANSI Z87.1 –1968
Shielded Arc 10 – 14 (depends on electrode size and material)
Carbon Arc 14
Cutting and Brazing 3 – 6 (depends on work)
Gas Welding 5 – 8 (depends on work)
Describe the health effects of heat, uv light, and light intensity.
Selection depends on the need for skin protection and type of light.
Explain the need for certified and tested lens.

19. Protection of Personnel
Protective Clothing
Selection
Conform to requirements of 29 CFR Personal Protective Equipment
Appropriate for the welding operation with respect to type, size, nature and location of the work to be performed
Avoid pockets and cuffs
Avoid items in pockets (lighters)
Assessments must be made of each welding process and situation.
In general protective clothing must protect all exposed skin.
Be able to block the heat and radiation.
Standup to the heat and radiation.
Be fire proof or resistant.

20. Protection of Personnel
You may need a C.S. Permit
A Confined Space-like area may be created by ventilation issues
Health hazards
Physical hazards
Discuss the definition of confined spaces and permit required confined spaces as relates to the OHSA standard.
Explain that spaces may have inherent hazards and or workers may introduce hazards to a confined space, particularly in welding.
Discuss how confined spaces increase health hazards of exposure to welding toxins.
Explain ventilation and proper respiratory protection.
Discuss how confined spaces increase physical hazards.
Poor working surfaces, electrical hazards, moving equipment.

21. Health Protection &Ventilation
General
Dimensions of welding space
Number of welders
Screens
Possible hazardous fumes - 29 CFR toxic and hazardous substances
MSDS’s
Discuss how in general welders are not exposed to unsafe levels of fumes or gases in the welding process.
Explain that exposure depends on good natural ventilation.
Explain how these areas must be considered and how they may overcome natural ventilation, requiring other safety measures.

22. Health Protection &Ventilation
Mechanical Ventilation for Welding & Cutting
Space less than 10,000 cubic feet per welder
Ceiling height less than 16 feet
In confined spaces or obstructions to ventilation
Minimum rate of 2000 cubic ft/min/welder
Always use mechanical ventilation wherever possible
Discuss guide lines for when, area or building, forced ventilation may be needed.
Explain that there are standards to go by.

23. Health Protection &Ventilation
Screens
Arrange so that no restriction of ventilation exists
Keep bottoms of screens about 2 feet above floor
Explain that in setting up screens for light control be careful not to adversely affect ventilation.

24. Health Protection &Ventilation
Local Exhaust Hoods
Maintain air-flow of 100 linear feet per minute at the zone of welding
600 cubic ft./min /2 inch duct - 12 inches from the zone of welding
150 cubic ft./min. - 3 inch duct - 6 inches from the zone of welding
Explain the advantages and use of local exhaust systems.
Explain that there are guide lines and standards to go by when designing or purchasing equipment.
Explain that the system must exhaust to a safe area.

25. Health Protection &Ventilation
Booths
Fixed enclosure with a top and not less than two sides
Maintain air-flow of 100 linear feet per minute away from the welder
Same as last slide.

26. Health Protection &Ventilation
Toxic and Hazardous Substances in Welding
Fluorine compounds
Zinc
Lead
Beryllium
Cadmium
Mercury
Chlorinated solvents – Phosgene gas
Discuss the need to check for the presence of toxic substances in the welding process.
These materials may be in the flux, metals, or filler metal.
Use respiratory protection until testing proves safe exposure.

27. HOT WORK
THINK SAFETY
YOUR
LIFE
HEALTH
AND
INCOME
DEPENDS ON IT

28. Questions?
Contact your Supervisor, the Maintenance Supervisor in your plant, or the EHS Department.
Thank you and stay safe out there!