Report accidents and incidents to: HSE Manager, HSE Deputy Manager, HSE Supervisor
What is Hot Work?
Work performed with an open flame, welding arc, non-explosion proof electrical tools, or equipment capable of causing an ignition.
Training
Management and Supervisors must ensure that all employees engaged in hot work activities are trained.
Supervisor, Fitters, Welders and Helpers must be competent.
Personal Protective Equipment
Equipment is selected based on its intended use.
Employees are trained in its use.
Equipment is properly tested, maintained and worn.
The best protection comes from an interested management and work force committed to sound and safe work practices.
Protective Clothing
Required clothing varies with the size, nature and location of the work.
Only fire resistant clothing must be worn.
All welders shall use flameproof gloves.
Clothes should be free from oil and grease.
Flameproof leather (or similar material) aprons should be considered for long-term exposure to radiant heat or sparks.
PPE Components
Hardhat
Hood or Face Shield with the correct filter shade lens
Leather flame-resistant jacket
Leather spats
Respirator mask (for inadequate ventilation)
Leather, flame-resistant gloves
Leather safety boots with rubber soles and steel toe caps
Leather apron
Fire Prevention
Hot Work Permit
Required for all hot work in gas hazardous areas or near flammable/explosive materials.
Prepared by the Supervisor or Foreman involved in the work.
Should be accompanied by a risk assessment.
Clearing Combustibles
Clear the area of all combustible materials such as:
Wood
Textiles
Oils
Liquid Fuels
Grease
Fuel Safety
Fuel containers must be metal and equipped with an air-vent.
Fuel trucks must be properly grounded when refueling equipment.
Equipment must be switched off during refueling.
Fire Safety Precautions
Ensure a suitable fire extinguisher is present.
Cover immovable combustible materials with a fire blanket.
Observe all safety precautions on the Hot Work Permit.
Appoint a “Fire Watch” person.
Generator Sets
Position the Gen Set so it doesn't block work activities.
Gen sets must be securely connected to a copper grounding rod.
Direct exhaust away from workers, shelters, and confined space entrances.
A Fire Extinguisher must be placed near the Generator.
Cords, Leads and Hoses must not be a tripping hazard.
Inspect all leads, grounds, clamps, hoses, gauges, and torches daily before use.
Welding, Heating & Cutting
Welding Equipment Checks
Check for:
Loose cable connections
Loose screws
Burns or cracks in the insulation
Burned or split insulation
Damaged or dirty connection points
Electric Welding
All work must have an adequate ground / earth.
Do not leave welding rods in the electric holder when not in use.
All arcs must be shielded in all construction areas.
Never perform electric welding from ladders.
Using Welding Equipment
Perform daily inspections prior to use.
Never touch an exposed electrode with any unprotected part of your body.
Never dip an overheating electrode holder in water to cool it.
Use an insulating mat if kneeling on the work piece.
Dispose of electrode stubs into metal bins.
Place electrode holders on insulation material when not in use.
Switch off the Generator if work is stopped for an extended period.
Safety Related to the Use of Gas Cylinders
Compressed Gas Cylinder Colour Coding
Oxygen (Blue)
Acetylene (White)
Argon (Grey)
CO2 (Black)
Safety Signs for Storage
Cylinder storage areas must be signposted with Danger Warning signs.
Signs must identify each hazard in the area.
Securing Compressed Gas Cylinders
Always store cylinders:
In racks
In the upright position
Secured with steel chains or clamps
With the cylinder valve fully closed
Store full and empty cylinders separately by gas type.
Areas Where Cylinders Must Not Be Stored
Never store cylinders near:
Excessive heat sources (pipes, boilers, radiators, furnaces)
Flammable liquid storage containers
Emergency evacuation routes (doorways, exits, stairwells)
Areas where they can be knocked over by vehicles
Confined spaces or near their entry/exit/ventilation points
Manual Handling of Cylinders
Hands should be free of grit, grease, and oil.
Move cylinders in bottle carts or specially designed carriages.
If a cylinder falls, do not move it for 30-40 minutes.
Transporting Cylinders in a Vehicle
Transport upright in specially designed, certified vehicles.
Secure with steel clamps or chains.
Never transport in the vehicle cab.
Never allow any part to overhang the vehicle.
Raising and Lowering with a Crane
Must use cages.
Secure cylinders in the cage at all times.
Never lift by attaching chains or slings directly around the cylinder.
Positioning Cylinders and Hoses
Position hoses so they will not be:
Burned by sparks
Cut by sharp objects
Crushed by vehicles
A trip hazard
Checking Hoses
Hoses must be free of cuts, cracks, burns, or worn patches.
Never use the wrong coloured hose for the gas type.
Replace leaking hoses immediately.
Never use tape to repair leaks.
Use soapy water to check for leaks.
Shut off the cylinder valve and vent equipment before tightening connections.
Checking the Handpiece
Select the proper tip for the job.
Ensure the tip is clean and not blocked.
Always shut the gas OFF at the regulators when changing tips.
Never shut off gas by crimping the hose.
Check valves must be fitted between the handpiece and the hoses.
Checking Pressure Regulators
Open the cylinder valve slowly.
Open the pressure adjusting screw first.
Never drop or hit regulators.
Maintain a uniform gas supply.
Reduce gas pressure to the working pressure.
If a regulator leaks: close the cylinder valve, remove and tag it for repair.
Never allow oil, grease, etc., to contact an Oxygen regulator.
Flash Arrester / Safe Practices
Anti-flashback arrestors shall be installed on hoses.
Before connecting regulators, open the cylinder valve slightly to blow out particles.
Stand to one side when opening the cylinder valve after regulator connection.
Open the cylinder valve slowly.
Ensure the second stage of the regulator is closed before opening the cylinder valve.
PPE for Gas Cutting and Welding
Always wear the correct filter shade (#10 for welding, #4 for gas cutting).
Use a face shield.
Respiratory Protection
Provide ventilation and/or respiratory protection for hazardous fumes.
Respiratory protection is mandatory for cadmium alloys or coated materials.
Hot work on exotic metals/paints inside confined space requires Project Manager approval.
Any confined space work requires a PTW (Permit to Work).
Welding Gases, Fumes and Radiation
Toxic gases: Ozone, Nitrogen Oxides, CO2
Toxic fumes: Cadmium Oxide, Chromic acid, Copper, Nickel, Vanadium, Zinc Oxide
Radiation: Infra-red, Ultra-violet
Starting Up the Equipment
Always open the pressure adjusting screw before opening the cylinder valve.
Open the cylinder valve slowly with the standard key.
Never extend the key with a spanner or pipe.
Welding on Tanks
Requires Area Supervisor inspection to decide on precautions.
Tanks must be free from flammable gases/vapors and cleaned, or filled with an inert medium.
Test holes must be drilled and gas tests taken before cutting tank bottom plates.
Safe Practices (Gas)
Open fuel gas cylinder valves a quarter turn only.
Open oxygen cylinder valves completely.
Keep the valve wrench in place during use.
Do not exceed 15 psi on the torch side for acetylene.
Use a friction flint lighter to light a handpiece; point the tip away from people.
Never use matches, lighters, or cigarettes to light handpieces.
Never use oxygen to pressurize tools, blow out lines, or clean clothing/areas.
Shutting Down the Equipment
Always close the fuel gas first, then the oxygen.
Never put a torch down until gases are completely shut off.
Remove torch, roll up hose, remove regulators, and attach cylinder protective caps.
Use handpiece valves for short shutdowns.
For overnight: Close cylinder valves, open torch valves to vent, close torch valves, and cap cylinders.
Heat Stress
Supervisors should monitor personnel for signs of heat stress.
Provide adequate fluids to replace water and minerals.
Encourage water drinking and train on recognizing symptoms.
Normal body temperature is 98.6°F / 36.6°C.
Safety Related to the Use of Grinders
Selecting Grinding Wheels
Use reinforced organic bonded wheels.
Use soft grade wheels on hard materials.
Use hard graded wheels on soft materials.
Never use cutting wheels for grinding.
Ensure operating speeds of the wheel and grinder match.
Never exceed the rated speed of the wheel.
Never use discs after their expiry date.
Reasons for Angle Grinder Injuries
Using the wrong type of wheel.
Using an unbalanced wheel.
Exceeding the rated speed.
Using a cracked, chipped, or broken wheel.
Using a cutting wheel to grind.
Taking too deep a cut.
Incorrectly securing the work.
Failure to wear correct PPE.
Not securing the wheel tightly enough.
Over-tightening the wheel.
Testing the Wheel
Tap the wheel 45 degrees from the centre line and 25mm in from the edge.
A sharp "ping" sound is good; a dull sound means the wheel is damaged.
Checking the Grinder
No cracks in the casing.
Functional "Deadman" switch.
Secure grip handle.
Intact casing screws.
Secure guard.
No more than 150-degree exposure of the wheel.
Personal Protective Equipment (Grinding)
Face shield and safety glasses
Ear muffs
Overalls or close-fitting clothing
Close-fitting canvas or leather gloves
Safety boots
Operating the Grinder
Remove flammables.
Secure the work piece in a vice or clamp (never use your foot).
Keep work piece at waist height if possible.
Adopt a comfortable stance.
Keep both hands on the grinder.
Run the grinder up to speed before use.
Apply minimal pressure.
Avoid excessive force.
Fully position the guard between you and the work.
Position the wheel between 15 to 30 degrees.
Take frequent breaks.
Never put the grinder down until the wheel stops.
Don't drop grinders.
Unplug the power cord when not in use.
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