Welding and Hot Work

Introduction

What is Hot Work?

Hot work is any work process that produces flames or sparks that present a fire ignition
hazard to the surrounding environment and personnel.

Examples of hot work:

Gas torch welding and Arc welding and cutting Grinding uses a grinding Brazing and soldering uses
cutting uses a flame to join uses an electric arc between wheel that rotates at high heat to melt a filler metal that
or cut metal. a metal electrode and a base speed to cut metal. is used to join metal.
material to join or cut metal.
 Introduction

Course Overview

1. Hazards of Hot Work

2. Hazard Prevention Safeguards

3. Personal Protective Equipment (PPE)

4. Arc Welding

5. Torch Welding, Cutting, and Brazing

6. Cylinder Handling and Storage

1
Hazards of Hot Work

What you need to know:

1. The hazards associated with hot work

2. Which environments require unique hazard prevention

training and precautions
1 Hazards of Hot Work

Hazards Associated with Hot Work

Hot work presents a variety of hazards.

Before hot work can begin, your supervisor will identify the hazards in your workplace.

Fire Burns
Intense heat, sparks, or metal splatter produced during hot Radiant energy, sparks, or metal splatter can cause serious
work can create fire hazards. burns.

Electric shock Flammable gases

If you touch two metal objects containing voltage, you will If allowed to accumulate, flammable gases can flash or
become a part of the electrical circuit. Higher voltages explode with catastrophic results.
increase the risk of injury or death.
Intense light
Arc flash
The incredibly bright light of arc welding can cause serious
Arc flash occurs when an electric current leaves its eye damage.
intended path and travels through the air from one
conductor to another or to the ground.
1 Hazards of Hot Work

Hazards Associated with Hot Work

Combustion creates gases, and molten metal releases fumes, both of which are
dangerous to inhale. However, certain metals and coated surfaces are
especially prone to emitting toxic fumes and gases.

Toxic metals and coatings:

Proper ventilation and respiratory protection are critical when performing hot
work on materials containing the following:

• Zinc

• Chromium

• Lead

• Cobalt

• Cadmium

• Mercury

• Beryllium
1 Hazards of Hot Work

Environments with Special Hazard Considerations

The hazards of hot work intensify in certain environments, such as wells or other confined spaces.

Potential hazards in oil or gas wells: Hazards in confined spaces:

• Flammable or combustible gases, vapors, and • Limited escape routes
liquids
• Limited visibility, which impedes awareness of injuries
• Toxic gases in deadly amounts and delays emergency response

• Limited ventilation, presenting a greater risk of

exposure to harmful fumes

• Displaced oxygen caused by welding flames in a

confined space, which can be fatal
2
Hazard Prevention Safeguards

What you need to know:

1. Roles and responsibilities

2. Administrative procedures

3. General hazard controls

4. Additional controls

5. Safety restrictions
2 Hazard Prevention Safeguards

Roles and Responsibilities

You, supervisors, and management all have the responsibility to assure a safe environment for hot work.

The employee: The supervisor: Management:

• Lays out the work area • Conducts hazard assessments • Appoints a qualified supervisor
and identifies safety
• Keeps the work area clean precautions • Establishes the proper locations,
policies, and procedures
• Follows fire prevention and • Communicates and enforces
other safety controls safety procedures • Assures that employees have the
• Follows related procedures, training they need to work safely
• Assigns fire watches, if
such as lockout/tagout required • Advises contractors of hazards
• Uses all personal protective • Secures authorizations
equipment (PPE) properly
• Assures that equipment is safe
• Uses all equipment properly to use
• Reports any safety issues • Tells the employee when to
proceed
2 Hazard Prevention Safeguards

Hazard Assessment

Your supervisor must take certain precautions before hot work begins. The
most important of these is the hazard assessment.

The hazard assessment considers:

• All the activities required for completing the task.

• The hazards associated with each of those activities.

• Any additional environmental hazards.

The hazard assessment will

guide the choice of hazard
controls and PPE.
2 Hazard Prevention Safeguards

Administrative Procedures

Next, your supervisor will perform the following administrative tasks.

Notification:
Notify area management and employees of planned hot work activities.

Permits:
To certify that hazards are thoroughly identified and addressed, acquire and
complete hot work permits.
• Each separate operation requires a permit.
‒ Sometimes a new permit is needed for each shift or if new hazards
are introduced.
• The organization should keep permits for at least one year after the hot
work has been performed.
 2 Hazard Prevention Safeguards

Hazard Controls

Based on the hazard assessment, your supervisor will establish hazard controls
for each risk.

Controlling combustible materials:

• Remove all combustible materials 35 feet from the work area.

• Move combustibles located on the opposite side of partitions and ceilings

that will be subject to welding or cutting.

• Avoid unmovable combustible materials, such as wooden floors.

If unable to remove or avoid fire hazards:

• Cover combustible floors or materials with fire blankets or other suitable
non-combustible material to contain slag and sparks.

• Use guards.

• Establish restrictions.

• In some cases, hot work may be prohibited entirely.

2 Hazard Prevention Safeguards

Additional Fire Prevention Measures

• Fire watch: Establish a fire watch in areas where fires might develop.
Continue the watch for at least 30 – 60 minutes after completion of hot
work.

• Fire extinguishers: Provide at least one 10-pound ABC fire extinguisher

in each hot work zone.

• Ducts and conveyer systems: Shut down ducts and conveyor systems
that might carry sparks.

• Atmosphere control: Monitor the air, checking for flammable or

explosive gases or vapors. If necessary, purge and inert the atmosphere.

• Safe disposal: Provide metal buckets or containers for safe disposal of

hot work debris.
2 Hazard Prevention Safeguards

Other Hazards

• Welding arc rays: Position welding curtains to protect

employees from intense light. Provide the proper shade
of lens.

• Electrical shock: Keep working conditions dry, and

provide proper PPE.
A welding curtain shields
• Arc flash: Provide high-resistance grounding and employees from the
proper PPE. direct rays of arc
welding and cutting
• Burns: Install guards, and provide proper PPE. operations.

• Fumes and other toxic byproducts: Properly

ventilate work areas, and provide adequate respirators.

• Toxic coatings: When possible, strip toxic coatings

from metal before beginning hot work.

A welder uses a local

exhaust duct to quickly
remove toxic fumes and
gases.
2 Hazard Prevention Safeguards

Controlling Hazards Around Confined Spaces

Certain environments, such as well sites, vessels, and other confined spaces, require additional precautions.

• Move all ignition sources outside the hot work area. • Before beginning hot work on vessels that formerly
contained flammable or toxic materials, thoroughly
• Use local exhaust ventilation to keep exposures within clean them.
acceptable limits.
• Always vent and purge hollow spaces.
• Follow your organization’s respiratory protection
program. • Assure that oxygen is not displaced, or use a supplied
air respirator.
• Your supervisor will arrange for monitoring to evaluate
air quality, potential contaminants, and ignition • Do not bring cylinders or welding machines inside of
sources. confined spaces.

• Follow your organization’s policies for working in

confined spaces.
2 Hazard Prevention Safeguards

Safety Restrictions

In some conditions, you should never perform hot work.

Never weld in the following locations: Never weld on the following materials:

• Rooms where fire sprinklers are impaired • Metal that has combustible covers or layers

• Spaces with potentially explosive atmospheres • Metal in close proximity to combustibles

• Areas near the storage of large quantities of readily

ignitable materials
2 Hazard Prevention Safeguards

Before Beginning Any Hot Work

• Wait for your supervisor to finalize the permit.

• Only work on equipment if properly trained and authorized by

the organization.

• Inspect all PPE.

• Inspect all hot work equipment.

• Follow the lockout/tagout program requirements.

• Follow respiratory protection requirements.

3
Personal Protective Equipment (PPE)

What you need to know:

1. Common PPE designed for hot work

2. How to select eye protection

3. The proper use of respirators

3 Personal Protective Equipment (PPE)

Common PPE

Your supervisor will identify To protect against burns, Buttonable collar

required PPE as part of the cover all exposed flesh.
hazard assessment. Welding hood
Required PPE for hot work PPE that protects against with adjustable lens filter
may include skin, body, and electric shock includes
foot protection. insulated gloves and Fire resistant gloves
rubber-soled shoes.
Fire resistant jacket
hanging outside of pants
without open pockets

Fire resistant trousers

without cuffs on pant legs

Leather high-top boots

with steel toes
3 Personal Protective Equipment (PPE)

Eye Protection

Your supervisor will specify the type of eye protection needed for the task.

Types of eye protection: Auto-darkening lenses:

• Welding hoods with properly Auto-darkening lenses provide
shaded lenses continuous protection by adapting to
varying levels of light.
• Cutting or burning goggles for
torch cutting If using an auto-darkening lens:

• Full face shields for grinding • Check the manufacturer

specifications to confirm that it is
• Safety glasses worn under welding rated for the correct intensity.
hoods or face shields when
grinding • Before starting work, check that
the battery power is sufficient.
3 Personal Protective Equipment (PPE)

Protective Lens Shading

Lens filter shade numbers range from 2 – 14. Higher

numbers providing greater protection. The chart below
shows the recommended lens filter shade number for
specific types of hot work.
3 Personal Protective Equipment (PPE)

Respiratory Protection

Filter-type respirators use cartridges to filter incoming air

and remove contaminants.

Uses:
• They are required for open-air hot work with metals
containing toxic substances such as galvanized steel,
zinc, or chromium.

• They will not provide adequate protection in

confined spaces lacking sufficient ventilation.

Consult manufacturer specifications to REMEMBER: You must be trained and authorized

determine the appropriate type of cartridges. before using a respirator. Only wear a respirator
designed and rated for the hazards involved.
4
Arc Welding

What you need to know:

1. How to safely handle arc welding tools

2. Safety procedures
4 Arc Welding

The Electrode Holder

Check that all components of arc welding are in good condition, starting with the electrode holder.

Electrode holder requirements: Safe practices:

• Specifically designed for arc • When done welding or if leaving

cutting and welding the holder unattended, remove
and properly dispose of the
• Properly insulated electrode to prevent contact with
people or conducting objects.
• Able to safely handle the
maximum current • NEVER dip a hot electrode or
electrode holder in water.

The welder inserts one of these

electrodes (right) into the
electrode holder (left).
4 Arc Welding

Cables

Before starting the welding machine, check the condition of the cables.

Cable requirements: Repair or splices:

• Completely insulated Areas that have been repaired or
spliced must be at least 10 feet away
• Flexible from the electrode holder, unless the
connectors and connecting lugs have
• Capable of handling the maximum the same level of insulation as the
current requirements cable.

One cable carries electricity to power the

electrode, and the other grounds the welding
machine.
4 Arc Welding

Cables

Additional cable requirements:

• Ground the welding machine properly.

• Keep cables clear of walkways, ladders, and

stairways. For example, they can be strung overhead
with non-metallic hangers.

• Immediately remove all damaged and worn cables

from service until properly repaired.

Signs of improper grounding include sparks, arcs, and

heat.
4 Arc Welding

Additional Procedures

Follow your organization’s lockout/tagout program and any PPE requirements.

Before you begin: When you are finished:

• Inspect your PPE. • Shut off the welding machine at the end of each shift
and whenever the machine is moved.
• Inspect all equipment to assure that it meets the
manufacturer’s specifications. • Assure that stored energy is released in accordance
with the manufacturer’s specifications.
• Make sure that the welding machine’s power supply
has a circuit breaker or can be easily disconnected.
5
Torch Welding, Cutting, and Brazing

What you need to know:

1. Equipment inspection procedures

2. Safe use of torch cutting equipment

3. Safety guidelines for supply hoses

4. Safe use of cylinder valves

5 Torch Welding, Cutting, and Brazing

Inspection and General Torch Use

Before torch welding, cutting, or brazing, inspect all equipment. Regularly follow preventive maintenance procedures, and
consult the manufacturer’s specifications.

Pre-shift inspection: Maintenance:

• Torches and hoses: Check for leaks, damage, and • Tag and remove defective, damaged, or worn
loose connections. equipment from service. Either repair or discard it.

• Oxygen cylinders and fittings: They must be properly • Properly clean clogged torch tips.
labeled, distinguishable, and free of oil and grease.
Safe torch use:
• Welding apparatus: Make sure all components are
clean and free of oil and grease. • Use flashback arrestors.
• Valves • Light torches only with approved tools.
• Regulators • When finished working, shut off valves and relieve hose
pressure.
5 Torch Welding, Cutting, and Brazing

Safe Hose Preparation and Use

Hose preparation: Safe hose use:

• Keep hoses clear of walkways, • Do not use the same hose for
ladders, and stairways. different materials.
‒ For example, you can string ‒ Oxygen and fuel-gas hoses
hoses overhead using non- are not interchangeable.
metallic hangers. ‒ Do not use a single hose with
more than one gas passage.
• You can tape parallel lengths of
hose together to prevent tangling, • When done with a task, relieve
but do not tape more than 1/3 of hose pressure.
each 12-inch section.
• When you are finished working,
• Check that hose couplings cannot store your hose in a ventilated
be disconnected with a pull. area or box.
Separating them should require a
twisting motion.
5 Torch Welding, Cutting, and Brazing

Using the Cylinder Valve

Proper use of cylinder valves keeps you safe and keeps the
equipment working longer.

• Always open valves slowly and carefully.

• When opening valves, stand to the side, not to the

front.

• Do not open fuel-gas cylinders near ignition sources.

• Do not open acetylene cylinders too far:

‒ ¾ of a spindle-turn or less is ideal.
‒ Never turn the spindle more than 1.5 times.

• Before you connect a valve to a regulator, open the

valve a crack and then quickly close it. This allows any
foreign material in the valve port to be discharged.
6
Cylinder Handling and Storage

What you need to know:

1. Hazard communication resources

2. Identification requirements

3. Safe handling practices

4. Guidelines for moving and storage

5. Environments and practices to avoid

6 Cylinder Handling and Storage

Cylinder Hazard Communication

Before beginning work, you must fully understand the hazards in your work area.
Hazard communication is a system for clearly conveying hazards to everyone who
needs to know.
Training:
Your employer will provide hazard communication training.

Safety data sheets (SDSs):

SDSs include the manufacturer’s statement of origin, the contents of the cylinder, and
the hazards of the contents.

PPE:
Use the SDS and your supervisor’s hazard assessment to select the proper PPE.
6 Cylinder Handling and Storage

Cylinder Identification

Tags:

Use status tags indicating if the cylinder is full, in use, or empty.

Labels:

All cylinders must have proper GHS-compliant labels that identify contents and
classify hazards.

Signage:

Be aware of signs at storage areas, such as "Danger: Flammable. No sources of

ignition, smoking, or open flames.”

Storage:

Store cylinders with caps and tags on.

6 Cylinder Handling and Storage

Cylinder Valve Safety

• Close valves, bleed the lines, remove regulators, and

replace valve safety caps:
‒ When storing cylinders.
‒ Before moving cylinders.
‒ When a cylinder is empty.
‒ When leaving cylinders unattended.

• All cylinders must be equipped with a handle or

wrench, so that they can be turned off immediately
when necessary.
6 Cylinder Handling and Storage

Moving Cylinders

Prior to moving cylinders:

• Get authorization.

• Confirm the cylinders’ contents and review the SDSs for handling
requirements.

• Close valves, bleed the lines, remove regulators, and replace valve safety
caps.

• Make sure that your planned route is clear of obstacles.

While moving cylinders:

• Use a cart designed for this purpose.

• Use a chain to secure them to the cart.

• Stay on designated pathways.

• Never lay cylinders on their sides, and never roll them by hand.
6 Cylinder Handling and Storage

Cylinder Storage Guidelines

Store cylinders according to SDSs and local, state, and federal requirements.

Storage area requirements: Segregation:

• Cool and dry • Keep all cylinders and combustible materials 20 feet
away from stairs, aisles, and elevators.
• Well-ventilated
• Keep combustible and flammable materials 20 feet away
• Clean and free from combustible materials
from all cylinders.
• Protected from recognizable hazards
• Keep oxygen cylinders separate from fuel-gas cylinders
and combustible materials with one of the following:
Storage practices:
‒ A 5-foot, noncombustible barrier with a ½ hour
• Limit access to authorized and trained persons. fire-resistance rating
• Always keep cylinders upright. ‒ A 20-foot distance
• Bleed the lines, remove regulators, and replace valve • Some gases have additional storage requirements.
safety caps.
• Follow safe practices for additional cylinders, whether
full or empty.
6 Cylinder Handling and Storage

Cylinder Storage and Handling Practices to Avoid

Never:
• Use cylinders for anything other than the intended use. • Use acetylene with a pressure greater than 15 psi
gauge or 30 psi absolute.
• Move or store gas cylinders in confined spaces.
• Use hammers or wrenches to open cylinders that have
• Position cylinders near ignition sources. fixed handwheels.
• Position cylinders between electrical sources. • Strike an electrode against a cylinder when striking an
arc.
• Hoist cylinders improperly, such as with magnets.
• Refill cylinders.

• Mix gases in a cylinder.

 Summary

Summary

Hot work can be dangerous: Your active participation in workplace safety is

essential.

Be able to recognize hazards: Be aware of the hazards in your workplace,

and know what factors increase the danger. Know when it is too dangerous to
perform hot work.

Be prepared: Be sure that you understand safety requirements and work

practices before starting work.

Conduct inspections: Be confident that all parts of your equipment and PPE
are undamaged and working properly.

Communicate: Communicate any hazards you discover to your supervisor and

coworkers.