HOT WORKS

SAFETY TRAINING

1
 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.

2
 HOT WORKS
Safety Training

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. 3
 HOT WORKS
Safety Training

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.

4
 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
ASSIGNMENT).

5
 HOT WORKS
Safety Training

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

PAPER CARDBOARD RAGS

GREASE LIQUID FUELS OILS 6

 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.

Never use defective equipment

7
 HOT WORKS
Safety Training

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.

8
 HOT WORKS
Safety Training
FIRE WATCH
Fire Watch is required during the
Hot Work activities with the FIRE
EXTINGUISHER equipment readily
available, and they must be trained
in its use.

Wears Red reflective vest.

9
 HOT WORKS
Safety Training

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.

10
 HOT WORKS
Safety Training

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;

11
 HOT WORKS
Safety Training

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.

12
 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.

13
 HOT WORKS
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.

14
HOT WORKS
Safety Training

Cords hung 6 ft.

above the ground

15
 HOT WORKS
Safety Training

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.

16
17
 HOT WORKS
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

18
 HOT WORKS
Safety Training

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.

•Never perform electric welding

from a metal ladder.

19
 HOT WORKS
Safety Training

ELECTRIC WELDING
All arcs must be shielded
in all construction areas.

20
 HOT WORKS
Safety Training

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.

21
 HOT WORKS
Safety Training

100 % Spark
Containment
policy.

Always use
Fire Blanket

22
 HOT WORKS
Safety Training

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.

23
 HOT WORKS
Safety Training

USING WELDING EQUIPMENT

Always switch off the

Generator if work is
stopped for any extended
period of time.

24
 HOT WORKS
Safety Training

WELDING, HEATING & CUTTING

Kpa Kpa

Oxy Cutting Equipment

25
 HOT WORKS
Safety Training

COMPRESSED GAS CYLINDER COLOUR CODING

OXYGEN ACETYLENE LPG NITROGEN

(BLACK) (CLARET) (SILVER GREY) (PEWTER) 26
 HOT WORKS
Safety Training
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 27

 HOT WORKS
Safety Training
WELDING, HEATING & CUTTING

Compressed Gas Cylinders

28
 HOT WORKS
Safety Training

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.

29
 HOT WORKS
Safety Training

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.

30
 HOT WORKS
Safety Training

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.

31
 HOT WORKS
Safety Training
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.
32
 HOT WORKS
Safety Training
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.

33
 HOT WORKS
Safety Training

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.
34
 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. 35
 HOT WORKS
Safety Training
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.

36
 HOT WORKS
Safety Training

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. 37
 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.

38
 HOT WORKS
Safety Training

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.
39
 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
40
 HOT WORKS
Safety Training

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.

41
 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.
42
 HOT WORKS
Safety Training

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.

43
 HOT WORKS
Safety Training

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.
44
 HOT WORKS
Safety Training
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 SHARQSafety
Department and Owner.
45
 HOT WORKS
Safety Training
FLASH
 Picture with FLASH
ARRESTER
ARRESTER, safety for flash Picture of cylinder

back to cylinder. without Flash Arrester.

46
 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.
47
 HOT WORKS
Safety Training

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.

48
 HOT WORKS
Safety Training

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.

49
 HOT WORKS
Safety Training

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.

50
 HOT WORKS
Safety Training
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
51
 HOT WORKS
Safety Training

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

52
 HOT WORKS
Safety Training

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.

53
 HOT WORKS
Safety Training

SAFE PRACTICES

• Open valves on fuel gas

Kpa Kpa

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.

54
 HOT WORKS
Safety Training

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.

55
HOT WORKS
Safety Training

SAFE PRACTICES

Always use
Friction Flint
Lighter to
ignite the
torch

56
 HOT WORKS
Safety Training

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.

57
 HOT WORKS
Safety Training
CHECKING THE GRINDER

“Deadman” switch
No cracks in the casing automatically returns to OFF

Casing screws intact

Grip handle is secure

No more than
150 degree exposure
of the wheel Guard secure

58
HOT WORKS
Safety Training

Ground
Fault
Circuit
Interrupter

59
 HOT WORKS
Safety Training
AIR POWERED GRINDERS
Injuries occur while using air powered grinders because operators:
 use the wrong type of wheel;

 use an unbalanced wheel;

 exceed the rated speed of the wheel;

 use a cracked, chipped or broken wheel;

 use a cutting wheel for grinding;

 take too deep a cut;

 incorrectly secure the work;

 fail to wear the correct Personal Protection

Equipment;

 don’t secure the wheel tightly enough; and

 over-tighten the wheel. 60

 HOT WORKS
Safety Training

SAFE PRACTICES

Sparks generated
while grinding must
be contained.
Keep other worker
away from the
grinding activity.

61
 HOT WORKS
Safety Training

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.
ow
Air fl WHIPLASH ARRRESTER
• Do not use compressed gas to
clean your clothing, blow out
62
anchor holes, or otherwise clean
 HOT WORKS
Safety Training

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.

63
 HOT WORKS
Safety Training

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.

64
 HOT WORKS
Safety Training

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.
65
 HOT WORKS
Safety Training

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.
66