hotwrkprog

MASTER BUILDERS OFIOWA

CUTTING / WELDING&

HOT WORK

Property of Master Builders of Iowa / Construction Safety Specialists - 2002

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Cutting, Welding, and Hot Work

WARNING: PROTECT YOURSELF AND OTHERS FROM POSSIBLESERIOUS INJURY OR DEATH

The purpose of this program is to ensure that employees and property are properly protected against fire,explosion, and other dangers resulting from hot work. Precautions must take place where welding andcutting involves the generation of temperatures up to thousands of degrees at which metals melt andvaporize and where fire may be evident. Other hot work such as grinding that creates a continuous spark orheat guns that can generate enough heat to start a fire must be taken into consideration. When properprecautions are taken to protect personnel and property against the heat, involved gases and fumes, electricshock, and radiation, no harm will result either to personnel or property. In gas welding and cutting, thehandling and storage of compressed gases present other hazards that must be addressed to protectemployees and provide a safe working environment. This program provides detailed procedures andinstructions for safe practices which, must be followed, to protect personnel and equipment from harm ordamage arising from any hot work operation.

Safe practices developed from experience in the use of welding and cutting are described in this program.Research, development, and field experience have evolved reliable equipment and safe installation,operation, and servicing practices. Accidents occur when equipment is improperly used or maintained.

Read and understand safe practices in the specific instruction manuals before attempting to install, operate,or service any equipment. Comply with these procedures as applicable to the particular equipment used, forpersonal safety and for the safety of others. Failure to observe these safe practices may cause serious injuryor death.

Responsibilities of installer, user, and serviceman. Installation, operation, checking, and repair of thisequipment must be done by a competent person, experienced with such equipment.

DEFINITIONS:The following is an alphabetical listing defining terms and abbreviations that each employeeperforming hot work must become familiar with. Where applicable, examples are given in order toprovide clarification. These examples are intended to show typical issues that may arise whenfollowing the hot work permit procedure. These issues are not intended to be an all-inclusive.Rather, it is intended to provide guidance when issuing the hot work permits.

Cutter/Welder:The individual performing the hot work.

Fire Watch:A Fire Watch must be in place whenever hot work is performed in locations where other than aminor fire might develop, or any of the following conditions exist:A) Combustible material is closer than 35 feet from the point of operation.B) Combustible materials are more than 35 feet away but are easily ignited by sparks.C) Wall or floor openings within a 35-foot radius expose combustible materials in adjacent areas

including concealed spaces in walls or floors.D) Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or

roofs and are likely to be ignited by conduction or radiation.E) The Fire Watch must have fire-extinguishing equipment readily available and be trained in its

use and limitations. They must be familiar in the procedures for sounding the alarm in theevent of a fire. The Fire Watch must watch for fires in all exposed areas and steel members,

pipes etc. that can transmit heat to walls, ceilings, or combustibles. The designated fire watch'sonly responsibility will be to watch for fires!


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The fire watch shares the responsibility for fire/safety with the cutter/welder. The fire watch shouldmaintain a constant vigil during the operation (including lunch and coffee breaks) to watch forstray sparks, ignition sources, or other fire hazards. This individual must be specifically trained inthe use of fire fighting equipment (example, fire extinguisher) and have the equipment readilyavailable. They must be familiar with the Job site and know how to sound the fire alarm.

Hazard:A potential for an incident involving employees or property with undesirable consequences,usually involving a loss of containment of flammable, combustible, or reactive materials.

Hazardous Location:A hazardous location is where a fire might develop, where there are wall or floor openings within35 feet, or where there is a presence of combustible material within 35 feet of the hot worklocation. A hazardous location is also one where flammable gases, vapors, or combustible dust are,or may be present in the air in sufficient quantities to produce a fire or explosion.

Hot Work Operations:Any operation that could cause a source of ignition in a hazardous location. Hot work includesactivities such as; welding, cutting with a torch or plasma cutter, cutting or grinding with a grinder,use of heat guns or other sources of heat that could support fire.

Source of Ignition:A source of ignition is a flame, tool spark/heat, static electric charge, internal combustion engines,or electric spark that would cause a fire or explosion. Any device that creates enough heat to causeignition is considered a source of ignition.

Example:• Welding, burning, brazing, soldering, melting, thawing, or any use of an open flame;

• Metal removing such as drilling, chipping, abrasive cutting, milling, grinding, etc.;

• Internal combustion engines;

• Explosive-actuated fastening tools;

• Cutting or chipping concrete with or without reinforcements:

• Operating non-explosion-proof equipment and tools in an explosion-proof area. Includesbattery-powered equipment and tools;

• Operating any cleaning device utilizing a metal or any other material that can producesparks;

• Work on live electrical circuits of any voltage in hazardous locations and,

• Other hot work such as a heat gun that can generate enough heat to start a fire.

There have been several incidents that involved the failure to follow required practices

- Welding sparks caught a conveyor on fire. The fire was not detected until several hours later.the fire destroyed a container storage area.


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- A welder was hospitalized when an electrode was jammed into his eye due to electric shock froman arc welder.

- Oxygen and acetylene bottles have been known to become missiles due to valves broken off.- A welder was killed due to electric shock from a welder that had poorly maintained welding

leads.- A fire destroyed a building under renovation when a grinding operation ignited a pile of

combustible materials. A fire extinguisher was not available to extinguish the fire.- A flammable container did not have a lid in place when a grinding operation ignited rags in the

container.

NOISEThere are two good reasons to use hearing protection:1) Ear plugs or earmuffs will help keep sparks or metal out of your ears, as well as dust and dirt.2) Hearing protection can help prevent hearing loss due to noisy equipment, power sources, and associated

work.

PREVENTING ELECTRIC SHOCKThe electrode and work (or ground) circuits are electrically "hot" when the welder is on. Do not touch these"hot" parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle orsemiautomatic welding gun are also electrically "hot".

Insulate yourself from work and ground using dry insulation. When welding in damp locations, on metalframework, floors, gratings or scaffolds, and when in positions such as sitting or lying, make certain theinsulation is large enough to cover your full area of physical contact with work and ground.

Always be sure the work cable makes a good electrical connection with the metal being welded.The connection should be as close as possible to the area being welded.

Ground the work or metal to be welded to a good electrical (earth) ground.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safeoperating condition. Replace damaged insulation.

Never dip the electrode in water for cooling.

Never simultaneously touch electrically "hot" parts of electrode holders connected to two weldersbecause voltage between the two can be the total of the open circuit voltage of both welders.

A welder or helper working on platforms, scaffolds etc. must be protected against falling. This may beaccomplished by the use of guard railings, personal fall protection, nets, or some other equally effectivesafeguard.

When using electrically powered equipmentTurn off input power using the disconnect switch before working on the equipment.

Install grounding equipment and ground it in accordance with the National Electrical Code, all local codesand the manufacturer's recommendations.


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Welders must place welding leads and other equipment so that it is clear of passageways, ladders, andstairways so as not to create a trip/fall hazard or block egress.

When using engine powered equipmentTurn the engine off before troubleshooting and maintenance work unless the maintenance workrequires it to be running. Make sure you are trained and qualified to perform the work.

Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

Do not add the fuel near an open flame, welding arc or when the engine is running. Stop theengine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hotengine parts and igniting. Be cautious not to spill fuel when filling tank. If fuel is spilled, wipe it up and donot start the engine until fumes have been eliminated.

Keep all guards, covers and devices in position and in good repair. Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

In some cases it may be necessary to remove safety guards to perform required maintenance.Remove guards only if you trained and authorized and replace them when the maintenance requiring theirremoval is complete. Always use the greatest care when working near moving parts.

Do not put your hands near the engine fan. Do not attempt to override the governor or idler bypushing on the throttle control rods while the engine is running.

To prevent accidentally starting gasoline engines while turning the engine or welding generator duringmaintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

REMEMBER: ALWAYS HAVE INSTALLATION, OPERATION, MAINTENANCE AND REPAIRWORK PERFORMED BY QUALIFIED PEOPLE.

****EVERYONE IS RESPONSIBLE FOR SAFETY IN THEIR AREA.********REPORT ALL SAFETY PROBLEMS IMMEDIATELY.****

ARC WELDINGArc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipmentcarries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise,ultraviolet and infrared energy radiates, welding rods and some parts are hot. At times, compressed gasesmay be used. Most arc welding and cutting processes, laser welding, and torch welding, cutting, andbrazing, or soldering produce quantities of radiation requiring precautionary measures. Some processes,such as resistance welding and cold pressure welding, ordinarily produce negligible quantities of radiantenergy.DEFINITIONRadiation is electromagnetic energy given off by the arc or flame that can injure eyes and burn the skin. Anoperator sees visible light radiation. However, they do not see ultraviolet or infrared radiation. Radiation isoften silent and undetected, yet injury occurs.

EFFECTS OF RADIATIONThe effects of radiation depend on the wavelength, intensity, and length of time one is exposed to theradiant energy. Although a variety of effects is possible, the following two injuries are most common:• Skin burns.• Eye damage


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BURN PROTECTIONThe welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing,reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, thosefrom gas-shielded arcs are more severe and painful.

Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of thearc when welding or observing open arc welding. Helmet shields and filter lens should conform to ANSIZ87.1 standards. See the following page to consult the shade chart.

Use suitable clothing made from durable flame-resistant material to protect your skin and that of yourhelpers from the arc rays.

Protect other nearby personnel with suitable non-flammable screening and/or warn them not towatch the arc or expose themselves to the arc rays or to hot spatter or metal.

Wear protective clothing - leather gauntlet gloves, hat, and high safety-toe shoes. Button shirtcollar and pocket flaps or better yet no pockets, and wear cuffless trousers to avoid entry of sparks and slag.

Wear a helmet with safety goggles or glasses with side shields underneath, appropriate filter lenses orplates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect theeyes from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered.

Avoid oily or greasy clothing. A spark may ignite them.

Hot metal such as electrode stubs and work pieces should never be handled without gloves.

Persons intending to perform hot work should not use flammable hair preparations.


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The following is a guide for the selection of the proper shadenumbers. The recommendations may be varied to suit theindividual's needs.

Shielded metal-arc welding 10Gas-shielded arc welding (nonferrous) 11Gas-shielded arc welding (ferrous) 12Shielded metal-arc welding 12-14Atomic hydrogen welding 10-14Carbon arc welding 14Soldering 2Torch brazing 3 or 4Light cutting, up to 1 inch 3 or 4Medium cutting, 1 inch to 6 inches 4 or 5Heavy cutting, 6 inches and over 5 or 6Gas welding (light) up to 1/8 inch 4 or 5Gas welding (medium) 1/8 inch to 1/2 inch 5 or 6Gas welding (heavy) 1/2 inch and over 6 or 8PLASMA ARC CUTTING (info from IOSH pamphlet) 8

Note: In gas welding or oxygen cutting where the torch produces ahigh yellow light, it is desirable to use a filter or lens that absorbsthe yellow or sodium line in the visible light of the operation.


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FUMES AND GASES CAN BE DANGEROUSWelding may produce fumes and gases hazardous to health. Avoid breathing these fumes andgases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arcto keep fumes and gases away from the breathing zone. When welding on galvanized, lead or cadmiumplated steel and other metals which produce toxic fumes, even greater care must be taken. There arespecialized respirator welding helmets for some of these more hazardous type fumes. As with anyrespirator, you must be properly trained and authorized to use one.

Shielding gases used for arc welding can displace air and cause injury or death. Most shielding gasesare non-toxic, but as they are released they displace oxygen in your breathing air, causing dizziness,unconsciousness, and possible death. Always use enough ventilation, especially in confined areas, to insurebreathing air is safe.

Read and understand the manufacturer's instructions for this equipment and the consumables to beused, including the material safety data sheet (MSDS) and follow all safety practices.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSIONIf possible take the item to be a safe place to weld, cut or perform the hot work. If this is not feasible thenremove the fire hazards from the welding area. If this is not possible, cover the hazard to prevent the hotwork from starting a fire. Remember that welding sparks and hot materials from welding can easily gothrough small cracks and openings to adjacent areas or lower level floors. If this is possible have a FireWatch in place and have a fire extinguisher readily available.

Where compressed gases are to be used at the job site; special precautions should be used toprevent hazardous situations.

When not welding, make certain no part of the electrode circuit is touching the work or ground.Accidental contact can cause overheating and create a fire hazard. When welding is suspended for anextended period of time for example breaks or over night the electrode must be removed for the electrodeholder.

No welding, cutting, or other hot work will be performed on used drums, barrels, tanks or othercontainers until they have been cleaned so thoroughly as to make absolutely certain that there are noflammable materials present or any substances such as greases, tars, acids, or other materials which whensubjected to heat might produce flammable or toxic vapors. Any pipelines or connections to the drum orvessel must be disconnected or blanked. Read your MSDS.

NOTE: A good policy does not allow welding, cutting, or hot work to be performed on any used drums,barrels, tanks or other containers unless the container is damaged and needs to be repaired to put it backinto service. And a qualified person performs the work.

Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such asleather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of positions or in confined places. Always wear safety glasses with side shieldswhen in a welding area.

Connect the work cable to the work as close to the welding area as practical. Work cablesconnected to the building framework or other locations away from the welding area increase thepossibility of the welding current passing through lifting chains, crane cables or other alternatecircuits. This can create fire hazards or overheat lifting chains or cables until they fail. Also current goingthrough bearings may cause them to become pitted, or welded solid.


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WELDING IN WET AREASPrecautions must be taken when welding in wet areas. The following steps must be taken to preventelectrical shock.

Cables and welding units must be kept out of standing water.

Welding units should be kept dry.

All employees in the area must be notified by the welder and must keep a safe distance from the area wherewelding is occurring.

When welding in damp locations the welder should wear non-conductive gloves under the welding gloves.

WELDING SAFETYAny employee that uses a welder must assure a complete inspection of the welder is performed and that thewelder is safe for use. Make sure you have read and understand the instruction manual for the welder yourgoing to operate. Read all warnings and instructions on the equipment and nameplate. It is also importantto review the Material Safety Data Sheet for any consumables used during the welding operation.

1) The main power cord and leads must be visually inspected before use for external defects (such as outer jacket or insulation damage) and for evidence of possible internal damage (such as pinched or crushed outer jacket).

2) All welders are required to have rubber boots on the lead ends closest to the welder.

3) Machines that have become wet must be thoroughly dried before used.

4) The welder must assure that the power cord and lead ends are up and out of the way of any vehicle traffic or any other device which could cause damage to the power cords or leads.

5) Before starting operations all connections to the machine must be checked to make certain they are properly made.

6) If there is a defect or evidence of damage that might expose an employee to injury the defect or damaged item must be removed from service, and no employee may use it until necessary repairs and tests have been made to render the equipment safe.

7) Repairs to welding leads must be made with rubber and friction tape or equivalent means. Anydamaged lead beyond repair must be replaced. Electrical tape alone must not be used to repair damagedleads.

8) Employees welding should not coil or loop cable leads around parts of their body. Electric current flowing through any conductor causes localized Electric Magnetic Fields (EMF). Welding current creates EMF around welding cables and the welding machine. EMF may interfere with some pacemakers. Consult with your Doctor before using a welder.

9) Welding rod. When arc welding is to be suspended for any substantial period of time, (such as during lunch or over night), all welding rods must be removed from the holders and the holders carefully located so that accidental contact can not occur and the machine disconnected from the power source.


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10) Check fire extinguisher for full, pin in place, plastic retainer, and no damage.

11) The Supervisor is responsible to ensure all welders are being inspected for safe operations.

12) All operators must inspect their welders before each use. Fill out the Welder Safety Inspection Sheet, and have it with you while welding. This sheet must be turned into the Superintendent at the end of the workday.

13) Make sure the settings are correct for the job you’re about to perform.

SAFE HANDLING OF COMPRESSED GAS CYLINDERS

Use only compressed gas cylinders containing the correct shielding gas for the process used andproperly operating regulators designed for the gas and pressure used. All hoses, fittings, etc.should be suitable for the application and maintained in good condition.

Always keep cylinders secured in an upright position, with safety caps in place, in an area away formcombustibles and fuels, and safeguard them from damage, heat, and flames.

Cylinder location:

Keep cylindres away from areas where they may be struck or subjected to physical damage.

Oxygen and acetylene cylinders must be stored separately, at least 20 feet apart, or have a fire wall five feetin height with a fire rating of at least one-half hour between them. Keep oxygen away from combustiblematerials and fuels.

Never allow the electrode, electrode holder, or any other electrically "hot" parts to touch a cylinder. Theycan produce short circuit arcs that may lead to a serious incident.

Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. Alwaysstand to the side when opening the valve.

Valve protection caps should always be in place and hand tight except when the cylinder is in use orconnected for use.

Read and follow the instructions on compressed gas cylinders and associated equipment.

Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safetydevices.

ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder isproperly handled.

Identifying gas content. Use only cylinders with name of gas marked on them; do not rely oncolor to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter the name,number, or other markings on a cylinder. It is illegal and hazardous.

Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLSand return promptly.

Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as asupport or roller.


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Transport cylinders by strapping them to carts so they don’t fall or bang into each other. Never drop orroll a cylinder. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylindersoff the ground by their valves or caps or by chains, slings, or magnets.

Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture.

Stuck valve. Do NOT use a hammer or metal wrench to open a cylinder valve that can not beopened by hand. Notify your supplier.

Mixing gases. Never try to mix any gases in a cylinder.

Never refill any cylinder yourself. Have the professionals do it.

Cylinder fittings should never be modified or exchanged.

CYLINDER’S MAY EXPLODE IF DAMAGED, OR HANDLED IMPROPERLY

“Compressed Gas Cylinder Explodes”

During a filling operation where an employee of a compressed gas distributor was filling a nitrogen/COcylinder, the cylinder exploded, sending shards of shrapnel throughout the facility. The employee lost bothlegs in the explosion - some of the shrapnel was close to 1' in diameter.

OSHA has conducted forensic testing of the cylinder material, they have determined that the facilityfollowed all prescribed procedures, and that all appropriate hydrostatic testing of the cylinder had beenperformed. No citations were issued.

At issue in the case, is that the cylinder was US Army issue, and, according to serial number research, wasoriginally manufactured in 1919! It is interesting to note that NFPA requirement mandate the retirement ofLP tanks after 12 years, but there are no standards governing the retirement of other types of compressedgas cylinders

It is recommended that you take an inventory of your cylinders, and note the testing stamps (the one abovehad stamps all the way back to 1919, every five years like clockwork). A good idea would be to contactyour distributor and work out a replacement plan for older cylinders, based on a mutual understanding ofthe risks involved.

Hose'sProhibited use. Never use hose other than that designed for the specified gas. A general hoseidentification rule is: red for fuel gas, green for oxygen, and black for inert gases.

No copper tubing splices. Use only standard brass fittings to splice hose.

Avoid long runs to prevent kinks and abuse. Suspend the hose off ground to keep it from being runover, stepped on, or otherwise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sharp edges, sparks, slag, and open flame.

Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubblesindicate leaks.


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Repair leaky or worn hose by cutting the area out and splicing. Use ferrules or clamps designed for thehose (not ordinary wire or other substitute as a binding to connect hoses to fittings). Do NOT use tape.

PRESSURIZING STEPS:1. Before attaching regulator to outlet of cylinder valve, open cylinder valve for a few seconds,

allowing gas to force out any possible foreign matter.

2. Attach regulator to cylinder valve and tighten inlet nut securely with regulator wrench. Theregulator outlet (or hose) connections may be identified by right hand threads for oxygen and lefthand threads (with grooved hex on nut or shank) for fuel gas.Before opening cylinder valve, turn adjusting screw to the left until no spring tension is felt.(Never open cylinder valve until spring tension on adjusting screw has been released in thismanner).

3. Open cylinder valve slowly. DO NOT STAND IN FRONT OF OR BEHIND REGULATORWHILE OPENING THE CYLINDER VALVE. When gauge ispressurized (gauge reaches regulator maximum) leave cylinder valve in following position:

- For oxygen, and inert gases, open fully to seal stern against possible leak. For fuel gas, open toless than one turn to permit quick emergency shutoff.

- Check for leaks on first pressurization and regularly thereafter. Remove leaky or defectiveequipment from service immediately and repair them only if recommended in equipmentinstruction manual. Send others for repair to manufacturer's

4. Turn adjusting screw to the right until the low pressure gauge registers the desired workingpressure.

CAUTION: Never turn adjusting screw to the left while the low pressure gauge shows pressure, unless theoutlet leading from the regulator is open and gas is escaping. Never use oil or petroleum base grease onregulator, inlet connection or cylinder valve. When leaving Equipment Unattended Close gas supply atsource and drain gas from hoses.

HOT WORK PERMITS

BACKGROUNDA hot work permit is issued as a documented checklist / procedure to ensure that the area you are going tobe doing the hot work in is completely safe from having any fire hazard. The program also assures that allpotential fire hazards have been removed or covered. Other wise the hot work can not be performed! Hotwork includes activities such as; welding, cutting with a torch or plasma cutter, cutting or grinding with agrinder, use for heat guns or other sources of heat that could support fire. See Appendix C for the trainingoutline and employee certification of training.

HOT WORK MAY NEVER BE PERFORMED:a) In the presence of explosive atmospheres (mixtures of flammable gases, vapors, liquids, or dusts with air), or explosive atmospheres that may develop inside uncleaned or improperly prepared tanks or equipment which have previously contained such materials, or thatmay develop in areas with an accumulation of combustible dusts.

b) In areas near the storage of large quantities of exposed, readily ignitable materials.


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PROCEDURES:INITIATING A HOT WORK PERMIT

The first step in the hot work permit procedure is the identification of the need for a hot work permit. Anyemployee may make the request for a hot work permit if they feel that an operation presents an unusualhazard that requires special safety precautions. Remember that a hot work permit is required for anyoperation that could cause a source of ignition in a hazardous location. The request for a hot work permitshould be made to the Jobsite Supervisor on the day that the hot work is to be performed.

ISSUING A HOT WORK PERMITThe Jobsite Supervisor has the responsibility to fill out the hot work permit once a request for a hot workpermit is made. The permit must be filled out before the hot work is started. The supervisor must inspectthe work area before filling out the hot work permit.

The hot work permit must show the date and time that the work will be performed, the location, a shortdescription of the work to be performed, the name of the cutter/welder, and the name of the fire watch (ifone is required). The hot work permit is valid only for the job and the time listed on the permit. The hotwork permit will be valid for no longer than the work shift for the day of request.

The next step is for the Jobsite Supervisor to review the list of hot work precautions with the cutter/welderand with the fire watch. These precautions are summarized on the hot work permit. Note that the hot workprecautions outlined on the permit are minimum precautions; the Jobsite Supervisor or owner may takeadditional measures for safety of personnel and property.

After the Jobsite Supervisor is assured that all necessary hot work precautions have been taken, they mustinitial each item on the permit, sign the permit, and then issue it to the cutter/welder. The cutter/welder andthe fire watch then signs the permit indicating that they have reviewed the hot work precautions with thesupervisor and understand their responsibilities. The Jobsite Supervisor will keep a copy of the permit andthe cutter/welder will post the original at the job site on or near the equipment where the work is to beperformed as a warning to other workers of the hot work operation. The permit should remain in this placeuntil the hot work is completed.

PERFORMING HOT WORKThe cutter/welder is responsible for conducting the hot work within the authorized parameters and timelimit set by the permit. Hot work may continue as long as conditions remain safe and no new hazards havebeen introduced.

The following precautions should be taken when performing any hot work operations:

• Perform hot work in a fire safe area except when the job cannot be moved.

•Use only equipment that is in good condition. Valves, regulators, hoses cables and torches should bethoroughly checked before each use. See the Equipment Safety Check program found inAppendix B.

• Do not perform portable welding, cutting, or other hot work operation in a building wheresprinklers are out of service.

• Move combustibles at least 35 feet from hot work operations. If combustibles cannot be moved,they should be protected by metal guards or by flameproof curtains or covers rather than byordinary tarpaulins.

•Do not perform hot work in or on any vessels containing flammable, combustible materials, until they havebeen disconnected or blanked, completely cleaned out, and purged.


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• Check the atmosphere for combustible gases or vapors, where necessary, using reliable detectionequipment. If there is a chance of gas release during hot work operations, continuous monitoringmust be performed. (Refer to our companies Confined Space Program).

• Ensure that a fire extinguisher is readily available for instant use in the area.

• Do not perform hot work until surrounding floors have been swept clean and if combustible, wetdown with water or covered with flameproof material.

• Do not perform hot work until all wall and floor openings within 35 feet of the operations havebeen tightly covered and or protected with flame proof material.

• Do not perform hot work until a fire watch has been assigned to watch for dangerous sparks in thearea and on floors above and below the operation.

• Secure gas cutting and welding cylinders so they will not be damaged and replace protective caps(and closed gas supply valves) on all cylinders not actually in use.

• Carefully and securely connect the ground clamp when using electrical arc welding equipment.Since improperly made ground can be a source of ignition, the ground clamp should be connectedas close to the work as possible so that it may easily be observed.

• Use portable stands to elevate welding hose or cable off floor areas to avoid damage to the hose orcable.

• Ensure adequate ventilation is maintained during hot work operations to assure that employees arenot exposed to harmful fumes. This may include positioning of an exhaust blower close to thepoint of the exhaust fumes. Respiratory protection may also be considered.

• Remove all electrodes from the holders, carefully locate them so that accidental contact cannotoccur, and disconnect the welding machine from the power source if hot work is to be suspendedfor any substantial period (e.g., lunch or overnight).

The fire watch shares the responsibility for fire/safety with the cutter/welder. The fire watch shouldmaintain constant watch during the operation (including lunch and breaks) to watch for stray sparks,ignition sources, or other fire hazards. The fire watch must be trained in the use of a fire fightingequipment, stages of fire, and must have the equipment readily available. He/she should be familiar withthe job site and also know how to sound the alarm. It’s the fire watch's responsibility to attempt toextinguish any fire that might occur, as long as the equipment has the capacity available. If the fire watchfeels they are in danger because of the fire stage then they must sound the alarm and evacuate.

The Jobsite Supervisor should inspect the work area during the hot work operations to ensure that theconditions of the hot work permit are being fulfilled.

COMPLETING THE HOT WORK PERMIT PROCEDURE

When the hot work is completed, the fire watch must remain for at least 30 minutes, carefully inspecting thework area and adjacent areas for the possibility of any smoldering fires. This inspection extends to floorsabove and below the work area and to adjacent rooms.

Barring any fires, the fire watch removes the hot work permit. The fire watch then signs the permit, writesthe completed time and then returns the permit to the Jobsite Supervisor.


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The Jobsite Supervisor must return to the area one hour later; smoldering fires may take that long to becomeapparent. After this final inspection, the Jobsite Supervisor will sign the hot work permit, write the time ofthe final inspection, and send the original to the safety office to be filed.

PERSONNEL RESPONSIBILITIES The following describes the various persons/departments who may be involved in the hot work permit

procedure, and summarizes their responsibilities.

OriginatorIdentifies the need for a hot work permit;

Submits hot work permit request to the Jobsite Supervisor;

Works with other trades, as assigned, during the implementation of the hot work permit procedure.

Jobsite Supervisor Has overall responsibility for ensuring that the hot work permit procedure is followed.

Inspects the work area before filling out the hot work permit;

Makes a determination as to whether a fire watch is necessary;

Completes the hot work permit after completing inspection of work area;

Reviews the list of hot work precautions with the cutter/welder and the fire watch;

Specifies any additional precautions that may be necessary for the hot work permit;

Signs the hot work permit and issue it to the cutter/welder when assured that all necessary hot workprecautions have been taken;

Inspects the work area during the hot work operations to ensure that the conditions of the hot workpermit are being fulfilled;

Returns to the hot work area (or direct cutter/welder or fire watch to return to the area) one hourlater to inspect for smoldering fires; and,

Signs the hot work permit after the final site inspection has been completed and sends the originalto the safety office to be filed.

Cutter/WelderReviews the list of hot work precautions with the Jobsite Supervisor and signs the permit;

Affixes the hot work permit and precautions to a visible place in the work area;

Conducts the hot work operations within the authorized parameters and time limit set by the hotwork permit;

Stops hot work operations if any new hazards are introduced to the process;

May remain in the area for 30 minutes after work is completed, carefully inspecting the work areaand adjacent areas for any smoldering fires;


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May sign and return the hot work permit to the Jobsite Supervisor after the 30 minute inspection;and,

May return to the hot work area one hour later to inspect for smoldering fires if instructed to do soby the Jobsite Supervisor.

Fire WatchReviews the list of hot work precautions with the Jobsite Supervisor and signs the permit;

Maintains a constant watch during the hot work operations (including lunch and breaks) to watchfor stray sparks, ignition sources, or other fire hazards;

Ensures that fire-extinguishing equipment is readily available for instant use in the area;

Stops hot work operations if any new hazards are introduced to the process;

Extinguishes any fires if they occur as long as they are within the capacity of the equipmentavailable, or otherwise sounds the fire alarm;

Remains in the area for at least 30 minutes after work is completed, carefully inspecting the workarea and adjacent areas for any smoldering fires; and,

May return to hot work area one hour later to inspect for smoldering fires if instructed to do so bythe Jobsite Supervisor.

DOCUMENT MANAGEMENT:The only document associated with hot work permit procedures is the permit itself, found inAppendix A of this program. Documentation should be managed as follows:

Hot Work PermitThe Jobsite Supervisor retains the supply of blank permits. Upon request they fill out the permitand sign it to authorize the work. The permit is then signed by the cutter/welder and one copy ofboth sides of the permit is made. The Jobsite Supervisor retains the copy and cutter/welder takesthe original to the job site where it is posted. Upon successful completion of the work theSupervisor or Fire Watch (if needed) signs the permit. The completed permit is then filed asfollows:

Original - Sent to the Safety Director

Copy - Filed at the job site

1. When a Hot Work Permit is required, a signed permit must be issued before cutting, welding, orother hot work is permitted, the area must be inspected by the individual responsible forauthorizing the hot work operations. This individual must designate precautions to be followed ingranting the authorization.

2. If automatic sprinklers are in the area, check that they are in service.

3. Floors must be swept clear. Combustible floors must be wet down, or covered with other fireretardant material. Where floors have been wet down, personnel operating arc welding or othercutting equipment must be protected from possible shock.

4. Remove flammable liquids and clean up oily deposits.


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5. Move combustibles to a minimum distance of 35 feet. If not practicable, cover the storage areawith fire -resistant drop cloths or isolate the welding with a temporary fire resistant enclosure.

6. Ducts and conveyor systems that might carry sparks to distant combustibles must be suitably protected or shut down.

7. Combustible walls. Where cutting or welding is done near walls, partitions, ceiling or roof of combustible construction, fire-resistant shields or guards must be provided to prevent ignition.

8. Noncombustible walls. If welding is to be done on a metal wall, partition, ceiling or roof, precautions must be taken to prevent ignition of combustibles on the other side, due to

conduction or radiation, preferably by relocating combustibles. Where combustibles are not relocated, a fire watch on the opposite side from the work must be provided.

9. Combustible cover. Welding must not be attempted on a metal partition, wall, ceiling or roof having a combustible covering.

10. Pipes. Cutting or welding on pipes or other metal in contact with combustible walls, partitions, ceilings or roofs must not be undertaken if the work is close enough to cause ignition by conduction.

11. Station a Fire Watch. A Fire Watch must be in place whenever hot work is performed in locationswhere other than a minor fire might develop, or any of the following conditions exist:• Combustible material is closer than 35 feet from the point of operation.• Combustible materials are more than 35 feet away but are easily ignited by sparks.• Wall or floor openings within a 35-foot radius expose combustible materials in adjacent areas

including concealed spaces in walls or floors.• Combustible materials are adjacent to the opposite side of metal partitions, walls, ceilings, or

roofs and are likely to be ignited by conduction or radiation.• The Fire Watch must have fire-extinguishing equipment readily available and be trained in its

use and limitations. They must be familiar in the procedures for sounding the alarm in theevent of a fire. The Fire Watch must watch for fires in all exposed areas and steel members,pipes etc. that can transmit heat to walls, ceilings, or combustibles. The designated firewatch's only responsibility will be to watch for fires!

12. When the work is completed, the Fire Watch must check adjoining areas and/or floors (above andbelow) for smoldering fires that might have started unnoticed. The Fire Watch must maintain awatch for 30 minutes after completion of welding or cutting operations to detect and extinguish possible smoldering fires.

13. The Jobsite Supervisor must return to the scene within one hour after the work has been done tosign and retrieve the permit and to check the area to assure no fires have started.

14. Restrictions. If the above stated in this section cannot be followed, then welding, cutting, orother hot work must not be performed.

15. Permits are located in the job trailer. Ask your supervisor when you need one.

FIRE EXTINGUISHERSThere are four basic types of fire extinguishers we may use. These are:

Type A - ordinary combustibles. Those consisting of ordinary combustible materials such as wood, cloth, and paper.


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Type B - Flammable Liquids. Those involving flammable liquids, gases and greases.Type C - Electrical Equipment. Those involving energized electrical equipment.Type D - Combustible Metals. Fires which occur in combustible metals such as magnesium,

titanium, zirconium and sodium.

The most commonly used fire extinguisher available is the ABC type, which will cover types A, B, C fires.In some areas where electrical fires are the only concern, such as electrical rooms B, C type fireextinguishers may be used. This type is good for both class B and class C fires. (liquids, greases, andelectrical) These can not be used on type A fires (ordinary combustibles).

Anytime there is a possibility that you might have to use a fire extinguisher, such as doing hot work; youhave to do a pre-check on the fire extinguisher. You need to check the following things on the fireextinguisher;

1) Clean and in good condition.2) Pin sealed to the handle with plastic retainer in place. If this has been broken get it replaced. Ifthe plastic retainer is broken on a B type fire extinguisher remove the fire extinguisher fromservice and replace it with a known charged one.3) Check the pressure gauge to make sure it is full and not damaged.4) See that the inspection tag is on the fire extinguisher and that it has not expired.

Anyone who is expected to use a fire extinguisher must be properly trained in its use, the stages of fire andhow to report a fire. Remember the simple acronym P.A.S.S. Pull the pin; Aim at the base of the fire,Squeeze the handle, Sweep side to side.


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Confirmation of UnderstandingHot Work

Name: ______________________________

S.S. #: ______________________________

Date ________________________________

1. What is a Hot Work permit? ______________________________________ _____________________________________________________________

2. When is a Hot Work Permit required?_______________________________

3. What are 3 things that can be done in the area immediately around the work to reduce the potential for fire?

a) ________________________________________________________b) ________________________________________________________c) ________________________________________________________

4. Why does there need to be a second person who is the fire watch? ______________________________________________________________________________________________________________________________________________________________________________

5. How long after the hot work is done, does the fire watch need to stay at the scene and why?______________________________________________

______________________________________________________________________________________________________________________

6. a. Who signs the hot work permit? _________________________________________________________________________________________________________________________________________________

b. Why does the above person/persons need to sign the permit?___________________________________________________________________________________________________________________________


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7. T or F A fire watch can be a co-worker that is working nearby.

8. When is the permit removed from the area of hot work? __________________________________________________________

9. What four things need to be checked on a fire extinguisher to make sure it is ready for service?1)2)3)4)

10. When putting out a fire what type of motion are you using?

11. Explain P.A.S.S. when dealing with fire extinguishers.P.A.S.S.

12. Name the four types of fire extinguishers and their use.1. ________________________________________________________________2. ________________________________________________________________3. ________________________________________________________________4. ________________________________________________________________

13. What are two things you must do to prevent breathing welding fumes? ______________________________________________________________________________________________________________

14. What should be done if bad insulation is found on a cable lead or power cord of a welder? _____________________________________________________________________________________________________

15. What is the maximum pressure acetylene can be used in a free state? _____________________________________________________P.S.I.


21

16. What are three requirements for storage of oxygen and acetylene?____________________________________________________________________________________________________________________

17. When should you purge the lines of an oxygen/acetylene rig?____________________________________________________________________________________________________________________

18. What are two ways to avoid electrical shock while welding? __________________________________________________________

__________________________________________________________

19. List two requirements for the transportation of compressed gas cylinders.____________________________________________________________________________________________________________________

20. Explain two different accidents that could happen from the misuse ofacetylene.______________________________________________________________________________________________________________________________________________________________________

21. Explain two accidents that could happen from electric arc welding.______________________________________________________________________________________________________________________________________________________________________________

22. What should be done if an item on your Welder Safety Inspection Sheet checks out bad? ________________________________________________________________________________________________________________________________________________________________

23. How often do you have to do your welder's safety checklist?__________________________________________________________

24. What are the disciplinary actions for not performing the Welder Safety Inspection? __________________________________________________________________________________________________________

25. With the regulator hooked up, where should you not stand when turningon the cylinder’s valve? ______________________________________________________________________________________________


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26. When lighting a torch what should be lit first?_____________________________________________________________________________

27. If the cylinder valve is stuck shut what should you do?______________________________________________________________________

28. What color is the oxygen hose? _______________________________

What color is the acetylene hose? _____________________________

What color is the inert gas hose? ___________________________

29. Before attaching the regulator to the outlet of a cylinder valve whatmust be done?_____________________________________________

________________________________________________________

30. When must cylinder caps be in place? ___________________________________________________________________________________

31. How must cylinders be secured? ______________________________ ________________________________________________________


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Confirmation of UnderstandingHot Work

ANSWER KEY

1. What is a Hot Work permit?Documented check list/procedure to make sure there are no fire hazards present

2. When is a Hot Work Permit required?Anytime you do any “Hot Work” and your not in a designated area for that work.

3. What are 3 things that can be done in the area immediately around the workto reduce the potential for fire?Remove combustibles, sweep floor back 35’, shut down conveyors, ductwork, cover combustibles, wet floors, have fire watch, follow hot work permit.

4. Why does there need to be a second person who is the fire watch? The person doing the hot work might be to busy working to notice a small fire.

5. How long after the hot work is done, does the fire watch need to stay at the scene and why?

30 min, to make sure no smoldering fire start up.

6. a. Who signs the hot work permit? The hot worker, The fire watch, and the jobsite supervisor

b. Why do the above person/persons need to sign the permit?To hold them accountable for the hot work.

7. T or F A fire watch can be a co-worker that is working nearby.

8. When is the permit removed from the area of hot work? 1 hr after the hot work is done the jobsite supervisor goes and retrievesthe permit. Making sure no fire have started up.

9. What four things need to be checked on a fire extinguisher to make sure it is ready for service? 1) Clean and good condition 2) Pin sealed to the handle 3) Check gauge for fullness 4) The monthly tag is on it and has been punched for the month


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10. When putting out a fire what type of motion are you using? Sweeping motion side to side at the base of the fire.

11. Explain P.A.S.S. when dealing with fire extinguishers. P. Pull the pin A. Aim the nozzle S. Squeeze the handle S. Sweep side to side

12. Name the four types of fire extinguishers and their use. 1.Type A - Combustibles 2.Type B - Flammable liquids 3.Type C - Electrical 4.Type D – Combustible Metals

13. What are two things you must do to prevent breathing welding fumes?Head out of the fumes, and ventilation, use respirator if qualified

14. What should be done if bad insulation is found on a cable lead or power cord of a welder?Tagged out, the cable or power cord replaced or properly repaired

15. What is the maximum pressure acetylene can be used in a free state? 15 psi

16. What are three requirements for storage of oxygen and acetylene?Caps on, Chained in storage rack, upright, separate

17. When should you purge the lines of an oxygen/acetylene rig?Before each use of the rig.

18. What are two ways to avoid electrical shock while welding?Gloves and clothing dry, rubber gloves under gloves, Don’t weld in standing water, don’t become path between the ground and work cables.

19. List two requirements for the transportation of compressed gas cylinders.Chained to a cart, in cart or cradle designed for carrying compressed gases, upright, safety caps on etc

20. Explain two different accidents that could happen from the misuse ofacetylene.

Explosion, frost bite, affixation, burns


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21. Explain two accidents that could happen from electric arc welding.Shock, burns, eye burns, fume poisoning, fire

22. What should be done if an item on your Welder Safety Inspection Sheet checks out bad?Welder tagged out of service, and repaired.

23. How often do you have to do your welder's safety checklist?Each time you use the welder.

24. What are the disciplinary actions for not performing the Welder Safety Inspection?Discipline up to and including discharge.

25. With the regulator hooked up, where should you not stand when turning onthe cylinder’s valve?In front or behind the regulator

26. When lighting a torch what should be lit first?Acetylene

27. If the cylinder valve is stuck shut what should you do?Tag it out of service and return it to the supplier to be fixed.

28. What color is the oxygen hose? Green

What color is the acetylene hose? Red

What color is the inert gas hose? Black

29. Before attaching the regulator to the outlet of a cylinder valve what must bedone?Check to make sure there is no grease or oil around outlet, then crack the valve for a moment to blow out foreign material.

30. When must cylinder caps be in place?Anytime they are not hooked up to be used.

31. How must cylinders be secured?By a chain or strap to a cart or a fixed support.


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APPENDIX A

HOT WORK PERMIT


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HOT WORK INHOT WORK INHOT WORK INHOT WORK INPROGRESSPROGRESSPROGRESSPROGRESS

WATCH FOR FIRE!WATCH FOR FIRE!WATCH FOR FIRE!WATCH FOR FIRE!IN CASE OF ANIN CASE OF ANIN CASE OF ANIN CASE OF ANEMERGENCY:EMERGENCY:EMERGENCY:EMERGENCY:

CALL: _________________________CALL: _________________________CALL: _________________________CALL: _________________________AT:____________________________AT:____________________________AT:____________________________AT:____________________________

HOT WORK PERMITHOT WORK PERMITHOT WORK PERMITHOT WORK PERMIT

SAFEGUARD CHECKLIST___ Hot Work Equipment must be in safe workingcondition and operators trained in its use.___ Standby Fire Fighting Equipment must beavailable.___ Combustible materials shall be swept clean within35 ft. of work.___ Eliminate explosive atmosphere (gaseousflammables in area/confined space) ___ Remove Combustibles where practical,otherwise, protect with flameproof covers.___ Combustible constructed walls (Kemlite Included)shall be covered.___ Remove combustibles from the back side of thewall.___ Cover all floor and wall openings.___ Are the Oxy/Acet tanks outside the confinedspace.___ Mechanical ventilation provided to remove toxicgases or vfapors from spaces.___ Shutdown ducts –conveyor systems that mayconvey sparks to distant combustibles.___ Maintain a fire watch for 30 minutes aftercompletion of work.___ Fire watchers shall have fire extinguishingequipment and be trained in usage.___ Fire watchers shall watch for fires in all exposedareas and steel member, pipes etc. that can transmitheat to walls, celings, or combustibles.___ Fire Watchers will be trained in sounding alarm.___ Other Safeguards taken:_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

INSTRUCTIONS1.) To person authorized to issue HOT WORKPERMITS.a.) While visiting the jobsite, complete the checklist onthe left.b.) Next, fill in the portion below.c.) Retain PART 1 (this must be kept until the work iscompleted)d.) Issue PART 2 to person doing the job.

_____________________________________________

HOT WORK BEING DONE BY:

____ Employee

____ Contractor_______________________________

Date:________________________________________

Job / W.O. Number:____________________________

Location:_____________________________________

Object that Hot Work is to be Performed On:_________

_____________________________________________

Name of PersonDoing Hot Work:________________________________

I Have Examined The Job Site Listed Above and TheSafeguards on the Checklist Have Been Taken ToPrevent a Fire.

Signed (Authorized Supervisor)

_____________________________________________

Permit Date: Time: amExpires pm


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30

APPENDIX B

EQUIPMENT

SAFETY CHECK


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OXY / ACETYLENE WELDER SAFETY CHECKLIST

If any defects or evidence of damage is noted that might expose an employee to injury the equipment will be removed from service.Before the equipment is used, this checklist must be completed. A copy turned into the Jobsite Supervisor by the end of the shift.

“TANKS / CYLINDERS”All cylinder / tank valves should be inspected to ensure that they are free of dirt, rust, lubricant, oil orgrease. Valves should be “cracked” to clear the valve of any particles of dirt or rust. Inspect the label toensure that the proper types of gases are being used. Cylinders should be secure upright in the stands.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“REGULATORS”Ensure that the proper regulator is being used for the proper gas. Regulators should be mounted on cylinderso that the readings of the gauges are visible to the operator. Gauges should be inspected to ensure that theyare working properly, lenses shouldn’t be cracked or broke etc.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“HOSES / GAS LINES”All hoses / gas lines should be inspected for cracks, breaks and leaks around fittings etc. Ensure thatbackflow preventors are in place.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“TORCH HEAD”Inspect valves, fittings and tips for leaks. O-Rings should be inspected and replaced if worn. Torch headshould be free of greases, oils and lubricants just as the valves should be.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Welder # Date: Inspector


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HELIARC SAFETY CHECKLIST


“TANKS / CYLINDERS”All cylinder / tank valves should be inspected to ensure that they are free of dirt, rust, lubricant, oil orgrease. Valves should be “cracked” to clear the valve of any particles of dirt or dust. Inspect label toensure that the proper type of gas is being used. Cylinders should be secured upright in the stands.

COMMENTS:______________________________________________________________________________________________________________________________________________________________

“REGULATOR”Ensure that the proper regulator is being used. Regulators should be mounted on cylinder so that thereadings of the gauges are visible to the operator. Gauges should be inspected to ensure that they areworking properly, lenses shouldn’t be cracked or broke etc.

COMMENTS:______________________________________________________________________________________________________________________________________________________________

“HOSES / GAS LINES”Hose / gas line should be inspected for cracks, breaks and leaks around fittings etc.

COMMENTS:______________________________________________________________________________________________________________________________________________________________

“LEAD / CABLE”Lead / cable should be inspected for cuts, breaks and cracks.

COMMENTS:______________________________________________________________________________________________________________________________________________________________

“TORCH HEAD”Inspect valve for leaks. O-Rings should be inspected and replaced if worn. Rubber insulation on electrodehousing should be inspected for cracks and tears etc.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Welder # Date: Inspector:


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PLASMA CUTTER’S SAFETY CHECKLIST


“AIR REGULATOR / GAUGE”Inspect regulator and air gauge ensuring they are operating properly. Glass dome on regulator / gaugeshould be in good condition, not cracked or broken.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“HOSE”Air hose should be inspected for cracks, breaks and leaks around fittings.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“LEADS / CABLES”Leads / cables and power cord should be inspected for cuts, breaks, cracks or exposed wires.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“TORCH HEAD”Inspect torch head for loose or exposed wires and hose fittings. Torch head casing should be clean and ingood condition.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“GROUNDING”All ground leads and connections should be strong and electrically adequate for the required current.

COMMENTS:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Plasma Cutter # Date: Inspector:

ARC WELDER SAFETY CHECKLIST


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“WELDING LEADS / CABLES”All leads / cables and terminal covers should be inspected for cuts, breaks and cracks. All defects must berepaired or replaced. There must be no defects within 10 feet of the stinger / electrode holder. All repairsto cables and leads must be done by approved methods.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“STINGER / ELECTRODE HOLDER”The stinger / electrode holder should be inspected for cracked or broken porcelain. If any defects are foundthe stinger / electrode holder must be replaced.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“GROUNDING”All ground connections shall be inspected to determine that they are mechanically strong and electricallyadequate for the required current.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“SWITCHES / MISCELLANEOUS”All switches and dials shall be inspected to ensure proper functioning and the welder frame and housingshould be inspected to ensure that it is in good condition.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Welder # Date: Inspector

MIG / WIRE FEED WELDERS SAFETY CHECKLIST



35

“TANK / CYLINDER”Inspect cylinder valve ensuring that it is free of dirt, rust, lubricant, oil or grease. Valve should be crackedto clear the valve of any particles of dirt or dust. Inspect label to ensure proper gas is being used. Cylindershould be upright and secure in stand.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“REGULATOR”Ensure proper regulator is being used for the proper gas. The operator of the welder should mountregulator on cylinder to allow readings to be visible. Inspect gauges ensuring that they are operatingcorrectly, lenses should be in good condition not cracked or broken.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“HOSE / GAS LINE”Inspect hose / gas line for cracks, breaks and leaks around fittings.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“LEADS / CABLES”Inspect leads / cables and power cord for cuts, breaks, cracks or exposed wires.

COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“TORCH HEAD”Inspect torch head for loose leads, wires and hose fittings. Torch head casing / housing should be inspectedfor cracks and breaks.

COMMENTS:_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

“GROUNDING”Ground clamp shall be inspected to determine that they are strong and electrically adequate for the requiredcurrent.COMMENTS:________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Welder # Date: Inspector:


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APPENDIX C

HOT WORK PERMIT

TRAINING OUTLINE


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HOT WORK PERMIT TRAINING OUTLINE1. Review Definitions

2. Review operations needing a hot work permit. a) Review the types of operations that a hot work permit is required

3. Review the hot work permit a) Cover each section of the hot work permit b) Have employee complete a hot work permit

4. Review the hot work permit procedure a) Initiating a hot work permit b) Issuing a hot work permit c) Performing hot work d) Completing the hot work permit

5. Review responsibilities a) Originator responsibilities b) Site Supervisor responsibilities c) Cutter or welder responsibilities d) Fire watch responsibilities

6. Review document management section of the programa) Management of the hotwork permitb) Location of permitsc) Posting of permitsd) Retention of permits

7. Review the equipment preventive maintenance safety checklists a) Oxy/Acetylene checklist b) Heliarc checklist c) Plasma cutter checklist d) Arc welder checklist

e) Mig/Wire feed welder checklist

8. Complete employee training certification and confirmation of understanding


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NAME:____________________________________

DATE:__________________________

HOT WORK PERMIT PROGRAM

CERTIFICATION OF TRAINING IN THE HOT WORK PERMIT PROGRAM

This is to certify that I have received training and instructions in the Companies HotWork Permit Program. I have learned about specific hazards, hot work operations andprocedures that will enable me to actively participate in this program. I have checked thetopics that have been covered and I understand each topic:

( ) Definitions( ) Safety precautions for hot work( ) Equipment Safety Checklist( ) Fire extinguishers; types, use and care( ) Operations that require a hot work permit( ) Each section of the hot work permit( ) Hot work permit procedure( ) Responsibilities in program( ) Document management( ) Equipment Preventive Maintenance Program( ) Confirmation of understanding (test)

________________________________ __________________________________INSTRUCTOR SIGNATURE EMPLOYEE SIGNATURE

_________________________ _________________________ DATE DATE

hotwrkprog

Documents

hot work operation

hot work permits

employeeperforming hot

safe practices

hot workwarning

hot work permit procedure

safe installation

reliable equipment