Hot Work Permit Program

ONLINE SELF-STUDY

UNC Hot Work Permit Program Safety Training

Course Objectives

1) Be able to identify the general hazards associated

with Hot Work Activities

2) Be able to explain the procedures involved in theUNC Hot Work Permitting System.

3) Be able to explain the roles of personnel for the Hot Work Permit System including: the Hot Work Operator, Permit Authorizing Individual, and the Fire Watch.

Course Objectives

4) Be able to explain the difference between a

designated hot work area, a controlled hot work area, and an area where hot work is not permitted under any circumstances.

5) Understand Contractor Responsibilities, Mutual Responsibility, and the importance of individual initiative to halt work operations when workplace conditions develop that could pose a hazard.

Hot Work Definitions



Hot Work

Defined as “work involving burning, welding, or similar

operation that is capable of initiating fires or explosions”.

Hot work also includes other activities with the potential to

create a source of ignition such as cutting, brazing, grinding,

soldering, or hot riveting.

The OSHA hot work standard 29 CFR 1910.251-257,

defines practices that should be implemented during the

performance of hot work. This standard covers the safety

requirements of the different types of welding processes. In

addition, refer to the UNC-CH IMAC Safety Manual for

Welding and Cutting Safety Policy Requirements.


Hot Work

Hot work also includes other activities with the potential

to create a source of ignition and process applications

that produce sparks, flame, or heat.

Hot work is a familiar routine activity at most industrial

facilities. But because hot work tools are highly

portable source of ignition, improperly conducted hot

work is a major cause of fires and explosions which

have resulted in extensive property damage, serious

personnel injury, and worker deaths.


Hot Work Operator is the Departmental employee

who is qualified and authorized by management to

perform hot work such as welding, brazing,

soldering, and other associated work tasks.


Permit Authorizing Individual (PAI) is the

Departmental employee who is trained and

authorized to issue a hot work permit by

management.

The Fire Watch is the Department employee who is

trained in hot work safety and monitors the hot work

area for changing conditions, watches for fires and

extinguishes them if possible.


Designated Area is a permanent location approved for

routine hot work operations made safe by removal of all

possible sources of combustion that could be ignited by the

hot work tool.

Above: Illustrations of two Designated Areas at one of the UNC Energy Services Maintenance Shops.

Combustible materials have been removed to make this a safe location to perform welding operations.


Controlled Area is a work area in which safe conditions for hot work exist or where safe conditions can be created by moving or protecting combustibles.

A hot work permit is required in a controlled area.

An example of a controlled area is in a campus building construction area where welding must take place and the work area has been made safe by removing all combustibles and implementing the requirements of the hot work permit in order to make it safe.


Non- Permissible

Area(s)/Location

is a location which hot work is

prohibited.

Fires and explosions

caused by improperly conducted hot

work can have deadly consequences.

In the last decade their have been

numerous worker injuries and deaths

in general industry that have resulted

from not following proper hot

work procedures.


Welding Blanket is a heat-resistant fabric designed to be placed in the vicinity of a hot work operation. Intended for use in horizontal applications with light to moderate exposures such as that resulting from chipping, grinding, heat treating, sand blasting, and light horizontal welding. Designed to protect machinery and prevent ignition of combustibles such as wood that are located adjacent to the underside of the blanket. They are made from different materials such as fiberglass, Silica, and other fire resistant materials.

Above Illustration: Courtesy of Northern Tool &

Equipment Company


Welding Curtain is heat-resistant fabric designed to be placed in

the vicinity of a hot work operation. Intended for use in vertical

application with light to moderate exposures such as that

resulting from chipping, grinding, heat treating, and light

horizontal welding. Designed to prevent sparks from escaping a

welding area. An illustration of a welding curtain is provided

below.

Above Illustration: Courtesy of UNC Energy Services CoGeneration Facility Maintenance Shop


Welding Pads are heat-resistant fabric designed to be placed

directly under a hot work operation such as welding or cutting.

Welding pads are intended for use horizontal applications with

severe exposures such as that resulting from molten substances of

heavy horizontal welding. Welding pads are designed to

prevent the ignition of combustibles that are located adjacent to

the underside of the pad.

Hot Work Hazards

Hot Work Hazards

Hot Work Hazards

Fire Hazard: Molten metal, sparks, slag, and hot work

surfaces can cause fire or explosion if precautionary

measures are not followed.

Hot Work Hazards

Flying sparks are the main cause of fires and explosions

in welding and cutting. Sparks can travel up to 35 feet

from the work area. Sparks and molten metal can travel

greater distances when falling.

Sparks can pass through or become lodged in cracks,

clothing, pipe holes, and other small openings in floors,

walls, or partitions which can cause fires to start.

Hot Work Hazards

Combustible Materials are anything that is combustible or flammable and is susceptible to ignition by cutting and welding. The most common materials likely to become involved in fire are those of combustible building construction such as the following:

1. Floors, partitions, and roofs

2. Wood, paper, textiles, plastics, chemicals, and flammable liquids and gases, and dusts.

3. Ground cover such as grass and brush.

Hot Work Hazards

Explosion Hazard

Welding and cutting can cause explosions in spaces containing flammable gases, vapors, liquids, or combustible dusts, and tanks and vessels that contain or have held flammable substances.

Above Courtesy U.S. CSB, Tanks involved in the 2006 accident that killed three workers

Hot Work Hazards

Physical and Health Hazards

There are many hazards to the hot work operator (i.e. welder) associated with hot work such as:

Burns,

Sparks,

Electric shock hazards,

Optical (UV) radiation,

Inhalation of welding fumes.

Engineering controls, personal protective equipment, and safe work practices safeguards the welder from many physical and health hazards.

Hot Work Hazards

Can you Identify Some of the Hazards in the following

Illustrations?

Hot Work Hazards

What Hazards Exist in the below illustrations?

Hot Work Hazards

What Hazards Exist?

Eye hazards (UV optical radiation and burn hazards) to the eyes.

Skin burn hazards from the welder and hot surfaces.

Electrical hazards (for above electric welding processes); notice that the work area is dry and free from water and moisture at the welding work area.

Slip, Trip, and Fall hazards from welding hoses and shop equipment.

Inhalation (respiratory) hazards of welding fumes and smoke generated from welding processes when inadequate ventilation is used as illustrated in the top left picture. Notice that in the right picture there is less welding smoke.

Hot Work Hazards

What Hazards Exist in the below illustration?

http://images.google.com/imgres?imgurl=http://www.nasa.gov/centers/glenn/images/content/270043main_2008_01300 _welding_sparks_946-710.jpg&imgrefurl=http://www.nasa.gov/centers/glenn/multimedia/imagegallery/if036_weld_sparks.html&usg=__JddlZEnzMNVlqk2bZPYI0qRgAvY=&h=710&w=946&sz=155&hl=en&start=99&um=1&itbs=1&tbnid=yf6RnNHy0cRZVM:&tbnh=111&tbnw=148&prev=/images?q=welding+pictures&start=80&um=1&hl=en&sa=N&ndsp=20&tbs=isch:1

http://images.google.com/imgres?imgurl=http://www.nasa.gov/centers/glenn/images/content/270043main_2008_01300 _welding_sparks_946-710.jpg&imgrefurl=http://www.nasa.gov/centers/glenn/multimedia/imagegallery/if036_weld_sparks.html&usg=__JddlZEnzMNVlqk2bZPYI0qRgAvY=&h=710&w=946&sz=155&hl=en&start=99&um=1&itbs=1&tbnid=yf6RnNHy0cRZVM:&tbnh=111&tbnw=148&prev=/images?q=welding+pictures&start=80&um=1&hl=en&sa=N&ndsp=20&tbs=isch:1

Hot Work Hazards

What hazards exist?

Eye hazards: Impact hazards from flying chips and

debris, hot slag, and sparks.

Inhalation (respiratory) hazards of dusts generated

when grinding on metal surface coatings.

Fire & Ignition Hazard(s) from flying sparks that could

ignite combustible materials in the work area. Sparks

can travel up to 35’ and ignite combustible materials.

Hot Work Hazards Summary

Hot work can be dangerous because the tools used are highly portable sources of ignition that can be introduced into areas where ignition sources do not usually exist.

Sparks, flame, or heat can travel great distances by various means and ignite combustibles in other areas far away from the hot work.

There are also explosion, fire, and physical and health hazards associated with hot work as previously reviewed.

The goal of hot work safety practices is to avoid bringing sparks, flame, or heat produced by the tool into contact with a source of fuel.

Hot Work Permit Program Requirements;

Hot Work Locations

Hot Work Permit Program

Requirements- Hot Work Locations

Hot work is allowed in two types of locations:

1) Designated area is a permanent location approved for routine hot work operations made safe by removal of all possible sources of ignition that could be ignited by the hot work tool.

2) Controlled Area is one in which safe conditions for hot work exist or where safe conditions can be created by moving or protecting combustibles.

Non permissible location: Hot work is never permitted in certain types of locations where safe conditions do not exist and cannot be created.



Designated Area is a permanent location approved for

routine hot work operations made safe by removal of all

possible sources of combustion that could be ignited by the

hot work tool.

Above: Illustrations of two Designated Areas at one of the UNC Energy Services Maintenance Shops.

Combustible materials have been removed to make this a safe location to perform welding.



Designated Area:

An example, is the Welding Shop or Maintenance Shop (as illustrated below) where all combustibles have been removed.

A Hot Work Permit is not required in a Designated Hot Work Area.

Above: Illustration of UNC Art Lab Welding Area, which is considered a Designated Area. A hot work permit is not required in a Designated Hot Work Area.



Controlled Area is one in which safe conditions for hot work exist

or where safe conditions can be created by moving or protecting

combustibles.

An example of a controlled area is in a campus building

construction area where welding must take place and the work

area has been made safe by removing all combustibles and

implementing the requirements of the hot work permit in order to

make it safe.



In a Controlled Area, a Hot Work Permit must be obtained by

the hot work operator. The permit must be obtained from the

Departmental designated Permit Authorizing Individual (PAI)

before the hot work can proceed in a controlled area.

The permit includes a checklist of precautions, each of which

must be considered and then implemented if the PAI determines

that is applicable to the specific situation, such as: ensuring fire

protection equipment is available in the work area, controlling

potential and existing fuel sources, and posting a fire watch

when required.

Hot Work Permit Program Requirements-

Hot Work Locations

Non- Permissible Area(s)/Location: Hot work shall not

be permitted in the following areas:

(1) In areas not authorized by Management.

(2) In sprinklered buildings where sprinklers are impaired.

(3) In the presence of explosive atmospheres (i.e., where mixtures of flammable gases, vapors, liquids, or dust with air exist).

(4) In the presence of uncleaned or improperly prepared equipment, drums, tanks, or other containers that have previously contained flammable materials that could develop explosive atmospheres.

(5) In areas with an accumulation of combustible dusts that could develop explosive atmospheres.

Hot Work Permit Program Requirements

Hot work is prohibited:

In, on, or near tanks, vessels, or containers that

contain or have contained flammable substances.


Hot Work Location Examples

Non- Permissible Area(s)/Location Examples:

Fuel/ Fuel Oil Storage Tanks

Hot work is not allowed in, on, or near fuel and fuel oil storage

tanks such as illustrated below:
















DIESEL FUEL NO SMOKING

MATCHES OR

OPEN FLAMES The University of North Carolina at Chapel Hill Department of Environment, Health & Safety 1120 Estes Drive Ext., CB# 1650 Chapel Hill, North Carolina 27599



For hot work in the vicinity of any potential hazardous location, the atmosphere must be tested for atmospheric hazards including flammable gasses using a combustible gas indicator by a trained PAI or EHS before commencing hot work.

Contact EHS at 962-5507 before commencing any hot work in a potentially hazardous location.



Analyze the Hazards- Prior to initiation of hot

work, perform a hazard assessment that identifies:

1) The scope of the work,

2) Potential hazards,

3) Methods of hazard control.


After analyzing the hazards, see if there is any possibility of Hot Work Alternatives. An alternative hot work method is termed “Cold Work”.

1) Can the job be completed with cold work?

An example of cold work is performing repairs with another method

instead of using a heat producing tool. If yes, a hot work permit is not required.

2) Can hot work be performed in a designated area (e.g. maintenance or welding shop). If yes, then a hot work permit is notrequired.

3) Is the proposed work to be performed in a non- permissible area?

HOT WORK AND PERMIT ARE NOT AUTHORIZED in a non-permissible location.


Here is an example of a decision flow that can be

utilized

to help determine if a hot work permit is needed or not.


YES

NO

YES

NO

YES YES YES

NO

YES

NO

1. Is there an acceptable

alternative to hot work??

Yes, Complete job with Cold

Work. No hot work permit is

needed.?

2. Can hot work be performed

in a designated area (e.g.

Maintenance Shop)?

Yes, Examine designated area,

then complete hot work there.

No hot work permit is needed.?

3. Is the proposed work to be

performed in a non-designated area

(e.g. NOT in a Maintenance Shop)??

Yes, Obtain a written hot

work permit.?

4. Is the proposed work to be

performed in a non-permissible area?

YES, Hot Work and Permit are Not

Authorized in a non-permissible area

No, Obtain a written hot

work permit to work in a

Controlled Area.


If it is decided that a hot work permit is required for

a job task, the Hot Work Permit must be obtained by

the hot work operator from the Permit Authorizing

Individual (PAI).

The PAI is designated by management before the

hot work can proceed in a controlled area.


The Hot Work Permit includes a checklist of

precautions, each of which must be considered and

then implemented if the PAI determines that it is

applicable to the specific situation.


UNC Hot Work Permit: Click on the below Hot Work

Permit

http://ehs.unc.edu/manuals/imac/docs/hot_work.pdf


Fire Protection Equipment: All required fire

protection, detection, and extinguishing equipment

must be available, in service, and fully operable.

Examples of equipment that needs to be considered

include:

- Fire extinguishers

- Fire Sprinklers,

- Hose stream, pales of water available?

- Proximity to the fire alarm.


Fuel sources: fuel sources within 35’ from hot work are easily ignited, so within this area:

Combustible materials must be removed or shielded.

The floor must be swept clean of combustible materials.

The absence of hazardous atmospheres and/or flammable materials must be verified, steps must be taken to ensure that none are introduced, and adequate ventilation must be assured.

Combustible floors must be covered with damp sand or fire resistant sheets.


Fuel sources (cont’d): fuel sources within 35’ from hot work are easily ignited, so within this area:

Openings or cracks in walls, floors, or ducts through which sparks might travel and ignite combustibles in other locations must be covered. Conveyer systems must be shut down.

Fire resistant tarps must be suspended beneath overhead work.

If hot work is done on one side of a wall, partition, ceiling, or roof, precautions shall be taken to prevent ignition of combustibles on the other side by relocating the combustibles.


Fuel sources (cont’d): If relocation is impractical,

combustibles shall be protected by a approved

welding curtain, welding blanket, welding pad, or

equivalent rated ANSI/FM 4950.

The above illustration is of a welding curtain used to prevent sparks from traveling to adjacent

work areas.


Fuel sources (cont’d):

If it is impractical to relocate combustibles, a

Fire Watch must be provided on the side opposite from where work is being performed.


A Fire Watch is needed when there is a chance that fire

might develop from combustible materials. A fire watch

is needed if combustible materials are located:

1) Closer than 35’ from the hot work.

2) More than 35’ away from the hot work but might be

easily ignited by sparks.

3) Walls or floor openings within 35’ expose

combustible materials in adjacent areas including

concealed areas spaces in walls and floors.

4) Adjacent to the opposite side of partitions, walls,

ceilings, or roofs.


The Fire Watch monitors the hot work area for changing conditions and watches for fires, and extinguishes them if possible. The Fire Watch shall be familiar with the facilities and procedures for sounding the fire alarm and contacting the Fire Department in the event of an emergency.

Note: When changing conditions are observed by anyone– whether the fire watch, hot work operator, PAI, or any other employee– that person should immediately halt the hot work on his or her own initiative!!


Remember, Fire Watches must:

1. Have fire extinguishing equipment readily available and be trained in its use.

2. Be familiar with facilities for sounding an alarm and contacting the Fire Department in the event of a fire.

3. Watch for fires in all exposed areas.

4. Try to extinguish fires only when obviously within the capability of equipment available, or otherwise sound the alarm.

5. Be maintained for at least a half-hour after completion of welding or cutting operations to detect and extinguish possible smoldering fires.


Contractor Responsibilities:

The designated departmental PAI should supervise

outside contractors that are planning to engage in

hot work activities.

The departmental PAI informs contractors about site-

specific hazards including the presence of

flammable materials at the work site.


Mutual Responsibility: Management, contractors,

the PAI, the fire watch, and the hot work operators

shall recognize their mutual responsibility for safety

in hot work operations.


Individual Employee Responsibilities:

Any employee that observes changing unsafe

condition associated with hot work activities must use

individual initiative to report the unsafe condition(s).

Each employee has the right to halt hot work

operations when new conditions develop that could

pose a hazard to employees.

An example of changing conditions might be the

introduction of a flammable substance into the hot

work area.

Hot Work Accident Case Studies


Case Study #1: Welding and cutting can cause explosions in

spaces containing flammable gases, vapors, liquids, or combustible

dusts, and tanks and vessels that contain or have held flammable

substances.

Above Courtesy U.S. CSB, Tanks involved in the 2006 accident that killed three workers


Case Study # 1: Explosion:

Previous Slide Photo & Below Information, Courtesy: U.S. CSB,

Tanks involved in the 2006 accident that killed three workers . On June 5, 2006, contract workers were installing a new pipe between two oil tanks at a rural oilfield when sparks from a welding torch ignited flammable hydrocarbon vapor venting from one of the tanks. That tank and another nearby tank exploded, killing three workers who were standing above the tanks and seriously injuring a fourth. All of the tanks were interconnected by piping and one of the tanks contained crude oil, the source of the vapor that fueled the explosions. The workers had not performed combustible gas monitoring prior to or during the hot work instead relying on the unsafe and unreliable practice of using a lit torch to check one of the tanks for flammable vapor.

Workers did not empty or isolate the tank that contained crude oil prior to initiating hot work activities.

Neither the contract company nor the parent company required written hot work permits. The contractor company did not provide hot work safety training to employees.

Hot Work Permit Program Case Studies

Case Study # 2: Explosion: Below Information and Photo, Courtesy: U.S. CSB,

A.V. Thomas Produce

Atwater, California, March 31, 2009

2 Workers Severely Burned

Two employees at A.V. Thomas Produce were using an oxygen-acetylene torch to loosen a fitting on an old fuel tank, which the company hoped to refurbish for field storage of diesel fuel. The workers, however, were unaware that the tank contained residual hydrocarbon liquid and vapor from an unknown prior use. The tank was not cleaned or purged before work began. Shortly after applying heat to the tank, an explosion occurred, blowing the end of the vessel off. Both employees were airlifted to a regional burn center, where they were treated for burns covering 30 to 50% of their bodies.

The facility had no formal hot work program, and no permit was issued for the hot work being performed. No combustible gas testing was performed prior to commencement of the hot work; the company did not have a policy that required it. In addition, many workers were mono-lingual Spanish speakers and had not been trained on safe hot work procedures or on the proper use of gas detectors in their native language.



Below Photo, Courtesy: U.S. CSB,

Exterior and interior views of the fuel tank

involved in the hot work accident at A.V. Thomas

Produce.



Below Information and Photo, Courtesy: U.S. CSB,

Bethune Point Wastewater Plant

Daytona Beach, Florida, January 11, 2006

2 Workers Killed, 1 Critically Injured

Two workers were killed and another critically injured in an explosion involving a methanol storage tank at a municipal wastewater treatment facility in Daytona Beach, Florida. The explosion occurred while the three workers were cutting a metal roof located directly above the tank vent. Sparks showered from the cutting torch and ignited methanol vapor escaping from the vent, creating a fireball on top of the tank. A corroded and ineffective flame arrester15 on the vent allowed the fire to propagate through the device, igniting methanol vapors and air inside the tank, resulting in an explosion.

Daytona Beach public employees were not covered by OSHA standards, which is typical for local and state governments in a number of jurisdictions. The city had no formal permitting system for hot work or non-routine maintenance activities, and workers had not received any training on methanol hazards in the previous 10 years. Combustible gas monitoring was not performed or required.


Case Study #4: Fire at a University Library

Courtesy: (NFPA 51B standard - Significant Hot Work Incidents)

University Library. Workers were using an acetylene torch to remove old heating ducts in a utility shaft between the 20th and 21st stories of the tower of a 27-story university library building. Flying sparks fell through a vent and ignited papers stacked against the vent in a storage room on the 20th floor. Apparently the fire burned 20 to 30 minutes before discovery.

There was no fire protection in the upper stories, except for portable fire extinguishers, and fire fighters had to connect to the standpipes in the 3rd and 4th stories and pull hose lines up the enclosed stairways to the 20th and 21st stories. They finally controlled the fire in 2.5 hrs, but damage extended to 4 stories when fire spread by way of nonfirestopped utility shafts and elevator shafts. The work was being done by two air-conditioning installation workers, on contract. They had not investigated the possibility of combustible material being in contact with the old heating duct on which they were working.


Case Study #5: Fire in Warehouse Facility

Courtesy: (NFPA 51B standard - Significant Hot Work Incidents)

Warehouse Facility. While an arc welder was being used on the

second floor, sparks dropped through an opening to cardboard

boxes below and the boxes ignited. There was no fire watch on

the first floor, and when the fire was discovered 15 minutes later,

employees could not put it out. They finally called the fire

department but were too late to save the two-story building of

ordinary construction. The total loss was $1.6 million.


Case Study #6: Lumber Mill. Workers had shut down one of several sprinkler systems in

the plant to remove branch lines to facilitate removal of a conveyer. While workers were cutting bolts from the conveyer with welding equipment, some of the sparks passed through cracks in the floor and landed in sawdust accumulations below. Smoldering occurred for 3 hours without being noticed by the maintenance employees, who were the only people in the plant. Meanwhile, the area in the region of the cutting operations, but not the floor below, had been washed down and visited regularly at ½-hour intervals.

When the fire was finally noticed, some time was spent in trying to extinguish it before the fire department was called. By the time the fire department arrived, it was too late to save the lumber storage and stacker buildings. Destruction caused a total loss of $1.25 million.

Hot Work Permit Program Training Summary


Summary

In Summary: Hot work activities creates various health and physical hazards. The goal of the hot work

permit program is to prevent heat sources from coming into contact with fuel sources in order to prevent the possibility of fires and explosions that could result in injury, death, and loss of property.

Hot work is allowed in 2 types of locations. Designated area is a permanent location (such as a Welding or Maintenance Shop) approved for routine hot work operations. A Designated area has been made safe by removal of all possible ignition sources.

A Controlled Area is an out of shop location which safe conditions exist or where safe conditions can be created by moving or protecting combustibles.

A Hot Work Operator must obtain a Hot Work Permit from the Departmental Permit Authorizing Individual before performing hot work in a Controlled Area.

A Fire Watch must be posted when hot work is performed in a location where other than a minor fire might develop.

A Non-Permissible Location is a hazardous location such as a tank that holds flammable chemicals. No Hot Work is allowed in this type of work environment.

It is critical that proper planning and communication be implemented by all involved in planning work involving hot work to reduce the possibility of injury, death, and property loss.

Conclusion

In conclusion, everyone involved with hot work needs to

understand and follow proper safety procedures to

prevent accidents associated with hot work activities.

References Used and Additional

Hot Work Information REFERENCES:

National Fire Protection Agency 51B, Standard for Fire Prevention during Welding, Cutting and Other Hot Work.

American National Standards Institute, Standard: Z49.1:2005, Safety in Welding, Cutting, and Allied Processes

US Chemical Safety Board: www.csb.gov

American Welding Society, Safety and Health Fact Sheets

OSHA General Industry Standard, Subpart Q, 1910.251- 1910. 255, Welding, Cutting, and Brazing

U.S. Army Corps of Engineers , Safety and Health Manual , Section 10 Welding and Cutting

Washington State Department of Labor and Industries, Hexavalent Chromium (chrome 6) Training on the hazards of hexavalent chromium in the workplace

http://www.csb.gov/

Hot Work Permit Program

Education