Mastering Safety in Hot Work Operations: A Comprehensive Guide

How does Hot work?

The works that generate the ignition of fire and fire risks are called hot work operations. The work generates heat, flame, spark, and ignition that cause fires, and needs safety for fire risks. So “Mastering Safety in Hot Work Operations: A Comprehensive Guide” guides you to do hot work operations safely.

Types of Hot Work Operations

1. Arc Welding:
   • Arc Welding is also known as electric welding and is a pervasive operation in all kinds of industries, production, and construction. This operation generates high temperatures to melt the metal for joints. There are many types of this operation.
     • Temperature Range: 3500 °C (up to more than 20,000 °C)
2. Gas Welding:
   • Gas welding is also known as Argon welding. Argon welding is also very common for S.S. (Stainless Steel) metal sheets and piping works. It is used in the metal industry, projects, and machinery-making industry. Due to argon welding being a non-flammable process, argon makes an ideal option for welding.
     • Temperature Range: (temperatures can reach 3,871°C)
3. Grinding:
   • Grinding is a metal-cutting process with the help of a grinding wheel. This process produces small hot metal particles that can be a fire risk.
4. Cutting:
   • Cutting is also like a grinding process and produces small hot metal particles. More safety is needed in the cutting process as hot metal particles are being thrown away.
5. Soldering:
   • Soldering is not more dangerous for fire risks than other processes. It nonflammable process and does not pose a fire risk compared to other hot work processes.
6. Drilling:
   • The drilling process is used to make holes in metal sheets with the help of a high stainless steel drill bit. This process is a minor fire risk.
7. Brazing:
   • The brazing process differs from the welding process in that brazing does not melt the base metals. Therefore, brazing temperatures are lower than the melting points of the base metals.

Importance of hot work operations

There is no other process to join the metal after melting or make it a hot process. So hot work processes are essential in metal works.

Essential Personal Protective Equipment (PPE) for Hot Work Operations

Hot Work permit

Hot work permit template.

Important Note: Permit filing names are temporary. If any name matches the actual name I apologize.

Hot Work Safety Training and Tips

“Safety in Hot Work Operations” is our top priority to perform the hot work safely. Hot work, such as welding, cutting, grinding, or any task involving open flames or sparks, can cause serious safety risks. Proper training and adherence to safety are essential for new workers. Here are some hot work safety training tips and points:

Hot Work Safety Training Phases

Here are 3 safety phases to perform any type of Hot Work. We also have 3 checklists for hot work. New workers need to remember these checklists gradually.

1. Personal Safety (Personal Protective Equipment):
   • Flame-resistant clothing: Wear long sleeves and pants made from flame-resistant materials. Exposure to fumes, heat stress, and burns are common dangers
   • Welding helmet and goggles: Protect eyes and face from sparks and UV radiation.
   • Heat-resistant gloves: Prevent burns and protect hands.
   • Respirators or masks: Use to avoid inhaling harmful fumes or particles.
2. Proper Use of Equipment
   • Inspect tools and equipment: Check for damage or defects before use.
   • Ensure proper grounding: Prevent electrical hazards with proper grounding of tools.
   • Use tools correctly: Follow the manufacturer’s instructions for safe operation.
3. Workplace Safety
   • Safety Gamba Walk: Perform a little Gamba walk to for check any risks and hazards in the workplace.
   • Perform a risk assessment: Identify potential hazards and plan to mitigate them.
   • Obtain necessary permits: Ensure a hot work permit is approved before beginning.
   • Check the environment: Verify the area is well-ventilated and free of flammable or combustible materials.
   • Work in well-ventilated areas: Prevent the buildup of toxic fumes and gases and remove hazardous fumes at the source.
   • Explosion Safety: Working near combustible gases, vapors, or dust can lead to explosions.

Hot Work Procedure Step-by-step

At the Start of work:

1. Checklist: Understand the nature of work. Make a checklist of all the equipment used in the hot work process like welding, grinding, and cutting.
2. Work Order and Work Permit: Get a Work Order and work permit from the engineer or HSE/EHS officer.
3. Machine Safety: Power off the machine that you want under the work process. All machines in the around 10-foot circle should be powered off. You can use fire-resistant blankets or curtains to protect nearby objects and machines.
4. Clear the area: Sparks, heat, and flames can ignite nearby flammable materials. Remove flammable materials within a maximum of 35 feet and a minimum of about 10 feet around the workplace. Remove fluff from the machine body and floor. A 10-foot area is the minimum requirement for welding. (or use fire-resistant shields)
5. Area Preparation: Prepare the area where you want to perform welding. Bricate the area with security tape to control the entrance of unauthorized personnel.
6. Have fire extinguishers ready: Ensure appropriate extinguishers are within reach.
7. Assign a fire watch: Have someone monitor for fire hazards during and after work. For this purpose, the depute-trained EHS worker and fire watchers watch areas where the fire is at risk.

During Work:

1. Fire Watcher: Disputes trained fire watchers to watch areas where the fire is at risk.
2. Safety Sheets: If you feel the need to place some safety sheets around the hot work area.
3. Safety Tip: If you perform welding work at height you can put a metal body tub or bucket with water filled under the welding point. Where the welding hot flux falls. It cools down the temperature of flux and does not let flux go away from the welding point.
4. Supply Connection: Before starting the welding or other hot work process, ensure the supply of liquid and other material is cut off, locked out, and tagged out of the machine.
5. Rest or Break time: Depute a fire watch to look after during rest or break time.

After Work Completion:

1. Fire Watcher: Firewatchers should take 30 minutes of watch time after the work process. To prevent any incidents.
2. Clear the Area: Clear the area and remove barricades, sheets, and all safety types of equipment. Check the welding under pressure.

“Safety in Hot Work Operations” gives you guidelines until the end of the hot work.

In case of an Emergency Situation

1. Know emergency procedures: Be familiar with evacuation routes and emergency contacts.
2. Training on fire extinguisher use: Ensure workers can use them effectively in case of a fire.
3. Keep first aid kits accessible: Be ready to address minor burns or injuries immediately.

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What does hot work mean?

Hot work means work that produces heat, hot flux, and friction which can cause fire. It involves electric or gas welding, cutting, brazing, and flame or spark-producing operations.

What are hot work activities?

1. Electric or gas welding
2. Cut it with a grinder, gas cutter, and ignition system.
3. Brazzling Operation
4. Making holes in metal
5. Friction of metals for a long time

Is welding a hot work?

Yes, welding is a hot work operation.

What are hot work accidents?

Fires and explosions are common hazards in hot work.

What is a fire watcher?

A person deputed by the EHS department to watch out for the hazard of fire during hot work.

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