AL-MADINAH 3

TSESF PROJECT
WELDING AND HOT WORK
TRAINING
 BURAYDAH 2 ISTP TSESF HSE
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WELDING & HOT WORK TRAINING

What is Hot Work?

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

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

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WELDING & HOT WORK TRAINING

Course Overview
1. Hazards of Hot Work
2. Hazard Prevention Safeguards
3. Personal Protective Equipment (PPE)
4. Arc Welding
5. Torch Welding, Cutting, and Brazing
6. Cylinder Handling and Storage
BURAYDAH 2 ISTP TSESF HSE
WELDING & HOT WORK TRAINING

Hazards of Hot Work

What you need to know:
1.The hazards associated with hot

1
work
2.Which environments require
unique hazard prevention
training and precautions
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WELDING & HOT WORK TRAINING

Hazards Associated with Hot Work

Hot work presents a variety of hazards.
Before hot work can begin, your supervisor will identify the hazards in your workplace.
Fire - Intense heat, sparks, or metal splatter Burns- Radiant energy, sparks, or metal splatter can
produced during hot work can create fire hazards. cause serious burns.

Electric Shock - If you touch two metal objects Flammable gases- If allowed to accumulate,
containing voltage, you will become a part of the flammable gases can flash or explode with
electrical circuit. Higher voltages increase the risk of catastrophic results.
injury or death. Intense light- The incredibly bright light of arc
welding can cause serious eye damage.
Arc flash- Arc flash occurs when an electric current
leaves its intended path and travels through the air
from one conductor to another or to the ground .
Hazards in confined spaces:
• Limited escape routes
• Limited visibility, which impedes awareness of injuries and delays emergency response
• Limited ventilation, presenting a greater risk of exposure to harmful fumes
• Displaced oxygen caused by welding flames in a confined space, which can be fatal

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WELDING & HOT WORK TRAINING

Hazard Prevention
Safeguards
What you need to know:
1.Hazard Assessment

2
2.Administrative procedures
3.General hazard controls
4.Additional controls
5.Safety restrictions

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WELDING & HOT WORK TRAINING

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

The hazard assessment considers:

• All the activities required for completing the task.

• The hazards associated with each of those activities.
• Any additional environmental hazards.
* The hazard assessment will guide
the choice of hazard controls and
PPE.

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WELDING & HOT WORK TRAINING

Administrative Procedures
Next, your supervisor will perform the following
administrative tasks.

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

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

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

Controlling combustible materials:

• Remove all combustible materials 35 feet from the work
area.
• Move combustibles located on the opposite side of
partitions and ceilings that will be subject to welding or
cutting.
• Avoid unmovable combustible materials, such as wooden
floors.

If unable to remove or avoid fire hazards:

• Cover combustible floors or materials with fire blankets or
other suitable non-combustible material to contain slag and
sparks.
• Use guards.
• Establish restrictions.
• In some cases, hot work may be prohibited entirely.

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WELDING & HOT WORK TRAINING

Additional Fire Prevention Measures

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

• Fire extinguishers: Provide at least one 10-pound

ABC fire extinguisher in each hot work zone.

• Ducts and conveyer systems: Shut down ducts and

conveyor systems that might carry sparks.

• Atmosphere control: Monitor the air, checking for

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

• Safe disposal: Provide metal buckets or containers

for safe disposal of hot work debris.

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WELDING & HOT WORK TRAINING

Controlling Hazards Around

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

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

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WELDING & HOT WORK TRAINING

Safety Restrictions
In some conditions, you should never perform hot work.

Never weld in the following Never weld on the following

locations: materials:
• Rooms where fire sprinklers are • Metal that has combustible
impaired covers or layers
• Spaces with potentially • Metal in close proximity to
explosive atmospheres combustibles
• Areas near the storage of large
quantities of readily ignitable
materials

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WELDING & HOT WORK TRAINING

Personal Protective
Equipment (PPE)
What you need to know:

3
1. Common PPE designed for hot work
2. How to select eye protection
3. The proper use of respirators

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WELDING & HOT WORK TRAINING

Common PPE Buttonable collar

Your supervisor will
identify required PPE Welding hood
as part of the hazard with adjustable lens
To protect against filter
assessment. Required
burns, cover all
PPE for hot work Fire resistant
exposed flesh.
may include skin, gloves
body, and foot PPE that protects
protection. against electric shock Fire resistant
includes insulated jacket
gloves and rubber- hanging outside of
soled shoes. pants without open
pockets
Fire resistant
trousers
without cuffs on
pant legs
Leather high-top
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boots with steel toes
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WELDING & HOT WORK TRAINING

Eye Protection
Your supervisor will specify the type of eye protection needed for the task.
Types of eye protection:
• Welding hoods with
properly shaded lenses

• Cutting or burning
goggles for torch cutting

• Full face shields for

grinding

• Safety glasses worn

under welding hoods or
face shields when
grinding

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WELDING & HOT WORK TRAINING

Respiratory Protection
Filter-type respirators use cartridges to
filter incoming air and remove
contaminants.

Uses:

• They are required for open-air hot

work with metals containing toxic
substances such as galvanized steel,
zinc, or chromium. * Consult manufacturer specifications to
determine the appropriate type of cartridges.

• They will not provide adequate

protection in confined spaces lacking
sufficient ventilation.
! REMEMBER: You must be trained and authorized
before using a respirator. Only wear a respirator
designed and rated for the hazards involved .

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WELDING & HOT WORK TRAINING

Arc Welding
What you need to know:
1. How to safely handle arc welding

4
tools
2. Safety procedures

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WELDING & HOT WORK TRAINING

The Electrode Holder & Cable Requirement

Check that all components of arc welding are in good condition.
Electrode holder requirements: Cable requirements:

• Specifically designed for arc • Completely insulated

cutting and welding
• Flexible
• Properly insulated
• Capable of handling the
• Able to safely handle the maximum current The welder inserts one of these electrodes
(right) into the electrode holder (left).
maximum current requirements
Safe practices:
Additional cable requirements:
• When done welding or
• Ground the welding machine properly. if leaving the holder
unattended, remove and
• Keep cables clear of walkways, ladders, and properly dispose of the
stairways. For example, they can be strung electrode to prevent
overhead with non-metallic hangers. contact with people or One cable carries electricity to power the electrode,
conducting objects. and the other grounds the welding machine.
• Immediately remove all damaged and worn
• NEVER dip a hot
cables from service until properly repaired. electrode or electrode Signs of improper
holder in water. grounding include
sparks, arcs, and
heat.

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WELDING & HOT WORK TRAINING

Torch Welding, Cutting, and Brazing

What you need to know:
1. Equipment inspection procedures
2. Safe use of torch cutting equipment

5
3. Safety guidelines for supply hoses
4. Safe use of cylinder valves

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WELDING & HOT WORK TRAINING

Inspection and General Torch Use

Before torch welding, cutting, or brazing, inspect all equipment. Regularly follow preventive maintenance
procedures, and consult the manufacturer’s specifications.
Pre-shift inspection:
Maintenance:
• Torches and hoses: Check for leaks,
• Tag and remove defective, damaged, or
damage, and loose connections.
worn equipment from service. Either
• Oxygen cylinders and fittings: They repair or discard it.
must be properly labeled,
distinguishable, and free of oil and • Properly clean clogged torch tips.
grease.
Safe torch use:
• Welding apparatus: Make sure all • Use flashback arrestors.
components are clean and free of oil
and grease. • Light torches only with approved tools.

• Valves • When finished working, shut off valves

and relieve hose pressure.
• Regulators

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WELDING & HOT WORK TRAINING

Safe Hose Preparation and Use

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

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WELDING & HOT WORK TRAINING

Using the Cylinder Valve

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

• Always open valves slowly and

carefully.

• When opening valves, stand to the side,

not to the front.

• Do not open fuel-gas cylinders near

ignition sources.
• Do not open acetylene cylinders too far:
‒ ¾ of a spindle-turn or less is ideal.
‒ Never turn the spindle more than 1.5
times.

• Before you connect a valve to a regulator,

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

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WELDING & HOT WORK TRAINING

Cylinder Handling and

Storage
What you need to know:
1. Hazard communication resources
2. Identification requirements

6
3. Safe handling practices
4. Guidelines for moving and storage
5. Environments and practices to avoid

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WELDING & HOT WORK TRAINING

Cylinder Hazard Communication

Before beginning work, you must fully understand the hazards in
your work area. Hazard communication is a system for clearly
conveying hazards to everyone who needs to know.

Training:Your employer will provide hazard communication

training.

Safety data sheets (SDSs): SDSs include the manufacturer’s

statement of origin, the contents of the cylinder, and the hazards of
the contents.

PPE: Use the SDS and your supervisor’s hazard assessment to

select the proper PPE.

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WELDING & HOT WORK TRAINING

Cylinder Identification
Tags: Use status tags indicating if the cylinder is full, in
use, or empty.

Labels: All cylinders must have proper GHS-compliant

labels that identify contents and classify hazards.

Signage: Be aware of signs at storage areas, such as

"Danger: Flammable. No sources of ignition, smoking,
or open flames.”

Storage: Store cylinders with caps and tags on.

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WELDING & HOT WORK TRAINING

Cylinder Valve Safety

• Close valves, bleed the lines, remove
regulators, and replace valve safety
caps:
‒ When storing cylinders.
‒ Before moving cylinders.
‒ When a cylinder is empty.
‒ When leaving cylinders unattended.

• All cylinders must be equipped with a

handle or wrench, so that they can be
turned off immediately when
necessary.

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WELDING & HOT WORK TRAINING

Prior to moving cylinders:

Moving Cylinders
• Get authorization.

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

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

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

• While moving cylinders:

• Use a cart designed for this purpose.

• Use a chain to secure them to the cart.

• Stay on designated pathways.

• Never lay cylinders on their sides, and never roll them by hand.

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WELDING & HOT WORK TRAINING

Cylinder Storage Guidelines

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

Segregation:
Storage area requirements:
• Keep all cylinders and combustible materials 20
• Cool and dry
feet away from stairs, aisles, and elevators.
• Well-ventilated
• Keep combustible and flammable materials 20
• Clean and free from combustible materials feet away from all cylinders.
• Protected from recognizable hazards • Keep oxygen cylinders separate from fuel-gas
cylinders and combustible materials with one of
Storage practices: the following:
• Limit access to authorized and trained ‒ A 5-foot, noncombustible barrier with a ½
persons. hour fire-resistance rating
• Always keep cylinders upright. ‒ A 20-foot distance

• Bleed the lines, remove regulators, and • Some gases have additional storage requirements.
replace valve safety caps.
• Follow safe practices for additional
cylinders, whether full or empty.

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WELDING & HOT WORK TRAINING

Cylinder Storage and Handling Practices

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

• Hoist cylinders improperly, such as with

• Mix gases in a cylinder.
magnets.

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WELDING & HOT WORK TRAINING

Summary
Before Beginning Any Hot Work
• Wait for your supervisor to finalize the
permit.

• Only work on equipment if properly trained

and authorized by the organization.

• Inspect all PPE.

• Inspect all hot work equipment.

• Follow the lockout/tagout program

requirements.

• Follow respiratory protection requirements.

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Thank you